Vector VC-EVCC Technical Reference

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VC-EVCC

Technical Reference

Version 1.1.0

Authors

Vector Informatik GmbH

Status

Released

Technical Reference VC-EVCC

based on template version 6.0.2

Document Information

History

Author

Date

Version

Remarks

dim

2020-12-14

0.1.0

Initial document (based on VC-VCCU TechRef Version 9.2.0)

dim

2021-01-13

0.2.0

Updated after first review (by rpl)

dim/rpl/ssm

2021-01-14

1.0.0

Finalized for OR

dim

2021-03-31

1.1.0

Chapter 4.7 Remark about HSOUT added

Reference Documents

No.

Source

Title

[1]

DIN

DIN 70121:2014-12

[2]

DIN

DIN EN 61851-23 - Konduktive Ladesysteme für Elektrofahrzeuge

- Teil 23 Gleichstromladestationen für Elektrofahrzeuge (IEC 61851-23:2014)

[3]

DIN

DIN EN 61851-23 Berichtigung 1 - Konduktive Ladesysteme für Elektrofahrzeuge - Teil 23 Gleichstromladestationen für Elektrofahrzeuge (IEC 61851-23:2014/COR1:2016)

[4]

Vector

User Manual VC-EVCC (available within SOP)

[5]

ISO

ISO 15118-2:2014(E)

[6]

VDV

VDV 261 specification

[7]

SAE

SAE J3068 Electric Vehicle Power Transfer System Using a Three-Phase Capable Coupler

Technical Reference VC-EVCC

based on template version 6.0.2

Safety Instructions

Caution

To avoid personal injuries and damage to property you have to read and understand the following safety instructions and hazard warnings prior to installation and use of this ECU. Keep this documentation always near the ECU.

Proper Use and Intended Purpose

Caution

The ECU may only be operated according to the instructions and descriptions of this manual. The ECU is exclusively designed for use by skilled personnel as its operation may result in serious personal injuries and damage to property. Therefore, only those persons may operate the ECU who have understood the possible effects of the actions which may be caused by the ECU. Users have to be specifically trained in the handling (e.g. calibration) with the ECU, the applied embedded software and the system intended to be influenced. Users must have sufficient experience in using the ECU safely.

Hazard Warnings

Caution

The ECU may control and/or otherwise influence the behavior of control systems and electronic control units. Serious hazards for life, body and property may arise, in particular without limitation, by interventions in safety relevant systems (e.g. by deactivation or otherwise manipulating the engine management, steering, airbag and/or braking system) and/or if the ECU is operated in public areas (public traffic). Therefore, you must always ensure that the ECU is used in a safe manner. This includes inter alia the ability to put the system in which the ECU is used into a safe state at any time (e.g. by “emergency shutdown”), in particular without limitation in the event of errors or hazards. Furthermore, all technical safety and public law directives which are relevant for the system in which the ECU is used must apply. Provided that serious hazards for life, body and property may occur and before the use in public areas the system in which the ECU is used must be tested according to recognized rules of engineering in a non-public area.

Technical Reference VC-EVCC

based on template version 6.0.2

Contents

1 General .......................................................................................................................... 7

2 System Architecture ..................................................................................................... 8

2.1 Supported Peripherals ....................................................................................... 8

3 ECU ................................................................................................................................ 9

3.1 ECU Overview ................................................................................................... 9

3.2 Key ECU Characteristics .................................................................................. 10

4 Functional Overview ................................................................................................... 11

4.1 Power Line Communication ............................................................................. 11

4.1.1 Low Level Communication with EVSE ............................................. 11

4.1.2 AC Charging with Low Level Communication ................................... 11

4.1.3 DC Charging with High Level Communication .................................. 12

4.2 Stop Button ...................................................................................................... 12

4.3 StopCharge CAN Signal .................................................................................. 13

4.4 Generic Switch Input ........................................................................................ 13

4.5 Clamp 15 Signal Input ...................................................................................... 13

4.6 Status LEDs ..................................................................................................... 13

4.7 High Side Outputs ............................................................................................ 13

4.8 Reprogramming of the ECU Software .............................................................. 14

4.9 Self-Diagnostics and Fault Memory.................................................................. 14

4.10 ECU State Handling ......................................................................................... 14

4.11 Coupler Present Detection ............................................................................... 15

4.12 Locking / Unlocking the Combo2 and Combo1 Coupler ................................... 15

4.13 Temperature Monitoring ................................................................................... 15

4.14 Configuration of Software ................................................................................. 15

4.15 Value Added Services (VAS) ............................................................................ 16

4.16 Charging Arbitration ......................................................................................... 16

4.17 3-Phase Charging ............................................................................................ 16

