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A small PBC to simulate the CP and PP signals of an electric vehicle (EV)

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pulsatrix-emobility/CP-PP-miniEVsimulator

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CP-PP-miniEVsimulator

This is a small PBC to simulate the CP signal of an electric vehicle (EV) and the PP signal of the IEC 62196 type 2 or SAE J1772 type 1 plug according to IEC 61851.

CP-PP-EV-simulator inclined

CP-PP-EV-simulator front

CP-PP-EV-simulator back

CP-PP-EV-simulator schematic

PDF Schematic

CP signal

The EV shows different resistor values to signal its status. 5 miniature toggle switches allow to simulate the CP signal for following EV states:

status S1 S2 S3 S4 S5 description
A off x x x x EV disconnected
B on off x off off EV connected
C on on off off off charging request
D on on on off off ventilation request
E on x x on off short circuit
R on x x x on diode shorted

PP signal

Different resistor values in the connector on each side fo the charging cable signal the EVSE and the EV the ampacity of the cable, to avoid an overload condition. Another 5 toggles switches allow to simulate the PP signal for the following cable ampacities:

ampacity S6 S7 S8 S9 S10
disconnected off x x x x
13A on off x x x
20A on on off x x
32A on on on off x
63A on on on on off
short on on on on on

The PP part of the PCB can be broken off to reduce PCB size when the PP simulation is not nedded.

Bill of materials

designator value  
R1 120Ω
R2 2.7kΩ
Ra2 39Ω
R3 1.3kΩ
R4 270Ω
D5 1N4934
R6 1.5kΩ
R7 1.2kΩ
Ra7 47Ω
R8 330Ω
R9 180Ω
R10 68Ω
S1,S2,S3,S4,S5,S6,S7,S8,S9,S10 miniature Toggle switch
case hammond 1551K
2mm zip tie

Simulation of the simulator

The simulator can be simulated here: https://tra.fo/cp-simulation

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A small PBC to simulate the CP and PP signals of an electric vehicle (EV)

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