insys icom Powerline GP User Manual
INSYS Powerline GP
Manual
Copyright © November 2017 INSYS MICROELECTRONICS GmbH
Any duplication of this manual is prohibited. All rights on this documentation and
the devices are with INSYS MICROELECTRONICS GmbH Regensburg.
Trademarks
The use of a trademark not shown below is not an indication that it is freely availa-
ble for use.
MNP is a registered trademark of Microcom Inc.
IBM PC, AT, XT are registered trademarks of International Business Machine Corporation.
INSYS®, VCom®, e-Mobility LSG® and e-Mobility PLC® are registered trademarks of
INSYS MICROELECTRONICS GmbH.
Windows™ is a registered trademark of Microsoft Corporation.
Linux is a registered trademark of Linus Torvalds.
Publisher:
INSYS MICROELECTRONICS GmbH
Hermann-Köhl-Str. 22
D-93049 Regensburg, Germany
Phone: +49 941 58692 0
Fax: +49 941 58692 45
E-mail: info@insys-icom.com
Internet: http://www.insys-icom.com
Date: Nov-17
Item: 10015596
Version: 1.4
Language: EN
Content
4
Nov-17
1 Preface ..................................................................................................... 6
1.1 Defects Liability Terms .......................................................................................... 6
1.2 Feedback ............................................................................................................... 6
1.3 Marking of Warnings and Notes ............................................................................ 7
1.4 Symbols and the Formatting in this Manual .......................................................... 8
2 Safety ....................................................................................................... 9
2.1 Intended Use ......................................................................................................... 9
2.2 Permissible Technical Limits .................................................................................. 9
2.3 Responsibilities of the Operator ........................................................................... 10
2.4 Qualification of the Personnel .............................................................................. 10
2.5 Instructions for Transport and Storage ................................................................ 10
2.6 Markings on the Product ..................................................................................... 11
2.7 Environmental Protection .................................................................................... 11
2.8 Safety Instructions for Electrical Installation ........................................................ 12
2.9 General Safety Instructions .................................................................................. 12
3 Scope of Delivery ................................................................................... 14
4 Technical Data ....................................................................................... 15
4.1 Physical features .................................................................................................. 15
4.2 Technological Features ........................................................................................ 16
4.3 Certifications ........................................................................................................ 16
5 Display and Control Elements ................................................................ 17
5.1 Meaning of the Display Elements ........................................................................ 18
6 Connections ........................................................................................... 19
6.1 Front Panel Connections ...................................................................................... 19
6.2 Terminal Connections on the Bottom .................................................................. 20
6.3 Terminal Connections on the Top ........................................................................ 21
7 Function Overview ................................................................................. 22
8 Assembly ............................................................................................... 23
9 Function ................................................................................................. 29
9.1 Firmware Update ................................................................................................. 29
9.2 Configuration ....................................................................................................... 29
9.2.1 Configuration using devolo dLAN SDK .................................................. 29
9.2.2 Configuration using open-plc-utils ......................................................... 32
9.3 SLAC Protocol ..................................................................................................... 35
9.3.1 SLAC Interface ....................................................................................... 36
9.3.2 Commands ............................................................................................. 45
Contents
Nov-17 5
10 Maintenance, Repair and Troubleshooting ............................................. 52
10.1 Maintenance ........................................................................................................ 52
10.2 Troubleshooting ................................................................................................... 52
10.3 Repair .................................................................................................................. 52
11 Waste Disposal ...................................................................................... 53
11.1 Repurchasing of Legacy Systems ........................................................................ 53
12 Declaration of Conformity ...................................................................... 54
13 Licenses ................................................................................................. 55
14 Tables and Diagrams.............................................................................. 72
14.1 List of Tables ....................................................................................................... 72
14.2 List of Diagrams .................................................................................................. 73
15 Index ...................................................................................................... 74
Preface
INSYS Powerline GP
6
1 Preface
This manual allows for the safe and efficient use of the product. The manual is part
of the product and must always be stored accessible for installation, commissioning and operating personnel.
