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SX2 EV New Model Course

Power Conversion System
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Power Conversion System

Overview
Overview Power Conversion System
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▶ Power Conversion
 Definition of “Power Conversion System”
- A system designed to convert the type of electricity (AC / DC <-> DC / AC)
- The system converts one or more attributes of electricity, such as voltage, current, fre-
quency, and phase, with minimum loss of electric power
 Types of Power Conversion Systems

Type Generic Term Input Output Remarks

 AC -> DC Converter AC DC -

 DC -> AC Inverter DC AC • Inverter

 DC -> DC • LDC
DC-DC Converter DC DC
• Buck / Boost Converter
 AC -> AC Transformer AC AC -

 Inverter & ICCU (Bi-directional OBC + LDC)

Type Remarks
 Inverter • Converts DC → AC
 Low Voltage DC-DC
• HV DC -> HV AC -> LV AC -> LV DC (Conversion Ratio : Appx. over 5)
Converter (LDC)
 Buck Converter • HV DC -> LV DC
 Boost Converter • LV DC -> HV DC (Conversion Ratio : Appx. under 5)
Overview Power Conversion System
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▶ Power Conversion System Comparison

[ OS EV ] [ SX2 EV]
Components Remarks Components Remarks
OBC VCU
• Low speed AC Charg- • Independent Controller
ing
VCMS • Independent Controller
EPCU • VCU : Charging Top Controller

• MCU + Inverter Inverter

• LDC • MCU + Inverter
CCM • PLC communication
(CP) gateway to BMS ICCU
• Bi-directional OBC
for DC quick charging. : AC Charging / V2L
• LDC

HV ICCU
J/Block OBC HV J/Block

EPCU Inverter
Overview Power Conversion System
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▶ VCMS (Vehicle Charge Management System)

OS EV E-GMP

Inlet OBC BMS Inlet VCMS

ICCU (OBC+LDC)
Power DC Charging AC Charging
Conversion Control Control
Power
CP / PD Inlet Temp. DC Charging Conversion
Recognition Sensing Control
EVSE Battery Con- EVSE CP / PD Recog-
AC Charging trol nition
Control BMS
PLC Communi-
EPCU (VCU) cation Battery Con-
Inlet Lock trol
CCM Scheduled Control
Charging
DC Charging Inlet Temp.
Control Sensing
IGPM (ICU) VCU
PLC Communi- V2L Control
cation Scheduled
Inlet Lock Charging
Control PnC Control
Overview Power Conversion System
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▶ VCMS Circuit Diagram

PE Room
B+ IG3 Inlet PDC
J/Block
Power Power DC+ DC- AC

CP(-) CP(+) PD + - + - + - + - Inlet Inlet IG3 Door

Inlet Lock Lock Unlock Relay On Unlock
Temp. Sensor Sensor Req.

VCMS
Relay AC
GND1/2/3 HI LO Socket PD Ctrl Feedback

G-CAN
Inner V2L Socket
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Power Conversion System

Main Components
Main Components Power Conversion System
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▶ VCU (Vehicle Control Unit)

1  MICOM

2  CAN
- CAN-FD Integrated
- High-speed Local CAN system applied

3  Interlock Detection Circuit

- Interlock detection circuit applied
: HV J/Block & HV Battery Heater side
Main Components Power Conversion System
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▶ VCMS (Vehicle Charging Management System)

 Top-level Charging Management System including general control of AC/DC charging control
and cooperative control with other controllers.
: Optimize cooperative control by integrating charge-related functions distributed to each con-
troller into the VCMS VCMS Tx Info.
VCMS Rx Info.

Vehicle Outside Vehicle Inside

 Charging Quick Charging Current Command (to EVSE) Charge/Discharge Sequence (Normal AC),
Inlet Lock/Unlock Signal (to Inlet Act.) EVSE Capacity Information, etc.
VCMS
EVSE Inlet OBC Operational Status Info. etc.
ICCU
CP (PLC or PWM) Communication Charge/Discharge Sequence (Fast DC),
PnC Billing Info. Charge Capacity Info (Fast DC), etc.

 V2G Vehicle Discharge Allowance / Power Multi-input Charge Operational Status, Etc.
Inverter
Generation, Vehicle Information, etc.
Charge/Discharge Sequence (Fast DC / Normal AC),
Charge Capacity Info.(Fast DC), etc.
Power or Load Type, Grid Information,
Billing Information, etc.
AC Grid BMS Status Info. etc.
BMS
Charge/Discharge Sequence (Fast DC / Normal AC),
etc.

 Other Remote Diagnosis via Dedicated Charger Scheduled Charging Information, etc. VCU
Function
(Vehicle Service) Charge/Discharge Status Information, etc.
Remote Diagnosis via Dedicated Charger

User-friendly Functional Interface Information, etc. AVN

Main Components Power Conversion System
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▶ HV Junction Block
No. Parts Remarks

1 Q/C Relay (+)

BMS Relay Control
2 Q/C Relay (-)

3 Q/C Inlet (+)

from Q/C Inlet
4 Q/C Inlet (-)

5 HV Cable (+)
7 8
from HV Battery
Battery (Direct Connection)
Heater 6 HV Cable (-)
ICCU
7 Inverter (+)

8 Inverter (-) to Inverter (Busbar)

1 5
HV
3
Battery 9 Battery Heater Relay
1 1 1 6 PTC
11
0 2 3 4 Heater
1 10 E-Comp Fuse 40A
4
2 9 11 Battery Heater Fuse 30A

