Fluke FEV100/TY1 KIT2, FEV100/TY1 KIT, FEV100/TY1 & TSL User manual

FEV100

Electrical V ehicle Charging

Station T est Adapter

Users Manual

5278136, April 2021

PN

© 2021 Fluke Corporation. All rights reserved.

Specications are subject to change without notice.

All product names are trademarks of their respective companies.

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Symbols

Symbol Description

WARNING. RISK OF DANGER.

W

WARNING. HAZARDOUS VOLTAGE. Risk of electric shock.

X

Consult user documentation.



Double Insulated.

T

Measurement Category II is applicable to test and measuring



circuits connected directly to utilization points (socket outlets

and similar points) of the low-voltage MAINS installation.

Earth.

J

Protective Earth.

PE

Control Pilot.

CP

Vehicles not requiring ventilation for indoor charging areas.
Vehicles requiring ventilation for indoor charging areas.

This product complies with the WEEE Directive marking
requirements. The a󰀩xed label indicates that you must not

discard this electrical/electronic product in domestic household

waste. Product Category: With reference to the equipment



types in the WEEE Directive Annex I, this product is classed as

category 9 "Monitoring and Control Instrumentation" product.

Do not dispose of this product as unsorted municipal waste.

Table 1. Symbols

Introduction

The FEV100 (the Product) tests the function and safety of AC charging
stations Level 2 (208 V AC or 240 V AC) and Level 1 (120 V AC). With this

adapter, charging stations are tested in accordance with SAE J1772.

The adapter imitates a car and opens up a charging cycle (activate voltage/
current output). Use additional test and measurement equipment, such as

but not limited to: Multimeters, Clamps, Insulation testers or Multifunction
Testers, to test a charging station. In addition, the adapter has a built in quick

safety test that does not require separate equipment.

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Safety Information

A Warning identies conditions and procedures that are dangerous to the
user. A Caution identies conditions and procedures that can cause damage
to the Product or the equipment under test.

To prevent the possibility of electric shock or personal injury:

• Read all safety information before you use the Product.

• Do not alter the Product and use only as specied, or the
protection supplied by the Product can be compromised.

• Carefully read all instructions.

• Do not touch voltages >30 V ac rms, 42 V ac peak, or 60 V dc.

• Before each use, examine the Product. Look for cracks or missing
pieces of the Product and cable assembly insulation. Also look for

loose or weakened components. Carefully examine the insulation

around the cable assembly connector.

• Only connect the Product to the charging stations as indicated in

the Specication section.

• Use the Product within the operating range only. The operating

range is specied in the Specication section.

• Do not touch any part of charging station during the GFCI test.
The GFCI test may place hazardous voltage onto conductive parts
of the charging station during the test if the charging station is
not properly grounded.

• Do not use the Product around explosive gas, vapor, or in damp
or wet environments.

• Do not apply more than the rated voltage, between the terminals
or between each terminal and earth ground.

• Use the correct terminals, function, and range for measurements.

• Do not use the Product if it operates incorrectly.

• Do not operate the Product with covers removed or the case

open. Hazardous voltage exposure is possible.

• Use only specied replacement parts.

• Do not use the Product if it is altered or damaged.

• Have an approved technician repair the Product.

WX Warning

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Transport and Storage

Please keep the original packaging for future transport (for example if
calibration is necessary). Any transport damage due to faulty packaging will
be excluded from warranty claims.

The adapter must be stored in dry, closed areas. In case of the adapter being
transported in extreme temperatures, a minimum recovery time of 2 hours is

required prior to any operation.