1.1 Defects Liability Terms
A usage not according to the intended purpose, an ignorance of this documentation, the use of insufficiently qualified personnel as well as unauthorised modifications exclude the liability of the manufacturer for damages resulting from this. The
liability of the manufacturer ceases to exist.
The regulations of our Delivery and Purchasing Conditions are effective. These can
be found on our website (www.insys-icom.de/imprint/) under “General Terms and
Conditions“.
1.2 Feedback
We are permanently improving our products and the associated technical documentation. Your feedback is very helpful for this. Please tell us what you like in particular on our products and publications and what can be improved from your point
of view. We highly appreciate your suggestions and will include them in our work
to support you and all our customers. We are looking forward to any of your feedback.
Please send an e-mail to support@insys-tec.de.
We'd like to know your applications. Please send us a few headwords that we
know the applications you solve using products of INSYS icom.
INSYS Powerline GP
Preface
7
1.3 Marking of Warnings and Notes
Symbols and Key Words
Danger!
Risk of severe or fatal injury
One of these symbols in conjunction with the key word
Danger indicates an imminent danger. It will cause death
or severe injuries if not avoided.
Warning!
Personal injury
This symbol in conjunction with the key word Warning
indicates a possibly hazardous situation. It might cause
death or severe injuries if not avoided.
Caution!
Slight injury and / or material damage
This symbol in conjunction with the key word Caution
indicates a possibly hazardous or harmful situation. It
might cause slight or minor injuries or a damage of the
product or something in its vicinity if not avoided.
Note
Improvement of the application
This symbol in conjunction with the key word Note
indicates hints for the user or very useful information. This
information helps with installation, set-up and operation of
the product to ensure a fault-free operation.
Preface
INSYS Powerline GP
8
1.4 Symbols and the Formatting in this Manual
This section describes the definition, formatting and symbols used in this manual.
The various symbols are meant to help you read and find the information relevant
to you. The following text is structured like a typical operating instruction of this
manual.
Bold print: This will tell you what the following steps will result in
After that, there will be a detailed explanation why you could perform the
following steps to be able to reach the objective indicated first. You can
decide whether the section is relevant for you or not.
An arrow will indicate prerequisites which must be fulfilled to be able to
process the subsequent steps in a meaningful way. You will also learn
which software or which equipment you will need.
1. One individual action step: This tells you what you need to do at this
point. The steps are numbered for better orientation.
A result which you will receive after performing a step will be marked
with a check mark. At this point, you can check if the previous steps
were successful.
Additional information which you should consider are marked with a
circled "i". At this point, we will indicate possible error sources and tell
you how to avoid them.
➢
Alternative results and steps are marked with an arrow. This will tell
you how to reach the same results performing different steps, or what
you could do if you didn't reach the expected results at this point.
INSYS Powerline GP
Safety
9
2 Safety
The Safety section provides an overview about the safety instructions, which must
be observed for the operation of the product.
The product is constructed according to the currently valid state-of-the-art technology and reliable in operation. It has been checked and left the factory in flawless
condition concerning safety. In order to maintain this condition during the service
life, the instructions of the valid publications and certificates must be observed and
followed.
It is necessary to adhere to the general safety instructions must when operating the
product. The descriptions of processes and operation procedures are provided with
precise safety instructions in the respective sections in addition to the general
safety instructions.
Moreover, the local accident prevention regulations and general safety regulations
for the operating conditions of the device are effective.
An optimum protection of the personnel and the environment from hazards as well
as a safe and fault-free operation of the product is only possible if all safety instructions are observed.
2.1 Intended Use
The product may only be used for the purposes specified in the function overview.
In addition, it may be used for the following purposes:
Usage and mounting in a charging station for electric vehicles.