12 PTC Heater Fuse 20A

13 ICCU Fuse 100A

14 LV Signal BMS Relay Control

E- (Q/C, Heater Relay Control)
Comp
Main Components Power Conversion System
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▶ HV J/Block Circuit Diagram

: (+)
: (-)
: Interlock

[w/o Battery Heater]

[with Battery Heater]

24 VCU
BMS

1
E-COMP
2 2 1
2 1 [with Battery Heater]
7 8 9 3 4 1 2
LUG
7 8 9 3 4 1 2 3
4 Battery
2 1

1 Heater

LUG
A_COMP
40A BATT

BATT HTR
QC (+)
HTR
2

20A
RLY
2 1 RLY

INLET 7 1 1 1 2
(CCS1) HV Battery
6 2 2 2 1
2 1
QC (-)
INLET 9 RLY PTC HTR
30A
(CCS2) 8 2 1 1 1
ICCU
100A
1 2 2 2
Inner PTC
1 1 3 Heater
2 2 4
4
5
LUG

2
DATC
2 3
ICCU_DC
1
Main Components Power Conversion System
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▶ HV J/Block Circuit Diagram

No. Name Capa.
1 ICCU Fuse 100A
2 BATT PTC Fuse 20A
3 A_COMP Fuse 40A
4 PTC Heater Fuse 30A
5 Battery Heater Relay 80A
6 Q/C Relays 250A

Battery HTR
ICCU
(OBC _ LDC) E_COMP

PTC HTR
V2L
Reducer
J/B
5
Motor
1 2 3 4

Inverter
HV Battery
6

PE Room 12V AGP

J/Block Battery HV J/Block
Main Components Power Conversion System
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▶ Inverter

 HV DC Input

 Busbar (U/V/W)
 Coolant
(In)

W
V
U
 Control Board
& Connector  Coolant
(Out)
 Main Components Power Conversion System
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▶ ICCU (Integrated Charging Control Unit)

 Signal
Connector

 HV DC Connector
- Charging (DC Output)

 Coolant
(Output)

 Coolant  AC Connector (to Inner

(In) V2L)
- Slow/Normal AC Charging
 LDC 12V  AC Connector (from In- - V2L Output
(Out)
let)
- Slow/Normal AC Charging
Main Components Power Conversion System
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▶ ICCU System Configuration

ICCU

LDC

B+ 12V Battery

IG3 DC-DC
Controller Converter
G-CAN

OBC

DC-DC Converter

Inlet(AC) HV Battery

AC-DC
Converter DC-AC Trans- AC- DC
(Rectification
Inverting former Converting

+ PFC)

V2L Socket
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Power Conversion System

System Configuration
System Configuration Power Conversion System
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▶ EV Charging Inlet Type (Combo Type 1 & 2)

Combo
AC Type Inlet Type Region No.
Single phase Three phases
(CCS 1) (CCS 2)

1 AC 220 V (L1)

Combo
Type 1 2 AC Neutral
1 2 Normal
Charging
Single 4 5 NA 3 PE Ground
3
Phase Quick
(5 pins + 6 7 Charging
2 pins) 4 Signal line (CP)

5 Signal line (PD)

Combo 6 DC (-)400V or 800V

Type 2 Normal
5 4
1 3 2 Charging 7 DC (+)400V or 800V
Three 8 9 Europe
Phases Quick
(7 pins + 6 7 Charging 8 - AC 220 V (L2)
2 pins)
9 - AC 220 V (L3)
 System Configuration Power Conversion System
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▶ Charging System Layout

• HV Connector
• HV Direct
• Busbar
• AC
• HV DC (+ & -)
• HV DC (+)
• HV DC (-)

E-
PTC
Compressor
Tractive Heater
W V U Motor
Battery System Assembly
Fuse
Inverter HV J/Block

M #01
M #27 M #20
DC(+) M #26 M #21
CDM Inlet PRA M #19
V2L M #25 M #22
Inverter
Capacitor
Pre-Charge RLY M #18
Gender DC(-)
M #02 M #24 M #23
M #17
Q/C
RLY Main
RLY (+)
M #03 M #16
(+)
M #15
ICCB Heater M #08 M #09

M #04
Q/C
RLY
Main M #14
RLY (-) RLY (-)
M #07 M #10
M #13
M #06 M #11

BMU
ICCU BAT. M #05 M#12
Heater
(OBC + LDC)

PE Room
J/Block 12V Cabin
AGM Bat. V2L Socket
System Configuration Power Conversion System
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▶ Charging System Configuration

• HV DC
• AC
• Signal
• CAN

EVSE
G-CAN FD
BMS
400V DC

HV Battery
(400V DC)
 Quick Charging
(400V DC) • CP (PLC)
• PD

VCMS
(Charging
Management)
EVSE PDC IG3 Relay
• CP (PWM)
• PD
 Normal Charging Inlet
(110V / 220V AC) AC Charging

Inlet Temp.
ICCU Sensing
(AC→DC)
AC V2L 400V DC

 V2L
(Cabin / Inlet)
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Power Conversion System

Fast DC Charging
Fast DC Charging Power Conversion System
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▶ System Configuration Inlet (CCS1)

3 7
Fast DC
CCS 1
EVSE 1 CP Communication 4 IG3 Relay ‘ON’
Inlet (CCS2) (PLC) 3 IG3 Relay
Charger
CP Wake-up
Connection
CCS 2
PD
2 VCMS PDC
PD Sensing

