Walther E-Boxx EV Simulator Operating Instruction And Technical Description
Operating instruction and
technical description
EV Simulator for charging devices with
charging plug / charging coupler / charging cable
type 1 and type 2 as service case
Photo: EV simulator/tester with enclosed measuring line.
by
Operating instruction and technical description EV tester type 1 and type 2 - 2.0
Contents
1 Operating instructions EV simulator/tester
2 Safety notes
3 Operating instructions
3.1 General description
3.2 Hardware
3.2.1
C
omponents
3.2.2 Hardware configuration
4 Operation
4.1 Handling
4.2 Features of the EV simulators
4.3 Measuring of built-in resistances inside plug type 2
4.4 Ampacity simulation of resistances inside plug type 2
4.5 Measuring of built-in resistances inside plug type 1
4.6 Checking the PE connection between PWM and vehicle
4.7 Simulation of a fault by means of a switchable fault current
4.8 Simulation of vehicle status B, C, D and display of charging voltage
4.9 Measuring of PWM signal (CP test jack)
5 Troubleshooting
6 Maintenance
6.1 Battery change
7 General technical specifications
© Walther-Werke Ferdinand Walther GmbH Seite 2 von 12
Operating instruction and technical description EV tester type 1 and type 2 - 2.0
1 Operating instructions EV simulator/tester
These operating instructions shall be a valuable help for operation and troubleshooting of the EV simulator/
tester.
This version of the document was last updated in May 2013, version 2.0.
The manual is continuously adapted to the technical enhancement of the devices.
We would appreciate your requests and suggestions or ideas for improvement.
Walther-Werke
Ferdinand Walther GmbH
Postfach 1180
D-67298 Eisenberg
Phone: (+) 49 6351 / 475-0
Fax: (+) 49 6351 / 475-227
E-mail: mail@walther-werke.de
Internet: www.walther-werke.de
2 Safety notes
Besides the technical protective measures, the following precautionary measures also help minimizing the
risk of accidents. Compliance with these recommendations helps minimizing the risk of health damages,
injuries, property damages and production downtimes.
Please see that these precautionary measures will be observed - it's in your own interest.
Train and instruct the operating personnel thoroughly!
The system must only be operated and opened by trained technical staff.
Store these instructions in a way that they are clearly visible and within reach
of the operating personnel.
Acquaint all operators with the safety precautions.
Ensure regular and professional care and maintenance of the system.
Orderly workplace = safety.
Do not remove or deactivate any safeguards. Damaged safeguards either have to be
repaired professionally or have to be replaced.
Protection against electric shock!
© Walther-Werke Ferdinand Walther GmbH Seite 3 von 12
Prior to any installation on or near electrical parts always switch off the supply or the
main switch and withdraw the mains plug.
Do not touch live parts.
Use insulated tools.
Never touch electric cables with wet hands
The system (mobile version) must not be permanently exposed to rain or humidity.
Operating instruction and technical description EV tester type 1 and type 2 - 2.0
3 Operating instructions
3.1 General description
By means of the EV simulator, the functions of charging devices for electric vehicles (charging stations, wall
boxes etc.) and pluggable charging cables (mode 3) can be tested by simulating the electric vehicle. After
installation or for service purposes, this is directly possible at the charging infrastructure.
The present version can be used for type 1 and type 2 charging devices, both with firmly connected charging
cable and with charging sockets and separate charging cable. By means of the provided measuring line, 4
different cable cross sections can be simulated.
The EV simulator comprises the following functions:
• Measuring the built-in resistance inside the type 2 plug (between PP and PE)
• Measuring the built-in resistances inside plug type 1 (between CS and PE) and
checking the interlock's switching function
• Ampacity simulation of a charging cable
• Checking the PE connection between PWM and vehicle
• Simulation of a leakage current > 30 mA from L1 to PE
• Simulation of vehicle status B, C, D and indication of charging voltage via LEDs
• CP test jack for PWM signal
The device simulates both faults which can occur during normal use, and different operating conditions of an
electric vehicle. It only comes to a small power drain of approx. 3 mA from the connected charging device.
Additionally, a load current of max. 6 A can be drawn from the built-in Schuko socket via L1 or a test device
for RCD control can be connected.
Attention:
The Schuko socket shall only be used shortly for measuring purposes. Permanent usage is not allowed.
Furthermore, Walther offers EV simulators both as service-case version for type 1 or type 2 charging devices
with integrated charging jack (acc. to SAE J1772 or IEC 62196, USA, Japan) and with firmly connected
charging cable and charging plug type 2 (acc. to IEC 62196).
Photos: EV tester/simulator for type 2, EV tester/simulator for type 1 and type 2 with firmly connected cable (from left to right)
© Walther-Werke Ferdinand Walther GmbH Seite 4 von 12
Loading...