2.2 Permissible Technical Limits
The product is only intended for the use within the permissible technical limits
specified in the data sheets.
The following permissible limits must be observed:
The ambient temperature limits must not be fallen below or
exceeded.
The supply voltage range must not be fallen below or exceeded.
The maximum humidity must not be exceeded and condensate
formation must be prevented.
The maximum switching voltage and the maximum switching current
load must not be exceeded.
The maximum input voltage and the maximum input current must not
be exceeded.
Safety
INSYS Powerline GP
10
2.3 Responsibilities of the Operator
As a matter of principle, the operator must observe the legal regulations, which are
valid in his country, concerning operation, functional test, repair and maintenance
of electrical devices.
2.4 Qualification of the Personnel
The installation, commissioning and maintenance of the product must only be performed by trained expert personnel, which has been authorised by the plant operator. The expert personnel must have read and understood this documentation and
observe the instructions.
Electrical connection and commissioning must only be performed by a person, who
is able to work on electrical installations and identify and avoid possible hazards independently, based on professional training, knowledge and experience as well as
knowledge of the relevant standards and regulations.
2.5 Instructions for Transport and Storage
The following instructions must be observed:
Do not expose the product to moisture and other potential hazardous
environmental conditions (radiation, gases, etc.) during transport and
storage. Pack product accordingly.
Pack product sufficiently to protect it against shocks during transport
and storage, e.g. using air-cushioned packing material.
Check product for possible damages, which might have been caused by improper
transport, before installation. Transport damages must be noted down to the shipping documents. All claims or damages must be filed immediately and before installation against the carrier or party responsible for the storage.
INSYS Powerline GP
Safety
11
2.6 Markings on the Product
The identification plate of the product is either a print or a label on a face of the
product. Amongst other things, it can contain the following markings, which are
explained in detail here.
Observe manual
This symbol indicates that the manual of the product contains
essential safety instructions that must be followed implicitly.
Dispose waste electronic equipment environmentally
compatible
This symbol indicates that waste electronic equipment must be
disposed separately from residual waste via appropriate collecting
points. See also Section Disposal in this manual.
CE marking
By applying a CE marking, the manufacturer confirms that the
product complies with the European directives that apply productspecific.
UL marking
By applying a UL marking, the manufacturer confirms that the
product complies with the obligatory safety requirements.
Appliance Class II - double insulated
This symbol indicates that the product complies with Appliance
Class II
Appliance Class III - protection by extra low voltage
This symbol indicates that the product complies with Appliance
Class III
2.7 Environmental Protection
Dispose the product and the packaging according to the relevant environmental
protection regulations. The Waste Disposal section in this manual contains notes
about disposing the product. Separate the packaging components of cardboard
and paper as well as plastic and deliver them to the respective collection systems
for recycling.
Safety
INSYS Powerline GP
12
2.8 Safety Instructions for Electrical Installation
The electrical connection must only be made by authorised expert personnel according to the wiring diagrams.
The notes to the electrical connection in the manual must be observed. Otherwise,
the protection category might be affected.
The safe disconnection of circuits, which are hazardous when touched, is only ensured if the connected devices meet the requirements of VDE T.101 (Basic requirements for safe disconnection).
The supply lines are to be routed apart from circuits, which are hazardous when
touched, or isolated additionally for a safe disconnection.
An easily accessible isolation device that disconnects all lines must be installed
prior to commissioning of the device to be able to isolate it completely from power
supply.
2.9 General Safety Instructions
Danger!
Potentially lethal operating voltage!
Risk of fatal injury from electric shock.
Prior to the installation, switch the power supply of the
cabinet off and secure it against being switched on again.
Danger!
Exposed electrical components!
Risk of fatal injury from electric shock.
Prior to the installation, switch the power supply of the
cabinet off and secure it against being switched on again.
Warning!
Moisture and liquids from the environment may seep into
the interior of the INSYS Powerline GP!
Risk of fatal injury from electric shock when touching as
well as fire hazard and damage of the product.