Available Measurements

• Grounding system Pre-Test (veries that there is no presence of dangerous

voltage at the Ground terminal)

• Phase indicator (presence of voltage)

• CP State simulation (A, B, C

• CP Error “E” simulation (Control Pilot CP signal short-circuited to PE)

• GFCI ground fault circuit interrupter test

• Fault Voltage test in normal conditions (no GFCI test current) and

during GFCI test

• PE Error (Earth Fault) simulation (interruption of PE conductor)

• Measurements on live conductors (L1, L2/N) and on PE ground

conductor

• Test of Control Pilot CP signal

, D ) for Control Pilot

Kit Components

The FLK-FEV100/TY1 Kit contains the following items:

1 FLK-FEV100/BASIC Test Adapter
1 FLK-FEV-COM/TY1 Type 1 Connector & Cable

1 Soft Carrying Case
1 Users Manual

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Description of Warning Marks on Front Panel

1

Terminals with low voltage
output (approx. ±12 V) powered

1

by the charging station. Terminal
marked with

PE. Use for test purposes only.
The CP Signal Output terminals

2

3

Figure 1. Front panel warning marks

3

Dangerous voltages can be present at L1, L2/N, and PE terminals while

the test adapter is plugged into the charging station. Use the test sockets
for test purposes only. Do not supply any appliance or charge an electric

vehicle via these connectors. Terminals N and PE can be hazardous if
there is a charging station error or incorrect wiring.

can be hazardous if there is

a charging station error or

incorrect wiring.

2

High danger of electric shock

is present when PE Pre-Test
indicator illuminates while
performing PE pre-test (see

Grounding protection Pre-Test).
In this case, stop testing
immediately. Make sure to

ground your body su󰀩ciently
while doing this test.

is connected to

J

Operation Elements and Connectors

1

CP Error “E” button

2

Protective Grounding

Pre-Test

test

J

warning indicator

3

Protective Grounding

Pre-Test touch

J

probe

4

Measurement
terminals L1, L2/N

5

Voltage presence
indicator

6

Measurement Ground
terminal

7

Grounding error

simulation button

8

GFCI test button and
green READY indicator

9

CP State rotary

switch selector
(A, B, C

10

Test cable input with 5-pole male connector

11

Test cable for specic EV charging station (Type 1 or Tesla)

, D )

1

2

3

4

Figure 2. Front panel function

10

9

8

7

6

5

11

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1 2 3

Figure 3. Top of the Product

1

Test cable input

2

CP Signal output terminal (yellow)

3

CP Signal output terminal
(connected to PE) (green)

Figure 4. Back of the Product

Testing Charging Stations

To prevent possible electric shock, re, or personal injury:

• Before starting any tests, the operator must be familiar with

the standard: SAE J1772, “SAE Electric Vehicle and Plug in

Hybrid Electric Vehicle Conductive Charge Coupler” and the
documentation of the charging station in use.

• Before starting any tests, refer to the local regulations and

standards for: safety at work and any relevant publications from

the Health and Safety Executive.

• Only skilled persons, competent in verication and the types of

tests suitable for installations and charging stations, should do

the tests.

• If the wrong types of tests are done or if testing is done in an

incorrect sequence then a potentially hazardous situation can
occur for both the operator and the DUT (Device Under Test).

• The operator must fully understand the various tests required and

how they should be done.

• The charging station must pass the Protective Earth (Ground) PE

Pre-Test prior to the operator touching exposed metal surfaces or
any other test. If the PE Pre-Test fails, stop further testing. Resolve
any faults before proceeding. In case of error, all metal parts of

the charging station including output terminals and PE can have

hazardous voltage. In this case, there is a high risk of electric

shock to the operator and other persons nearby.

• The PE Pre-Test detects the presence of hazardous voltage on

Protective Earth but may not detect an open Protective Earth.

WX Warning

Testing a charging station

To test the charging station:

1. Do a safety grounding protection pre-test (to verify that no dangerous

voltage is present in the grounding circuit due to possible miswire or
electrical wiring or grounding malfunction).

2. Verify station output voltage using an additional meter.

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3. Verify station maximum preset charge current using CP terminals and
a meter with duty cycle function or an oscilloscope.