CAN

5
Pre-charge Relay &
Resistor

Q/C (+) 5 9 Main Relay High-

6 8 Relay (+) voltage
battery

Q/C (-) Motor Inverter 5 9 Main Relay

6 8
Relay (-)
Inverter
5 9
Capacitor
High-voltage High-voltage
junction block battery
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Power Conversion System

Normal AC Charging
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Power Conversion System

V2L Discharging
V2L Discharging Power Conversion System
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▶ V2L (Vehicle to Load) System Configuration

 Home Appliance
Cabin
V2L Socket
VCMS

AC DC
V2L ICCU HV
Gender Inlet Battery
 EV
Connector

ICCB * VCMS : Vehicle Charging Management System

* ICCU : Integrated Charging Control Unit
* ICCB : In-Cable Control Box

* V2L : ICCB can be connected to gender socket for EV slow AC charging.

V2L Discharging Power Conversion System
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▶ ICCU System Configuration (V2L)

V2L
Gender
DC
AC Inlet Connector AC
Battery ICCU AC

(BMS) (OBC+LDC) Home

Appliance

Cabin
1) Gender Connector Engagement Signal
Socket
2) Gender Connector On/Off Button Signal

CAN
VCMS
(Main Control) 1) Cabin Socket Engagement Signal
2) Voltage Sensing Signal
3) Relay Control Signal

Items Functions Remarks

AVN/CLU  VCMS
Discharging Management (V2L
OBC (OS EV)
Control)
(Status Display)  ICCU AC Discharging OBC + LDC
 BMS HV Battery Control -
 AVN / CLU V2L Status Display -
V2L Discharging Power Conversion System
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▶ V2L Socket Layout (110V or 220V Output)

[ V2L Gender ] [ Cabin V2L Socket]

 Connect a separate V2L Gender  2nd Row Center Lower Area

Connector to the CDM Inlet

 Inlet  Cabin Socket

Gender (110V or 220V)
Connector
V2L Discharging Power Conversion System
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▶ V2L LED (Cabin V2L Socket)

Operating
State LED Color Lighting Condition
Condition

Ready 1 Blue Ready State (Unplugged)

Connector is plugged but V2L

Ready 2 Red IG3 On
power is not supplied

Connector is plugged and V2L

Run Green
power is supplied
V2L Discharging Power Conversion System
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▶ Cabin V2L Detection (Power Plug)

 VCMS recognizes power plug engagement via the detection circuit (V2L ~ VCMS)
 Voltage value of VCMS power plug detection circuit
Inner V2L Plug In Status Volt
Status
(Plug Detection Circuit Voltage)
Plug Connected 3.977 V

Plug Disconnected 2.200 V

V2L is not applied 0.000 V

▶ Cabin V2L Circuit Inspection (Current Data)

 Connect a plug to the inner V2L to check the current data is normal

Normal Value
Current Data
Plug Connected Plug Disconnected

Inner V2L Plug Connect

V2L Plug Open
Signal
Inner V2L Plug In Status
2.08~2.32v 3.78~4.17V
Volt

 If current data is abnormal, check inner V2L

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Power Conversion System

IG3 Relay Control
IG3 Relay Control Power Conversion System
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▶ IG3 Relay Control Circuit H/Wire

CAN

OS EV SX2 EV

IG3 RLY IG3

#1
B+
OBC
* EV-Off Charging IG1 1 * EV- On / Ready B+
GND
) IG3
* Scheduled Charging
IG3 RLY #2
VCU 2 * 12V Supplementary
Charging
AVN
* Connected Service
B+ ) B+
AVN 3 * Connected Service IG3 RLY
* Scheduled Charging
B+ IG3
* 12V Supplementary
)
VCU
Charging
PDC
B+ VCMS 4 * EV-Off Charging
Main IG3 RLY
IG1 ICU )
* EV- On / Ready IG3 Feedback

IG3
Feedback 5 * Dr Unlock
VCMS wake up (5V) VCMS
)
from Dr Unlock S/W
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Power Conversion System

CDM (Charge Door Module)
CDM (Charge Door Module) Power Conversion System
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▶ CDM Module

Charging Port
Lamp
Charging Level / Sta-
tus Indicator Lamp

Charging
Door
- with Heating System Push
Opener

Immediate
Charging
Button
Inlet System Power Conversion System
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▶ CDM Control Configuration

Cluster Charge Door

Open/Close Status

1. SOC Level Info. M-CAN

2. Charging Status Info.
3. EV-Ready Status
(from VCU)
4. Ambient Temp &
Glass Heating Button CCU G-CAN
B-CAN
(Gateway)

CDM

SOC Charging EV-Ready

SOC PDC Level Status Status
Indicator Push Opener
- Lock/Unlock
- Open/Close Status

H/Wire
Immediate
Charging BMU VCMS VCU
Button
B-CAN
CDM (Charge Door Module) Power Conversion System
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▶ CDM Heating System (Option)

The heating wire inside the door melts the frozen boundary so that the door can be opened eas-
ily.
 Performance
Possible to open the door within 2 minutes under the condition of -30 Celsius degrees
by melting the frozen boundary

 System Configuration
 Heating Performance
Heating Film Surface
Goose
temperature
Neck (℃)
Insulator

Door can be opened

Dr Inner
Door Cover
Outer Start 1Min. 2Min. 3Min. 4Min. 5Min.
Cover Time
Duration
[ Temperature Distribution ]