The INSYS Powerline GP must not be used in wet or damp
environments, or in the direct vicinity of water. Install the
INSYS Powerline GP at a dry location, protected from
water spray. Disconnect the power supply before you
perform any work on a INSYS Powerline GP which may
have been in contact with moisture.
INSYS Powerline GP
Safety
13
Caution!
Short circuits and damage due to improper repairs and
modifications as well as opening of maintenance areas.
Fire hazard and damage of the product.
It is not permitted to open the product for repair or
modification.
Caution!
Overcurrent of the device supply!
Fire hazard and damage of the product due to overcurrent.
The product must be protected against currents exceeding
1.6 A with a suitable fuse. Use an overcurrent protection
device with high interrupting rating (1500 A).
Caution!
Overvoltage and voltage peaks from the mains supply!
Fire hazard and damage of the product due to overvoltage.
Install suitable overvoltage protection.
Caution!
Damage due to chemicals!
Ketones and chlorinated hydrocarbons dissolve the plastic
housing and damage the surface of the device.
Never let the device come into contact with ketones (e.g.
acetone) or chlorinated hydrocarbons, such as
dichloromethane.
Scope of Delivery
INSYS Powerline GP
14
3 Scope of Delivery
The scope of delivery for the INSYS Powerline GP includes all accessories listed
below. Please check if all accessories are included in the box. If a part is missing or
damaged, please contact your distributor.
▪ INSYS Powerline GP
INSYS Powerline GP
Technical Data
15
4 Technical Data
4.1 Physical features
Danger!
Potentially lethal operating voltage!
Risk of fatal injury from electric shock.
Before working on the INSYS Powerline GP make sure to
disconnect the power supply of the INSYS Powerline GP
and protect it against re-connection.
Caution!
Overvoltage and voltage peaks from the mains supply!
Fire hazard and damage of the product due to overvoltage.
Install suitable overvoltage protection.
All specified data was measured with nominal input voltage, at full load, and an
ambient temperature of 25 °C. The limit value tolerances are subject to the usual
variations.
Physical Feature
Value
Operating voltage
minimum 10 V DC
maximum 60 V DC
Voltage at Powerline connection
0 – 240 V, 50 Hz
Power consumption idle
1.5 W
Power consumption connection
2 W
Weight
160 g
Dimensions (Width x Depth x Height)
45 x 110 x 75 mm
Temperature range
-20 °C – 55 °C
Maximum permissible humidity
95% non-condensing
Protection class
Housing IP40, Terminals IP20
Table 1: Physical Features
Technical Data
INSYS Powerline GP
16
4.2 Technological Features
Technological Feature
Description
Compatibility
HomePlug Green PHY™ 1.1
Transmission rates
Up to 10 Mbps on the powerline
(the actual usable data rate is lower due
to the coexistence with HomePlug AV
required in the HomePlug
specifications)
Pilot signal coupling
ISO/IEC 15118-3 compliant The
coupling circuit and filters against
feedback to the charging controller are
already integrated in the INSYS
Powerline GP.