4.18 Charging Schedules ......................................................................................... 16

4.19 Plug and Charge .............................................................................................. 16

4.20 Functional Safety ............................................................................................. 16

5 Industrialization .......................................................................................................... 17

6 Delivery Content ......................................................................................................... 18

6.1 ECU ................................................................................................................. 18

6.2 Packaging ........................................................................................................ 18

6.3 Software .......................................................................................................... 19

Technical Reference VC-EVCC

based on template version 6.0.2

6.4 Technical Documents ....................................................................................... 19

6.5 Quality Documents ........................................................................................... 19

7 Glossary and Abbreviations ...................................................................................... 20

8 Contact ........................................................................................................................ 21

Technical Reference VC-EVCC

based on template version 6.0.2

Illustrations

Figure 1-1 VC-EVCC (Representative Image) ............................................................. 7

Figure 2-1 System Overview Inlet Charging ................................................................. 8

Figure 3-1 VC-EVCC Interfaces ................................................................................... 9

Figure 6-1 VC-EVCC packed in Cardboard Package ................................................. 18

Tables

Table 1-1 Delivery Content ......................................................................................... 7

Table 3-1 VC-EVCC Key Characteristics .................................................................. 10

Table 4-1 Low Level Communication – Duty Cycle of CP PWM ............................... 11

Technical Reference VC-EVCC

based on template version 6.0.2

1 General

The Vector Controller - Electric Vehicle Communication Controller (VC-EVCC) is a generic

ECU for 24V environments.

It realizes electrical charging according to DIN SPEC 70121 see [1] and ISO 15118 see [5]

for power line communication (PLC) with the infrastructure.

The hardware is the VP-EVCC with an integrated flash bootloader. VC-EVCC includes a modern MICROSAR stack with all relevant application modules to realize electrical charging

communication.

Figure 1-1 VC-EVCC (Representative Image)

The following parts are included in the delivery:

Part

Description

VC-EVCC

ECU with integrated software

Documentation

Customer receives a Technical Reference (this document) as well as a User Manual and Charging Sequence Diagrams, see chapter 6.4

Remaining Bus Simulation

CANoe bus simulation for the VC-EVCC for bus test and evaluation purposes

 CAN database description (dbc)  Diagnostic description file (cdd)

Table 1-1 Delivery Content

Technical Reference VC-EVCC

based on template version 6.0.2

2 System Architecture

The VC-EVCC is designed to be integrated into the vehicle with the following system

architecture.

Figure 2-1 System Overview Inlet Charging

2.1 Supported Peripherals

The supported peripherals for inlet charging depend on the charging standard:

> Charging standard CCS-1 (Combo 1 Inlet):

> Phoenix CCS Type 1 Inlet EV-T1GBIE12-1AC series (inlet w. lock) > Phoenix CHARX T1HBI12 series (inlet w. lock)

> Charging standard CCS-2 (Combo 2 Inlet):

> Amphenol HVCO-CF6-ATR8-SF series (inlet) & C-NEVDC12V_ELOCK (lock) > Phoenix CCS Type 2 Inlet EV-T2GBIE12-1AC series (inlet w. lock) > Phoenix CCS Type 2 Inlet EV-T2GBIE12-3AC series (inlet w. lock) > Phoenix CHARX T2HBI12 series (inlet w. lock) > REMA REV-2C series (inlet) & REMA CCS Actuator (lock)

> Inlet manufacturers are continuously developing inlets and adapting them to the new

requirements. For this reason, the range of available inlets is also changing. Once other inlets are used than mentioned above, please contact the Vector support in order

to check the compatibility with the VC-EVCC.

Technical Reference VC-EVCC

based on template version 6.0.2

3 ECU

This chapter contains an overview about the VC-EVCC. A detailed description of the

electronics and housing can be found in the User Manual of the VC-EVCC.

3.1 ECU Overview

The following diagram and tables give an abstract overview of the interfaces of the hardware.

Note

There are many different configuration options for the hardware of the VC-EVCC. The following figure shows the configuration of the VC-EVCC.