 Operating condition
EV-On Status + Ambient Temp under 0 ℃ + Rear Glass Heating System ‘On’
 20 Min. Operating
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Power Conversion System

Inlet System
Inlet System Power Conversion System
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▶ Inlet Type
Combo Type 1 (NA/Korea) Combo Type 2 (EU/Aus.)
Item
AC DC AC DC

Inlet

Nominal
240V / 48A 1,000V / 310A 480V / 32A 1,000V / 310A
Voltage / Current

Communication CP PLC PLC

(Control Pilot)
CP
(Power Line Commu- (Power Line Commu-
Type nication)
(Control Pilot)
nication)
Inlet System Power Conversion System
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▶ Main Components (Combo Type 1)

AC AC
(110V / 220V) (110V /
220V)

Inlet
Inlet Lock AC Cap
CP Actuator Inlet AC Cap

Inlet
DC Cap
Inlet AC Cap
PD

PE GND

HV HV
DC (-) DC (+)
Inlet System Power Conversion System
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▶ Main Components (Combo Type 2)

PE GND

PD

AC L1 CP
(Single,3-
Phases) Inlet Lock Inlet
Actuator AC Cap
Inlet AC Cap

AC L2 Inlet
(3- DC Cap
Phases) Inlet AC Cap

AC L2
(3-
Phases)

AC
Neutral

HV HV
DC (-) DC (+)
Inlet System Power Conversion System
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▶ Emergency Inlet Release Cable

COMBO 5P COMBO 7P
Korea / NA EU / Australia

Pull
Pull

Emergency
Release
Emergency
Cable
Release
Cable
Inlet System Power Conversion System
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▶ Inlet Lock Control System Configuration (VCMS Control)

H/Wire
※ Vehicle Door Unlock  Wakeup Signal G-CAN FD
B-CAN
M-CAN
Vehicle Door
Unlock
PDC
PE Room
J/Block
Lock
Inlet Lock Mode Relay
Setting Signal Lock
ccNC
(Head Unit) Inlet Lock Mode
Status
CCU VCMS Unlock
(Gateway) Relay
Unlock
Vehicle Door
Lock / Unlock
BDC Inlet
Lock
Inlet Lock Position
CDM CDM Door Sensing Actuator
Lock / Unlock

CDM Door
Open / Close Status
Inlet System Power Conversion System
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▶ Inlet Temperature Sensor

 Increased number of temperature sensors (OS EV : 1EA → E-GMP : 3EA)

VCMS CCS1 CCS2

Temp. Sensor #3
Temp. Sensor #3 (AC L1)
(AC N)
Inlet AC Temp. SNSR (+)
Inlet AC Temp. SNSR (-)

Inlet DC+ Temp. SNSR (+)

Inlet DC+ Temp. SNSR (-)

Inlet DC- Temp. SNSR (+)

Inlet DC- Temp. SNSR (-)
Temp. Sensor #1 Temp. Sensor #2 Temp. Sensor #1 Temp. Sensor #2
(DC +) (DC -) (DC +) (DC -)

 Sensing Range (Current Data)

Category Normal Range Short Ground Open or Short Power

Temp. -49~124℃ under -49℃ over 124℃

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Power Conversion System

PD & CP Circuit
 PD & CP Circuit (Charging) Power Conversion System
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▶ PD (Proximity Detection), CP (Control Pilot) Circuit Diagram

 Charging Gun detection via PD (Proximity Detection) circuits
- Different resistor according to the capacity of the charging cable (CCS2) Duty &
Frequency
EVSE Charging Gun Inlet VCMS Sensing (Vb)
Va Op-amp
CP Vb VCP

1kΩ * GDS/KDS
5V 1.3kΩ : CP Voltage
Resonator
330Ω
1kHz ±12V PD Voltage
300pF Sensing
* GDS/KDS 3.3kΩ
: PD Voltage (VPD)
xxxΩ

VCMS
S/W1 & 330Ω 2.7kΩ
S/W
- CCS1 only 330Ω
- Lock Lever Switch
(Normal Open)
: Normal Close ‘On’

AC Earth
Body
 Charging Gun Resistor
CCS2
Type CCS1
AC Charger DC Charger
13A (1 Ph.) 1.5kΩ
20A (1 Ph.) 680Ω
 Lock Lever (CCS1 only) Resistance 150Ω 32A (1 Ph.) 220Ω 1.5kΩ

: Charging Gun Switch 63A (3 Ph.)

100Ω
70A (1 Ph.)
PD & CP Circuit (Charging) Power Conversion System
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Charging Gun Detection Signal

CCS1 CCS2

Ground

AC Neutral PD CP
AC L1 AC Neutral
AC L1
Ground Lock Lever
(Switch)
CP PD
AC L2 AC L3

DC 400V or 800V DC 400V or 800V

- The VCMS supplies 5V to the PD line and detects voltage changes to determine connection of the charger.