Table 2: Technological Features
4.3 Certifications
The INSYS Powerline GP has been developed in compliance with the following
guidelines and standards:
• DIN EN 55022 Class B
• DIN EN 61000-6-2
• DIN EN 60950-1
INSYS Powerline GP
Display and Control Elements
17
5 Display and Control Elements
Figure 1: LEDs on the front panel
Position
Description
1
Status LED for Ethernet connection (yellow)
2
Status LED for Ethernet connection (green)
3
Link LED
4
Power LED
5
Pilot LED (pilot coupling status)
Table 3: Description of the LEDs on the front panel
Display and Control Elements
INSYS Powerline GP
18
5.1 Meaning of the Display Elements
Description
Display
Meaning
Status LED (yellow)
LED on
100 MBit/s connection
LED off
No connection or connection with 10 MBit/s
Status LED (green)
LED on
Connected
LED blinks
Data traffic
LED off
Not connected
Link LED
LED on
Connected to AVLN (AV Logical Network)
LED off
Not connected to AVLN
Power LED
LED on
Supply voltage available
LED off
No supply voltage
Pilot LED
LED on
Powerline signal coupled to pilot line
LED off
Powerline signal coupled to mains line
Table 4: Meaning of the LED displays
INSYS Powerline GP
Connections
19
6 Connections
6.1 Front Panel Connections
Figure 2: Connections on the front panel of the device
Position
Description
1
Ethernet connection
Table 5: Connections on the front panel of the device
Connections
INSYS Powerline GP
20
6.2 Terminal Connections on the Bottom
Figure 3: Connections on the bottom of the device
Terminal
Description
Description
1
Reset
Reset input
2
GND
Ground
3
10 ... 60 VDC
Power supply 10 V – 60 V DC
4
-
not connected
5
Pilot In +
Input signal pilot line from pilot source
6
Pilot In –
Input signal pilot line from pilot source
7
Pilot Out +
Output signal pilot line to charging socket
8
Pilot Out –
Output signal pilot line to charging socket
Table 6: Connections on the bottom of the device
In order to minimise delays of the powerline signal, the connection
between PE and the negative pilot line signal should be made at the
charging socket, i.e. at the "Pilot Out" side. The two signals "Pilot In +"
and "Pilot In –" should be connected directly to the pilot signal source
without PE reference. See Figure 4.
INSYS Powerline GP
Connections
21
Figure 4: Pilot signal connection
6.3 Terminal Connections on the Top
Figure 5: Connections on the top of the device
Terminal
Description
Description
9 – 13
-
not connected
14 N Powerline connection
15
-
not connected
16
L
Powerline connection
Table 7: Connections on the top of the device
Function Overview
INSYS Powerline GP
22
7 Function Overview
Charging station (EVSE) and electric vehicle (PEV) communicate using the
powerline standard HomePlug GreenPHY™ 1.1 as per ISO/IEC 15118. The
requirements for this are described in ISO/IEC 15118-3. The INSYS Powerline GP
provides the communication connection between the EVSE controller (as per
ISO/IEC 15118-2) and the electric vehicle (PEV). The data stream will be modulated
to the pilot line of the charging cable or the power line as per ISO/IEC 15118-3
here.
The INSYS Powerline GP provides you with the following functions:
Communication via powerline standard HomePlug GreenPHY™
Coupling of the powerline signal to the pilot line
Coupling of the powerline signal to the power line
SLAC protocol as per ISO/IEC 15118-3
INSYS Powerline GP
Assembly
23
8 Assembly
This chapter describes how to mount the INSYS Powerline GP to a DIN rail,
connect the power supply, connect the communication line and uninstall it
again. Observe the instructions in the "Safety" section of this manual, in
particular the "Safety Instructions for Electrical Installation" for that purpose
unconditionally.
Danger!
Exposed electrical components!
Risk of fatal injury from electric shock.
Prior to the installation, switch the power supply of the
cabinet off and secure it against being switched on again.
Danger!
Potentially lethal operating voltage!
Risk of death through shock hazard when touching it.
The INSYS Powerline GP is an electronic device, which
may only be used for fixed installation. The INSYS
Powerline GP must be installed that it cannot be touched
by the user after installation. An access to the installed
device may only be possible using tools, keys or removing
an internal cover. Moreover, a warning sign must be
attached, which warns against potentially tangible
energised components.
Danger!
Potentially lethal operating voltage!
Risk of death through shock hazard when touching it.
The power line used for communication must provide an
easily accessible, fixed installed cut-off device and a an
automatic cutout. The automatic cutout must be designed
for a maximum nominal current of 16A. The cut-off device
must be designed bipolar for ungrounded power supply
networks (e.g. IT network or DC supply without PE
reference).
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