4. Simulate the error states as described in the SAE J1772 standard: CP
Error “E”, GFCI trip test, and Grounding Error.

Additional advanced tests such as Insulation Resistance, Power Quality,
Analysis of the Control Pilot waveform, and Loop Impedance can also be
done using the adapter in conjunction with appropriate test and measurement
equipment. The adapter is compatible with Fluke and Amprobe test and

measurement instrumentation.

Grounding protection Pre-Test

The Grounding

PE conductor for possible presence of dangerous voltage against earth. In

normal circumstances, the grounding conductor is connected to earth and

therefore has no voltage against earth. However, if the grounding conductor
is not connected to earth (for example, connected to phase by mistake or the
grounding wire is disconnected or broken) the situation may be hazardous.

Operator skin contact is required on the PE PRE-TEST button (do not wear
gloves) as well as a suitable operator reference to a known earth ground

(through the operator's shoes etc.) Do not touch any metal parts of the

charging station while performing this test. In case of improper connection to
earth (for example, isolated placement of your body) this indication may be
not reliable.

The PE Pre-Test detects the presence of hazardous voltage on

Protective Earth but may not detect an open Protective Earth.

Test procedure:

1. Connect the test adapter to the charging station.

2. Touch the probe with a bare nger. If PE Light (item
illuminated, then dangerous voltage is present at ground conductor.

Stop further testing immediately and check for a possible wiring fault of

the tested ground conductor. In case of this error, the ground terminal
carries hazardous voltage. There is a high risk of electric shock.

Pre-Test safety feature allows the operator to test the

J

WX Warning

, Figure 2) is

2

Possible errors are:

• PE interrupted / not connected

• PE carries voltage (for example, connected to phase)

Verifying charging voltage - vehicle simulation

Use the CP State rotary switch selector, to simulate various vehicle states
when the test adapter is connected to the charging station. Vehicle states
are simulated with di󰀨erent resistances connected between CP and PE
conductors. Correlation between resistance and vehicle states is shown in
Table 2 below.

Marking

of Vehicle

State

A EV not connected

B

C

D

Table 2. Correlation between resistance, vehicle state and CP voltage signal.

Electric Vehicle (EV)

State

EV connected, not ready
to charge

EV connected, ventilation
not required, ready to
charge

EV connected, ventilation
required, ready to charge

Resistance

between CP

and PE

)

Open (

∞

2.74 kΩ

882 Ω

246 Ω

Voltage at

CP terminal

±12 V
1 kHz

+9 V / -12 V

1 kHz

+6 V / -12 V

1 kHz

+3 V / -12 V

1 kHz

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Initiating a charging cycle:

1. Connect the adapter cable to the charging station.

2. Turn a CP switch to B position and wait 3 to 5 seconds – in commercial

stations this may initiate a station to ask for payment information

3. Turn a CP switch to either C or D position depending on the type of

station you are testing (respectively with or without indoor charging

area ventilation requirement) to open the charging cycle.

If the station does not begin the charging cycle, turn the CP switch
to position A. Then turn the CP switch to position B and wait 3 to
5 seconds. Then turn the CP switch to position C or D. Some EV
charging stations require a time delay to establish a proper connection
when CP State B is selected.

The red LED indicates that the charging station opened for the charging cycle

and voltage is present at the adapter terminals. The green READY indicator

should light up to indicate that the GFCI test circuit is ready for testing.
Measuring terminals of the adapter are directly connected to Phase 1 (L1),

Phase 2 (L2/N) or N (L2/N), and PE conductors of the charging station via

the test cable. Use these terminals for measuring purposes only. Do not use
the terminals to supply power to any other equipment.

Connect a meter to the L1 and L2/N terminals to perform output voltage

measurement. The terminals can be also used to perform other tests (for
example the loop impedance or Power Quality).