Figure 3-1 VC-EVCC Interfaces

Technical Reference VC-EVCC

based on template version 6.0.2

3.2 Key ECU Characteristics

Parameter

Description

CPU

SPC564B74L7, 120MHz

Memory

3,0 MB Code-Flash, 4x16 kB Data-Flash, 192 kB RAM

Voltage range

8V … 32V (ISO 16750, Code E)

Overvoltage 2 min

48V

Connector

Molex CMC36 Hybrid Sealed (36 Pins)

Communication

3x CAN 2.0B (incl. shielding) 1x PLC – Power Line Communication based on

IEC61851

I/O

Extensive Inputs and Outputs typically needed for in vehicle powerline charging systems

Temperature Range

-35°C … +85°C (ISO 16750, Code H)

Typical Current Consumption without loads

150mA

Quiescent Current

203µA

Weight

560 g

IP protection

IP6K6K / IP6K7 / IP6K9K (not valid for unsealed housing

Functional Safety

Safety targets according to ASIL B

Table 3-1 VC-EVCC Key Characteristics

Technical Reference VC-EVCC

based on template version 6.0.2

4 Functional Overview

4.1 Power Line Communication

4.1.1 Low Level Communication with EVSE

According to [2] and [3] a low-level communication via PWM on the CP pin is supported.

The following PWM duty cycles are valid:

Duty Cycle of CP PWM

Description

0% <= DC < 3%

No charging allowed

3% <= DC <= 7%

Usage of high-level protocol according to ISO 15118 and DIN 70121. Charging without this high-level protocol is not possible.

7% < DC < 8%

No charging allowed

8% < DC < 10%

Max current consumption is 6A

10% <= DC <= 85%

Available current = Duty Cycle * 0,6A

85% < DC <= 96%

Available current = (Duty Cycle – 64) * 2,5A

96% < DC <= 97%

Max current consumption is 80A

97% < DC <= 100%

No charging allowed

Table 4-1 Low Level Communication – Duty Cycle of CP PWM

4.1.2 AC Charging with Low Level Communication

With the low-level communication, AC charging can be performed in the following sequence:

> Lock coupler after plugged into inlet > Establish communication to EVSE via CP > Get charging clearance from vehicle > Start charging > Continuous monitoring of charging progress > Vehicle state monitoring; Stop button monitoring; Temperature monitoring; EVSE

communication; Self-diagnostic of actuators/sensors

> Stop charging > Release coupler after a pressed stop button or a CAN signal

Note

For detailed information, please refer to the AC Charging diagram.

Technical Reference VC-EVCC

based on template version 6.0.2

4.1.3 DC Charging with High Level Communication

According to [1] and [5], high level communication for DC charging is supported. The

supported charging profile is EIM (External Identification Means). The DC charging is done in the following sequence:

> Lock coupler after plugged into inlet > Get charging clearance from vehicle > Session setup with EVSE > Parameter exchange with EVSE (charging mechanism, schedule tables…) > Isolation measurement with EVSE > Start pre-charge > Start charging > Continuously monitoring of charging progress > Vehicle state monitoring; Stop button monitoring; Temperature monitoring; EVSE

communication; Self-diagnostic of actuators/sensors

> Stop charging > Release coupler after a pressed button or StopCharge CAN signal

Note

For detailed information, please refer to the DC Charging diagram.

4.2 Stop Button

The button is monitored continuously when the VC-EVCC is active. If the button is

pressed, the charging is stopped. Alternatively, the VC-EVCC checks a CAN signal for charge abortion information.

Technical Reference VC-EVCC

based on template version 6.0.2

Caution

The voltage levels at the inlet power supply pins are not checked by the VC-EVCC prior to unlocking the coupler. This must be done by the other system components and controlled by the CAN signal which sets the signal VCVCCU_Vehicle_PlugUnlockPermission.

Please refer to the UserManual_VC-EVCC for details (chapter TBD) [4].

4.3 StopCharge CAN Signal

The StopCharge CAN Signal is monitored continuously when the VC-EVCC is active and the feature is activated. If the StopCharge CAN Signal is set to pressed, the charging is

stopped.

4.4 Generic Switch Input

An additional digital input to connect an additional button. Besides, the generic input is used

for the charging arbitration.

4.5 Clamp 15 Signal Input

For a discrete wakeup of the ECU instead of a CAN network wakeup the Clamp 15 signal input may be used to wake the ECU and keep it awake. Clamp 15 has to be available during

the whole OppCharge sequence.

4.6 Status LEDs

The charging status can be displayed via three LEDs which can be controlled via CAN messages by an external ECU. For more details please refer to the User Manual of the VC-

EVCC.