PD Voltage (VCMS Current Data)

Type
Disconnected Connected Lock Lever Pressed
AC DC
CCS1 4.46V 1.5V 2.8V
3.73V
3.11V
CCS2 4.46V 3.73V -
1.91V
1.13V
 PD Circuit & Signal (Charging) Power Conversion System
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• Lock Lever ‘Released’ : S/W1 ‘ON’

▶ PD (Proximity Detection) Voltage – CCS1 • Lock Lever ‘Pressed’ : S/W1 ‘OFF’

Connected
Condition Disconnected
Lever S/W1 “ON” Lever S/W1 “OFF”

PD Voltage (VPD) 4.46V 1.5V 2.8V

PD Circuit
(Charging Gun ~ VCMS)

Charging Inlet VCMS 5V 5V 5V

Gun
5V
330Ω 330Ω 330Ω
330Ω
VPD
150Ω * GDS/KDS 4.46V 1.5V 2.8V
: PD Voltage (VPD) (VPD) (VPD)
S/W1 2.7kΩ
(Lock 330Ω 142Ω 408Ω
Lever)
2.7kΩ
* Parallel * Parallel
Composite Composite
Resistance Resistance
AC : 150Ω & 2.7kΩ : 480Ω & 2.7kΩ
Earth
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EXPERIENCIA DE APRENDIZAJE N°2 “SISTEMA DE CONVERSIÓN DE ALTA

POTENCIA”

OBJETIVOS GENERALES;

AL TÉRMINO DE LA SESIÓN, ESTARÁN EN CONDICIONES DE;

• Explicar el funcionamiento del circuito CP (Control piloto) y PD (Detección de proximidad)

• Reconocer la finalidad específica del circuito CP y PD y su importancia dentro de los conectores

de carga.
 PD Circuit & Signal (Charging) Power Conversion System
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▶ PD (Proximity Detection) Voltage – CCS2

Connected
Condition Disconnected 1.5kΩ 100Ω
(Fast DC)
680Ω 220Ω (AC 63A 3 Ph.)
(AC 20A 1 Ph.) (AC 32A 1 Ph.)
(AC 13A 1 Ph.) (AC 70A 1 Ph.)

PD Voltage (VPD) 4.46V 3.73V 3.11V 1.91V 1.13V

PD Circuit
(Charging Gun ~ VCMS)

Charging Inlet VCMS 5V 5V 5V 5V 5V

Gun 5V

330Ω
330Ω 330Ω 330Ω 330Ω 330Ω

* GDS/KDSVPD
1.5kΩ : PD Voltage 4.46V 3.73V 3.11V 1.91V 1.13V
680Ω 2.7kΩ (VPD) (VPD) (VPD) (VPD) (VPD)
220Ω
100Ω
2.7kΩ 964Ω 543Ω 203Ω 96Ω
* Parallel * Parallel * Parallel * Parallel
AC Composite Composite Composite Composite
Earth Resistance Resistance Resistance Resistance
: 1.5kΩ & 2.7kΩ : 680Ω & 2.7kΩ : 220Ω & 2.7kΩ : 100Ω & 2.7kΩ
 CP Circuit & Signal (Charging) Power Conversion System
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▶ CP(Control Pilot) Voltage – CCS1 & CCS2

Connected
Condition Disconnected
VCMS S/W “OFF” VCMS S/W “ON”

CP Voltage (VCP) 0.7V 9.21V 5.79V

 This circuit diagram is intended to understand the principle of CP voltage change,

CP Circuit
(Charging Gun ~ VCMS and some elements, such as OP-AMPs are omitted.
: based on 12V) So, calculated CP voltage may be different from the actual measurements.

EVSE VCMS
12V 12V 12V
Va
Vb VCP 1kΩ 1kΩ 1kΩ

Resonator 1kΩ
Op-amp
1kHz ±12V 1.3kΩ 3.3kΩ 12V (Va) 9.21V 5.79V
(VCP) (VCP)
300pF 0.7V (VCP)
VCMS
S/W 3.3kΩ 993Ω
3.3kΩ
* Parallel
Composite
AC Earth
Resistance
Body : 1.3kΩ & 3.3kΩ
PD Circuit & Signal (Charging) Power Conversion System
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- P0D5816 Proximity Detection Circuit Low

▶ PD line Inspection (Inlet Side) - P0D5917 Proximity Detection Circuit High

 CCS1

Normal Open Short

Voltage : 4.46V 0V 0V
Resistance : 2.7kΩ 2.7kΩ under 1Ω

※ Caution
Disconnect 12V power when measuring resistance

5V VCMS
 CCS2
330Ω

PD Line

PD Inlet
2700Ω
GRD
CP Circuit & Signal (Charging) Power Conversion System
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▶ CP line Inspection (Inlet Side)

- P1CFA00 : AC Charger Control Pilot Signal Incorrect
 CCS1
- P1CFB00 : DC Quick Charger Control Pilot Signal Incorrect

Normal Open Short

3.3kΩ ??
Resistance : ??? under 1Ω
under 1Ω ??

Inlet VCMS
 CCS2
CP Line
CP
???
GRD

 Since the CP circuit on EV side is composed of a complex

circuit, it is difficult to determine the normal state of the circuit
simply by measuring the resistance.
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▶ CP line Inspection (Inlet Side)

 VCMS Current Data : “CP Voltage”

- P1CFA00 : AC Charger Control Pilot Signal Incorrect

- P1CFB00 : DC Quick Charger Control Pilot Signal Incorrect

Charging Gun Normal Open Short

VCMS Disconnected : 0.7V 0.7V 0.7V

Connected : 9.21V  5.79V 0.7V 0.7V

CP Circuit & Signal (Charging) Power Conversion System
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▶ CP(Control Pilot) PLC(Power Line Communication) Waveform – Fast DC charging

 IEC(International Electrotechnical Commission) standard PLC is applied to communicate be-

tween EVSE and EV during fast DC charging.