Verication of the charging station’s preset maximum charging current

and CP signal

The purpose of the CP function is communication between a vehicle and

charging station. The duty cycle of the PWM Pulse Width Modulation signal

denes the maximum available charging current.

CP output terminals are connected to CP and Ground conductors of the

charging station under test via the test cable. The green socket is connected to
Ground. These outputs are for connection of a meter with a duty cycle function
or an oscilloscope to check the waveform and amplitude of the CP signal.

For details of communication protocol refer to SAE J1772 and the

documentation of the manufacturer of the charging station.

Note

Verication of the maximum charging current with a multimeter

Set a maximum charging current of the charging station using the internal
switch. The value of the maximum charging station current cannot exceed
the max current allowed by the gauge of the installed electrical wires and
breaker according to the National Electrical Code.

Testing maximum charging current:

1. Connect adapter to the charging station and select either state C or

D using rotary switch depending on the type of station to start the

charging cycle.

2. Connect meter set to Duty Cycle to the Control Pilot (CP) terminals

located on the top of the adapter. See Figure 3, use items
Make sure to connect COM input of the meter to the Green (Ground)
output of the CP terminal.

3. Read the duty cycle value and translate to maximum charging

current using the below formulas or a quick reference table (based on
J1772 standard).

Note

• Do not connect to L1, L2/N terminals.

• Connect the multimeter test leads after the charging station starts the

charging cycle. In some situations, the meter can inuence the CP

signal, and prevent the station from starting the charging cycle.

and 3.

2

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9.5 % ≤ Duty Cycle < 10 %, Maximum current = 6 A
10 % ≤ Duty Cycle ≤ 80 %, Maximum current = (duty cycle %) x 0.6
85 % < Duty Cycle ≤ 96 %, Maximum current = (duty cycle % - 64) x 2.5
96 % < Duty Cycle ≤ 96.5 %, Maximum current = 80 A
See detailed calculations in Table 3 below.

Duty Cycle (%)

9.5 6.0 40 24.0 70 42.0
10 6.0 41 24.6 71 42.6
11 6.6 42 25.2 72 43.2
12 7.2 43 25.8 73 43.8
13 7.8 44 26.4 74 44.4
14 8.4 45 27.0 75 45.0
15 9.0 46 27.6 76 45.6
16 9.6 47 28.2 77 46.2
17 10.2 48 28.8 78 46.8
18 10.8 49 29.4 79 47.4
19 11.4 50 30.0 80 48.0
20 12.0 51 30.6 81 48.6
21 12.6 52 31.2 82 49.2
22 13.2 53 31.8 83 49.8
23 13.8 54 32.4 84 50.4
24 14.4 55 33.0 85 51.0
25 15.0 56 33.6 86 55.0
26 15.6 57 34.2 87 57.5
27 16.2 58 34.8 88 60.0
28 16.8 59 35.4 89 62.5
29 17.4 60 36.0 90 65.0
30 18.0 61 36.6 91 67.5
31 18.6 62 37.2 92 70.0
32 19.2 63 37.8 93 72.5
33 19.8 64 38.4 94 75.0
34 20.4 65 39.0 95 77.5
35 21.0 66 39.6 96 80.0
36 21.6 67 40.2 96.5 80.0
37 22.2 68 40.8
38 22.8 69 41.4

Table 3. Calculations of max. charging current on basis of duty cycle.

Max

Amps

Duty Cycle (%)

Max

Amps

Duty Cycle (%)

Max

Amps

Error states:

Duty Cycle = 0 % (Duty Cycle < 3 %), State F or E (see SAE J1772
Standard); no charging allowed

Duty Cycle = 5 % (4.5 % ≤ Duty Cycle ≤ 5.5 %), Indicates that digital

communication is needed

7 % < Duty Cycle < 8 %, Error state; no charging allowed

Duty Cycle = 100 %, State B1, C1 or D1; no charging allowed

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CP Error “E” simulation

The standard SAE J1772 denes Error “E” as a state when charging station
is: disconnected from vehicle, disconnected from utility, there is a loss of
utility power or control pilot is short to control pilot reference (ground).