4.7 High Side Outputs

Three High Side Outputs are available for general purposes which can be controlled via CAN signals by an external ECU. For more details, please refer to the User Manual of the

VC-EVCC.

Caution

If the VC-EVCC suffers from an unintentional GND contact loss, the freewheeling diode inside HSOUT4 may lead to an unexpected flow of current from HSOUT4 via its

external load to GND.

As this may lead to undefined behavior of the external load (e.g. a BMS relay), the

usage of HSOUT4 must be considered with care. If in doubt, please contact the Vector support.

Technical Reference VC-EVCC

based on template version 6.0.2

Caution

If the High Side Outputs of the VC-EVCC are used, measures must be taken to ensure a load current greater than 15mA (HSOUT0, HSOUT1) respectively 330mA (HSOUT4).

An appropriate load resistor must be calculated depending on the supply voltage. Otherwise, the VC-EVCC will detect an OpenLoad error which leads to a switch-off of the respective High Side Output.

4.8 Reprogramming of the ECU Software

Reprogramming will be done via diagnostic CAN (CAN0). Therefore, the ISO 14229 UDS

protocol will be used. The following reprogramming features are supported:

 Download of one logic block of application and basic software  Download of one logic block of Ethernet transceiver firmware  Download of CWG software  Security via CRC (no signature)  Updater for the flash bootloader itself is not supported

4.9 Self-Diagnostics and Fault Memory

The VC-EVCC continuously monitors all relevant inputs and outputs. The information is

available in the self-diagnostic messages of the outputs.

In addition to that the self-diagnostic also includes faults during charging or in case of internal

faults. Furthermore, the VC-EVCC includes a fault memory that can store several DTCs.

4.10 ECU State Handling

An ECU wakeup is performed due to following reasons:

 Clamp 15 signal  CAN wakeup  Stop button pressed  Vehicle coupler connected  Control Pilot Pin active  Wake up from real time clock

Technical Reference VC-EVCC

based on template version 6.0.2

If the ECU is active there are the following awake reasons possible to stay active:

 Clamp 15 signal  Control Pilot activity  CAN active  Active Diagnostic session  Active OppCharge charging session

In all other cases, the VC-EVCC will go to sleep.

4.11 Coupler Present Detection

For the coupler present detection, the proximity pin (PP) or the PWM signal of the control

pilot line (CP) is used.

4.12 Locking / Unlocking the Combo2 and Combo1 Coupler

The locking / unlocking of the Combo2 and Combo1 coupler is done with a motor, controlled

by an H-Bridge. The coupler will be locked when:

> A vehicle coupler is detected and > A CAN lock signal is received > If the coupler was unlocked but not removed after a certain time

The locking is performed after a specified time the coupler was detected. The coupler will be unlocked when:

> An unlock message is received on CAN and > The charging stop button is pressed or > [in case of Combo1] the S3Switch is pressed or > The StopCharge CAN Signal is pressed

4.13 Temperature Monitoring

The supported Combo2 and Combo1 vehicle inlets have up to 3 temperature sensors:

> One sensor is used for AC charging > Two sensors are used for DC charging

4.14 Configuration of Software

The VC-EVCC allows configurations of the firmware on the diagnostic channel:

 Baudrate adjustment between 250 kBaud, 500 kBaud and 1 MBaud on the J1939 CAN  Automatic switch of high side output to wakeup other ECUs

Technical Reference VC-EVCC

based on template version 6.0.2

 Charging stop user interaction via charging stop button or dedicated CAN message  Configurable message cycle times of several messages  Security Key Constant

4.15 Value Added Services (VAS)

Value added service are additional service which are not part of the V2G communication and not mandatory for charging. The VC-EVCC supports VAS according to ISO 15118-2 [5]

and VDV 261 [6].

4.16 Charging Arbitration

The charging arbitration enables the operation of two VC-EVCCs on the same CAN channel. It targets use cases which require two charging inlets (two VC-EVCCs) per vehicle but only

one charging inlet is used for charging at a time.

For charging arbitration, the VC-EVCC provides the following configurations on the

diagnostic channel:

> Configuration of Primary Source Address > Configuration of Secondary Source Address > Activation/Deactivation of Charging Arbitration

For more details, please refer to the User Manual of the VC-EVCC [4].

4.17 3-Phase Charging

The VC-EVCC supports 3-Phase Charging ‘LIN over CP’ according to SAE J3068 [7].

4.18 Charging Schedules

The VC-EVCC supports Charging Schedules according to ISO15118 [5].