PWM PLC
Waveform Waveform
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▶ PLC(Power Line Communication) Circuit Diagram

EVSE (DC) CP Line High/Low 1 kHz PWM

High/Low
(PWM & PLC) CP Voltage
VCMS
Frequency Frequency
1kΩ Separation Separation
Circuit Circuit

2~28 MHz 2~28 MHz

Resonator PLC PLC 1.3kΩ 2.74kΩ
1kHz ± 12V

PLC Mo- PLC Mo- VCMS

dem dem S/W
(PCM) (PCM)

Body & AC
Ground
 PD & CP Circuit (V2L) Power Conversion System
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▶ V2L Circuit Diagram – PD / CP (V2L_Start)

 V2L gender detection via PD (Proximity Detection) circuits
- Consists of different resistance value according to the charging cable
 When the user presses the V2L Power switch, the VCMS detects it via the CP line.
- Power supply user request
V2L Gender Inlet VCMS
CP +
VCP
* GDS/KDS
Op-amp : CP Voltage
V2L S/W
- V2L
Power 5V
Switch VV2L_START
: Toggle 330Ω
PD Op-amp * GDS/KDS
: V2L Start button Volt
VPD
* GDS/KDS 3.3kΩ
75Ω (CCS1)
: PD Voltage
62Ω (CCS2)
S/W1 & 430Ω 2.7kΩ
- CCS1 only 430Ω
- Lock Lever Switch
: Normal Close ‘On’
CP -
AC Earth
 Lock Lever (CCS1 only) Body
: Charging Gun Switch Earth
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▶ V2L PD & CP Signal – CCS1

• Lock Lever ‘Released’ : S/W1 ‘ON’
 VCMS Current Data • Lock Lever ‘Pressed’ : S/W1 ‘OFF’

Connected

Items Disconnected Lock Lever ‘Released’ Lock Lever ‘Pressed’

V2L S/W ‘OFF’ V2L S/W ‘ON’ V2L S/W ‘OFF’ V2L S/W ‘ON’

PD Voltage 4.46V 1.5V 2.8V

Charger
9.21V (VCMS S/W ‘Off’)
CP Voltage 0.7V 5.79V
5.79V (VCMS S/W ‘On’)

PD Voltage 4.46V 0.91V 0.89V 2.82V 2.67V

V2L
Gender CP Voltage 0.7V 0.6V 1.00V 0.6V 2.7V
Connector
V2L Start
0.01V 0.01V 0.53V 0.01V 2.49V
button Volt

 V2L PD & CP Signal (Charging Connector vs. V2L Gender Connector)

1) The V2L gender connector has a resistance different from that of the charging connector for differentiation of
connection recognition.

2) The VCMS’s proximity detection voltage serves as the V2L gender connector’s control pilot voltage. (The
charging connector uses the charger’s 12C DC power.)

3) The internal resistance of the VCMS, connected to the V2L switch, being large, at 3.3kΩ, does not impact the
proximity detection circuit’s total resistance during V2L switch operation.
PD & CP Circuit (V2L) Power Conversion System
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▶ V2L PD & CP Signal – CCS2

 VCMS Current Data
Connected
Items Disconnected
V2L S/W ‘OFF’ V2L S/W ‘ON’

PD Voltage 4.46V 3.73V / 3.11V / 1.91V / 1.13V

Charger
9.21V (VCMS S/W ‘Off’)
CP Voltage 0.7V
5.79V (VCMS S/W ‘On’)

PD Voltage 4.46V 0.78V 0.76V

V2L
Gender CP Voltage 0.7V 0.7V 0.80V
Connector
V2L Start
0.01V 0.01V 0.38V
button Volt

 V2L PD & CP Signal (Charging Connector vs. V2L Gender Connector)

1) The V2L gender connector has a resistance different from that of the charging connector for differentiation of
connection recognition.

2) The VCMS’s proximity detection voltage serves as the V2L gender connector’s control pilot voltage. (The
charging connector uses the charger’s 12C DC power.)

3) The internal resistance of the VCMS, connected to the V2L switch, being large, at 3.3kΩ, does not impact the
proximity detection circuit’s total resistance during V2L switch operation.
 PD Circuit & Signal (V2L) Power Conversion System
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• Lock Lever ‘Released’ : S/W1 ‘ON’

▶ V2L PD Voltage – CCS1 • Lock Lever ‘Pressed’ : S/W1 ‘OFF’

Connected (V2L PWR off)

Condition Disconnected
Lever S/W1 “ON” Lever S/W1 “OFF”

PD Voltage (VPD) 4.46 V 0.91 V 2.82 V

Circuit Diagram
(V2L Gender ~ VCMS)

V2L Inlet VCMS

Gender 5V 5V 5V

5V
V2L S/W 330Ω 330Ω 330Ω 330Ω
(V2L
Power) VCP
VPD 4.46V 0.91V 2.82V
(0.89V:PWR on) (2.67V:PWR on)
Op-amp
75Ω

2.7kΩ 73Ω 425Ω

2.7kΩ 3.3kΩ
* Parallel Composite * Parallel Composite
S/W1 430Ω Resistance Resistance
(Lock : 75Ω & 2.7kΩ : 505Ω & 2.7kΩ
Lever)

AC
Earth
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▶ V2L PD Voltage – CCS2

Condition Disconnected Connected (V2L PWR off)

PD Voltage (VPD) 4.46 V 0.78 V

Circuit Diagram
(V2L Gender ~ VCMS)

V2L Inlet VCMS

Gender 5V 5V

5V
V2L S/W 330Ω 330Ω 330Ω
(V2L Power)
VCP
VPD 4.46V 0.78V
Op-amp (0.76V:PWR on)

62Ω
2.7kΩ 60.6Ω
3.3kΩ
2.7kΩ * Parallel Composite
Resistance
: 62Ω & 2.7kΩ

AC
Earth
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▶ V2L Gender PD line Inspection

 VCMS Current Data * If the data is abnormal, check the V2L Gender PD circuit.