To simulate the CP Error “E”:

1. Push and hold CP Error “E”.

2. While holding the CP Error “E” button turn the CP rotary switch to
either C or D position.

3. The station should NOT open the charging cycle and a new charging

process should be prevented.

The charging station is not required to actively generate the error
code, so the active charging process will not be interrupted if CP Error
“E” button is pushed after the charging cycle is initiated.

GFCI test

Each charging station is required to be equipped with GFCI protection. On

many stations the GFCI protection is fully automatic and does not need a
manual reset after the GFCI circuit is tripped.

Testing a GFCI protection:

1. Turn the CP switch to either C or D position depending on the type of
station you are testing (respectively with or without indoor charging

area ventilation required) to open the charging cycle.

2. The green READY indicator next to GFCI test button illuminates.

If the READY indicator blinks before you press the GFCI test button,

then fault voltage is higher than 45 V at the PE terminal. Check and

improve the grounding system before you do further tests.

Do not touch any part of charging station during the GFCI test.
The GFCI test may place hazardous voltage onto conductive parts
of the charging station during the test if the charging station is not
properly grounded.

3. Press the GFCI test button.
The station should terminate a charging cycle as soon as the GFCI

button is pressed.

If the READY indicator starts to blink after you press the GFCI test
button, then fault voltage during GFCI test was higher than 45 V. The
fault voltage was caused by the test current. Check and improve the
grounding system before you do further tests.

4. Unplug the adapter to reset the GFCI protection, if necessary.

Note

WX Warning

Ground Error (Ground Fault) simulation

The Ground

conductor. As a result, the pending charging process is aborted, and new

charging processes are prevented.

Error button simulates an interruption of the ground

J

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Maintenance

When using the test adapter in compliance with the Users Manual, no special
maintenance is required. However, should functional errors occur during
normal operation, after sales service will repair your instrument. Please
contact the local service o󰀩ce.

Cleaning

• Remove all input signals and measurement circuits before you
clean the Product.

• Never use acid-based detergents or solvent liquids for cleaning.

• After cleaning, do not use the Product until the Product is dried
completely.

To clean the Product, use a wet cloth and a mild household detergent.

WX Warning

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Specications

General Features

Input voltage ................................. U

EV connector (EVC-13) ................ SAE J1772 socket, 16 A (type 1, 5P

Internal power consumption .........2 W max.

Operating temperature .................-4 °F to 104 °F (-20 °C to 40 °C)

Storage temperature ....................-4 °F to 122 °F (-20 °C to 50 °C)

Operating humidity range ............. 10 % to 85 % relative humidity

Storage relative humidity ..............0 % to 85 % non-condensing

Operating altitude .........................6561 ft (2000 m) max.

Dimensions (H × W × D) .............. Approx. 8.66 x 4.33 x 1.77 in

Weight ...........................................Approx. 4.4 lb (2 kg)

Safety standards ........................... IEC 61010-1, Pollution Degree 2

Measurement category .................CAT II 250 V

IP protection class ........................IP54

Electromagnetic Compatibility (EMC)

International ................................. IEC 61326-1:

Group 1: Equipment has intentionally generated and/or uses
conductively-coupled radio frequency energy that is necessary for the
internal function of the equipment itself.
Class A: Equipment is suitable for use in all establishments other than
domestic and those directly connected to a low-voltage power supply
network that supplies buildings used for domestic purposes. There

may be potential diculties in ensuring electromagnetic compatibility in

other environments due to conducted and radiated disturbances.
Caution: This equipment is not intended for use in residential
environments and may not provide adequate protection to radio
reception in such environments.