4.19 Plug and Charge

The VC-EVCC supports Plug and Charge (‘PnC’) according to ISO15118-2 [5].

4.20 Functional Safety

The VC-EVCC is developed to fulfill functional safety according to ASIL_B.

Technical Reference VC-EVCC

based on template version 6.0.2

5 Industrialization

This section describes the elements of the VC-EVCC industrialization, which are installed

and released by Vector:

> Production engineering

> Production requirements > Quality requirements > Control plan > P-FMEA > D-FMEA

> Production installation

> Series Production line for electronic parts > Automated Optical Inspection (AOI) > In Circuit Test (ICT) > Production line for mechanical assembly > Leakage test > Generic End of Line Test (EOL)

> Production Specification

> The common part of production is described in the Production Specification and is

released by Vector.

Note

The documents listed in this chapter are for internal documentation of processes only. They are not released for external use or delivery to Customer.

Technical Reference VC-EVCC

based on template version 6.0.2

6 Delivery Content

The VC-EVCC hardware is packed in a single packaging and shipped as off-the-shelf product from Vector warehouse. The standard delivery for software and documents takes

place via download link as ZIP file from the Vector homepage.

6.1 ECU

Based on the offer and order the customer will receive an off-the-shelf product:

> VC-EVCC Series (No.:89524) > VC-EVCC Evaluation (No.:89523)

The ECUs are stored inside the cardboard package. The goods will be extracted from the stock as per ordered quantity and packed individually within our logistics department in

Stuttgart.

6.2 Packaging

The VC-EVCC is packed in a single box (non ESD) with the following description:

> Approximate sizing of a single package: 250 mm x 191 mm x 64 mm (L x W x H,

approximately)

> Approximate weight: 0,74 kg (approximately, Cardboard 0,18 kg + ECU 0,56 kg)

Figure 6-1 VC-EVCC packed in Cardboard Package

Several ECUs in one shipment are packed in overpacks, e.g.:

> 5 ECUs: Approximately 450 x 320 x 320 mm, 5 kg > 10 ECUs: Approximately 560 x 360 x 310 mm, 10 kg > 25 ECUs: Approximately 800 x 600 x 400 mm, 25 kg

Technical Reference VC-EVCC

based on template version 6.0.2

6.3 Software

> VC-EVCC for vFlash package (.vflashpack) > CANoe project (.cfg) > CAN J1939 communication matrix (.dbc) > Diagnosis CAN communication matrix (.dbc) > Diagnosis description file for CANdela Studio (.cdd)

6.4 Technical Documents

> Release Notes VC-EVCC (.pdf) > Technical Reference VC-EVCC (.pdf) > User Manual VC-EVCC (.pdf) > Safety Manual VC-EVCC (.pdf) > Charging Sequence Description AC/DC (.pdf) > Envelope model 3D (STEP) > VC-EVCC technical drawing (2D) > VV-Report VP-EVCC (.pdf) *

6.5 Quality Documents

> No additional quality documents will be provided

*will be provided if required

Technical Reference VC-EVCC

based on template version 6.0.2

7 Glossary and Abbreviations

Term

Description

Alternating Current

AOI

Automated Optical Inspection

BMS

Battery Management System

CAN

Controller Area Network

CCS

Combined Charging Standard

.cdd

CANdela Diagnostic Description File

Control Pilot

CPU

Central Processing Unit

CRC

Cyclic Redundancy Check

CWG

CAN-WiFi-Gateway

Direct Current

DCB

Disconnecting Circuit Breaker

ECU

Electronic Control Unit

EMC

Electromagnetic Compatibility

Electric Vehicle

EVSE

Electric Vehicle Supply Equipment

(D- / P-) FMEA

(Design / Process) Failure Mode and Effects Analysis

ICT

In Circuit Test

LED

Light Emitting Diode

PLC

Power Line Communication

Physical Earth

Proximity Pin / Plug Present

PWM

Pulse-Width Modulation

RAM

Random Access Memory

RESS

Rechargeable Energy Storage System

UDS

Unified Diagnostic Services

V2G

Vehicle-to-Grid

VAS

Value Added Services

VC-EVCC

Vector Controller – Electric Vehicle Communication Controller

VDV

Verband Deutscher Verkehrsunternehmen

Technical Reference VC-EVCC

based on template version 6.0.2

8 Contact

Visit our website for more information on

> News > Products > Demo software > Support > Training data > Addresses

www.vector.com

Vector VC-EVCC Technical Reference

Specifications and Main Features

Frequently Asked Questions

User Manual