Current Data V2L Connected V2L Disconnected

Charging Connector Status Connected Disconnected

V2L Connector Status V2L Plug Open

 V2L Gender Diagnosis - Multimeter

Items CCS1 CCS2

CP
PD

Check Point

Ground Ground

75Ω
PD Line ~ Ground Resistance 62Ω
505Ω
(Lock Lever pressed)

* In case of charging cable, There is no PD pin in the EVSE connector side.

 CP Circuit & Signal (V2L) Power Conversion System
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• Lock Lever ‘Released’ : S/W1 ‘ON’

▶ V2L CP(V2L_Start) Voltage – CCS1 • Lock Lever ‘Pressed’ : S/W1 ‘OFF’

V2L S/W “ON”

Condition V2L S/W “OFF”
S/W1 “ON” S/W1 “OFF”

CP Voltage (VCP) 0.70 V 1.00 V 2.70 V

V2L Start button Volt (VV2L_START) 0.01 V 0.53 V 2.49 V

Circuit Diagram  This circuit diagram is intended to understand the principle of CP voltage change,
(V2L Gender ~ VCMS) and some elements, such as OP-AMPs are omitted.
So, calculated CP voltage may be different from the actual measurements.
V2L Inlet VCMS
Gender 5V 5V

5V
V2L S/W 330Ω 330Ω 330Ω
VCP
(V2L Power)
VPD VV2L_Start 0.01V 0.53V 2.49V

Op-amp Op-amp Op-amp Op-amp

75Ω

3.3kΩ 3.3kΩ 73Ω 3.3kΩ 425Ω 3.3kΩ

2.7kΩ
S/W1 430Ω
(Lever)

* Parallel Composite * Parallel Composite

AC Resistance Resistance
Earth : 75Ω & 2.7kΩ : 505Ω & 2.7kΩ
CP Circuit & Signal (V2L) Power Conversion System
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▶ V2L PD & CP(V2L_Start) Range – CCS1

PD Sensing

5V Connected
PD Open
4.7V 4.46V
4.46V Lever Lever Lever
Cable
Unlock Unlock Unlock
Disconnected 2.80V
3.5V Lever Lever
Cable Lock Lock
0.89V
Connected 2.77V
(Lever Unlock)
2.0V
Cable
Connected V2L Start
1.53V Sensing
(Lever Lock) (Charging Cable)
1.2V
0.89V (V2L) V2L
V2L Range S/W-on
2.49V
V2L V2L
0.1V S/W-on S/W-on
0.53V V2L V2L
PD GND Short
S/W-off S/W-off
0V 0.01V
V2L V2L V2L V2L
Start Stop Start Stop
 CP Circuit & Signal (V2L) Power Conversion System
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▶ V2L CP(V2L_Start) Voltage – CCS2

Condition V2L S/W “OFF” V2L S/W “ON”

CP Voltage (VCP) 0.70 V 0.80 V

V2L Start button Volt (VV2L_START) 0.01 V 0.38 V

Circuit Diagram  This circuit diagram is intended to understand the principle of CP voltage change,
(V2L Gender ~ VCMS) and some elements, such as OP-AMPs are omitted.
So, calculated CP voltage may be different from the actual measurements.
V2L Inlet VCMS
Gender 5V

5V
V2L S/W 330Ω 330Ω
VCP
(V2L Power)
VV2L_Start 0.01V 0.38V
VPD

Op-amp Op-amp Op-amp

62Ω
3.3kΩ 3.3kΩ 61Ω 3.3kΩ
2.7kΩ

* Parallel Composite
AC Resistance
Earth : 62Ω & 2.7kΩ
CP Circuit & Signal (V2L) Power Conversion System
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▶ V2L PD & CP(V2L_Start) Range – CCS2

PD Sensing
5V
PD Open
4.7V
Cable 4.46V 4.46V
Disconnected Connected
4.0V
3.73V (AC 1Ph. 13A)
(Fast DC)
0.78V
3.11V (AC 1Ph. 20A)

Cable
2.0V Connected
1.90V (AC 1Ph. 32A)
V2L START
Sensing

1.13V (AC 3Ph. 63A)

1.0V (AC 1Ph.
0.76V 70A)
(V2L) V2L
V2L Range S/W-on
0.38V V2L V2L
0.1V PD GND S/W-off S/W-off
0.01V
0V Short
V2L V2L
Start Stop
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Power Conversion System

ICCB (In-Cable Control Box)
ICCB (In-Cable Control Box) Power Conversion System
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▶ ICCB Main Components (3rd Generation)

No. Parts EA Remarks

(1) Case 2  Display applied

(3) (2) Button 1  Waterproof Structure (IP67 Rating)

(1)
(3) Lens 1  Indication (Power / Charge / Fault)

(2)
(9) (4) Silicon 1  Waterproof Structure (IP67 Rating)
(10)
 CP Comm. / Blocking / Diagnostics
(5) (6) (5) MCU 1 (NXP Bollero, 32-bit, 64-pin)
(4)
(7)  AC Power Supply / Shut-off
(6) Relay 2 (SANYOU 22A)