USA (FCC) 47 ............................... 47 CFR 15 subpart B. This product is

Functions

CP states ......................................A, B, C, D

CP Error “E” ..................................On/o󰀨

PE Error ........................................On/o󰀨

GFCI test ...................................... Yes, test resistor of 2 kΩ connected

PE Pre-Test (typical) .....................Visible indication >30 V on PE conductor

Outputs (for test purpose only)

Measuring terminals

L1, L2/N, PE .................................Max. 250 V 50/60 Hz, CAT II 250 V

CP signal output terminals ........... Approx. ±12 V (under normal conditions),

= 120 V, U

L1/N

60 Hz (three-phase system) or
U

= 120 V, U

L1/N

V, 60 Hz (single-phase system), ±10%
voltage uctuations from nominal

single-phase)

non-condensing

(220 x 110 × 45 mm) without cable
assembly

IEC 61010-2-030

Basic Electromagnetic Environment;

CISPR 11: Group 1, Class A

considered an exempt device per clause

15.103.

between L1 and PE, time limitation 40 ms

in case of wrong wiring or error of the
charging station these terminals can be
hazardous ≥ max. 250 V against PE

= 120 V, U

L2/N

= 120 V, U

L2/N

L1/L2

L1/L2

= 240

= 208 V,

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LIMITED WARRANTY AND LIMITATION OF LIABILITY

Each Fluke product is warranted to be free from defects in material and
workmanship under normal use and service. The warranty period is three
years and begins on the date of shipment. Parts, product repairs, and
services are warranted for 90 days. This warranty extends only to the
original buyer or end-user customer of a Fluke authorized reseller, and does
not apply to fuses, disposable batteries, or to any product which, in Fluke's
opinion, has been misused, altered, neglected, contaminated, or damaged
by accident or abnormal conditions of operation or handling. Fluke warrants
that software will operate substantially in accordance with its functional
specications for 90 days and that it has been properly recorded on
nondefective media. Fluke does not warrant that software will be error free or
operate without interruption.

Fluke authorized resellers shall extend this warranty on new and unused
products to end-user customers only but have no authority to extend a
greater or di󰀨erent warranty on behalf of Fluke. Warranty support is available

only if product is purchased through a Fluke authorized sales outlet or

Buyer has paid the applicable international price. Fluke reserves the right to
invoice Buyer for importation costs of repair/replacement parts when product
purchased in one country is submitted for repair in another country.

Fluke's warranty obligation is limited, at Fluke's option, to refund of the purchase
price, free of charge repair, or replacement of a defective product which is
returned to a Fluke authorized service center within the warranty period.

To obtain warranty service, contact your nearest Fluke authorized service
center to obtain return authorization information, then send the product to
that service center, with a description of the di󰀩culty, postage and insurance

prepaid (FOB Destination). Fluke assumes no risk for damage in transit.

Following warranty repair, the product will be returned to Buyer, transportation
prepaid (FOB Destination). If Fluke determines that failure was caused by
neglect, misuse, contamination, alteration, accident, or abnormal condition of
operation or handling, including overvoltage failures caused by use outside the
product’s specied rating, or normal wear and tear of mechanical components,
Fluke will provide an estimate of repair costs and obtain authorization before
commencing the work. Following repair, the product will be returned to the
Buyer transportation prepaid and the Buyer will be billed for the repair and

return transportation charges (FOB Shipping Point).

THIS WARRANTY IS BUYER'S SOLE AND EXCLUSIVE REMEDY AND
IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. FLUKE
SHALL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR LOSSES, INCLUDING LOSS OF DATA,
ARISING FROM ANY CAUSE OR THEORY.

Since some countries or states do not allow limitation of the term of an
implied warranty, or exclusion or limitation of incidental or consequential
damages, the limitations and exclusions of this warranty may not apply to
every buyer. If any provision of this Warranty is held invalid or unenforceable
by a court or other decision-maker of competent jurisdiction, such holding will
not a󰀨ect the validity or enforceability of any other provision.

11/99

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