 AC -> DC Conversion
(7) SMPS 1 (Driver IC, Trans, Rectification Diode)

 Detecting Leakage Current

(8) (8) ZCT 1 (Power Shut-off in case of leakage)

 Displays ICCB states of operation

(9) LED 3 (Power / Charge / Fault)

 Numeric Display
(10) 7-segment 1 (Error codes, Charging Current)
ICCB (In-Cable Control Box) Power Conversion System
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▶ Indication Lamp Configuration

Plug-In
Plu
Plug
g-
-In
Plu In
g- Plug-In
In

Items Display Status

Power  On : Power Plug-In

 On : Charging
Charge  Blinking : Current Limits (Fault Code : 06)
due to Plug/ICCB High Temperature

 Blinking : Stop Charging

Fault
(Leakage, Excessive Current, Hi-Temp Protection)

 On : Charging Current Display

Charge Level (Current)  Blinking : Variable Charging Current Mode
ICCB (In-Cable Control Box) Power Conversion System
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▶ Indication Lamp Lights-On Condition (1)

No. Display Status

 Power Plug-In
1
- Power Light-on: Green

 Connect the ICCB’s Outlet to Vehicle’s Inlet

2
- Power Light-on : Green

 In Charging
- Power Light-on : Green
3
- Charge Light-on : Blue
- Numeric Display : Charging Current Display

 Before connecting to a vehicle

- Power Light-on : Green
- Fault Light-blinking : Red
4 : Current Leakage
: Too high temperature in Plug or ICCB inside
: Breakdown of ICCB’s Diagnostic Element
 Contact to A/S Center
ICCB (In-Cable Control Box) Power Conversion System
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▶ Indication Lamp Lights-On Condition (2)

No. Display Status

 Fault Code E2
- Power Light-on : Green
- Fault Light-blinking : Red
5 - Numeric Display : E2
 If the power plug is disconnected and reconnected again, and the
buttons on the ICCB remain pressed for more than 2 seconds, the
error is released.

 Power-save Mode
- Power Light-on : Green
6 - Charge Light-on : Blue
- Numeric Display : If status is not changed for more than 1 minute,
numeric display will be turned off.
ICCB (In-Cable Control Box) Power Conversion System
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▶ Status Display & Fault Code

Display Mode Details

Power - Power Light-on : Green

(Plug-in) - Numeric Display : Target Current

- Power Light-on : Green

Charge - Charge Light-on : Blue
- Numeric Display : Charging Current (off after 1min.)

 Current Limit due to Plug/ICCB High Temperature

Charge - Power Light-on : Green
(Current Limit) - Charge Light-blinking : Blue
- Numeric Display : Fault Code 06

 Error while self-Diagnostic

- Power Light-on : Green
- Numeric Display : Fault Code

 Error while Charging

Fault - Power Light-on : Green
(Error Or Failure) - Fault Light-blinking : Red
- Numeric Display : Fault Code
 Poor Ground – ICCB’s Power Plug (GM/I Fault mode)
- Power Light-blinking : Green
- Fault Light-blinking : Red
- Numeric Display : F2 (NA only)
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▶ Charging Current Setting Mode

Mode Display Details

 Numeric Display Blinking : Charging Current

Entering • Keep the button pressed for more than 2 seconds to

(Charge Cur-
8 seconds in Standby Mode or Charge Mode.
rent Setting
Mode)
('Fault' light-off Condition)

Keep Pressing
(2~8Sec.)

 Numeric Display Blinking : Charging Current Display

 Current Value Increases with every Single Button Input
• In the current setting mode,
Charge Cur- the charging current value Increases with every sin-
rent Setting gle button Input. (keep pressing below 1 sec.)
• The factory initial value is 6A.
Keep Pressing
below 1 sec.

• In the current setting mode, after changing to the

desired current value, press the button for more
Release
(Charge Cur- than 1 second to complete the setup.
rent Setting • After more than 10 seconds without a button input,
Mode)
it returns to the previously set value and automati-
Keep Pressing
over 1 sec. cally back to the Standby Mode.
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▶ Countermeasure for E2 Error Code

Case Display Details

CASE 1 • ICCB for North America

Automatically recover when power plug is
(NA) removed and reconnected

1) Fault Code 2) Plug off

3) Recovered
‘E2’ and in again

• ICCB for except on North America

CASE 2 : Remove the power plug and reconnect it.
After this, press the button for more than 2
(non-NA)
seconds to automatically recover.
1) Fault Code 2) Plug off 3) Keep Pressing
4) Recovered
‘E2’ and in again over 2 sec.

Remarks Please contact the A/S center if the above information cannot be recovered even after two to three repetitions.
ICCB (In-Cable Control Box) Power Conversion System
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▶ Fault Code History Monitoring & Reset

Items Display Details

• Continue pressing the button for at least 8 seconds to recall the

Fault
Code failure code history that occurred in the past.
Recall : Fault code calls can be made while ‘Standby Mode’ without
1) Standby 2) Keep Pressing 3) Code Fault Light.
Mode over 8 sec. History

Method
1) • Return to ‘Charging mode’.
Return to Method 1)
Charging : Remove and reconnect the power plug
Mode Method Keep Pressing Method 2)
2) 2~8 sec. : Keep the button pressed for 2 to 8 seconds.

Delete • If a button is pressed for more than 8 seconds while a fault code
Stored
Fault is called, the fault code is cleared and then back to ‘Charging
Codes Mode’.
1) Code 2) Keep Pressing 3) Cleared
History over 8 sec.