TRAVEL CORDSET AND WALL STATION TEST REPORT

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1 GENERAL MOTORS TRAVEL CORDSET AND WALL STATION TEST REPORT REVISION 4 EVSE Model: Click here to enter text. Serial Number: Click here to enter text. Test Engineer: Click here to enter text. Date: Click here to enter a date.

2 EVSE Summary Please use this section to document any comments regarding this EVSE. Issues observed, unique features, etc. Works with all GM features and functions (note any exceptions, are there any user configurations or software levels required) No DTC s during test procedure Time to achieve amber CSI Time to achieve green CSI and horn bip Weeks of GM exposure (indoor / outdoor, locations, etc.) J1772 Issues Vehicle Compatibility Issues Unique Features (delay, power meters, connectivity, etc.) Photos

3 General EVSE Information Current Rating of EVSE Specified temperature range Frequency Compatibility (50 Hz, 60Hz, Both?) North America Level 1 Voltage range (120 VAC) North America Level 2 Voltage range (240 VAC) Is 208 VAC supported? Is neutral required? Export Voltage Range EVSE vehicle plug type Manufacturer (Rema, Delphi, Yazaki, etc.) Type (SAE, Menekes) Pilot signal characterization Instruction: For 1 x tests, use a breakout box and oscilloscope to adjust the pilot voltage and measure EVSE reaction. Test 1 1: Measure the pilot voltage with no breakout box or vehicle connected Test1 2,3,4,5: Adjust the pilot voltage to the equivalent of S1 applied to simulate plugging into a vehicle. Measure the Frequency and Pulse Width of the Pilot. Repeat test to include any reduced power modes. Test 1 6,7: Adjust (reduce) the pilot voltage to engage the AC relays and record value. Continue to reduce the pilot voltage until the AC relays drop out and record value. Test Description Result 1 1 Disconnected voltage 1 2 Frequency Normal Rate (S1) 1 3 Pulse Width Normal Rate (S1) 1 4 Frequency Reduced Rate (S1) 1 5 Pulse Width Reduced Rate (S1) 1 6 Max Voltage to engage AC (S2) 1 7 Min Voltage to engage AC (S2)

4 Undervoltage fault Instructions: Use the Lab Variac to reduce the voltage to the EVSE to a point where the EVSE indicates a fault. Then raise the voltage and record where the EVSE clears its fault. Complete 1 x tests using a breakout box. Complete 2 x tests with the vehicle Test Description Result 1 a Voltage threshold to set fault lamp 1 b Pilot duty cycle during fault 1 c Does fault clear if voltage recovers? Voltage threshold to clear fault lamp. 1 d Time (if any) to clear fault condition 2 a While charging the vehicle, slowly lower AC input voltage (2 V/sec or slower) to 0 VAC. Verify no DTCs set 2 b Slowly raise the AC input voltage (2V/sec or slower) from 0 V to EVSE operating voltage. Verify vehicle resumes charging and no DTC s. Proximity (Cord Present) Resistance Description Proximity resistance, trigger not pressed Proximity resistance, trigger depressed VICM Proximity Voltage, trigger not pressed (EVSE Powered) VICM Proximity Voltage, trigger not pressed (EVSE Unpowered) VICM Proximity Voltage, trigger pressed Result

5 Ground monitoring characterization 120 VAC Instruction: Use the Wall Breakout box to test the following 1. Interrupt the ground using the breakout box switch. Note if the unit enters a fault state and record below. 2. Use breakout box to introduce a non zero Ground to Neutral resistance/voltage. Increase this resistance/voltage starting at zero until the EVSE enters a fault state. If unit does not fault, stop test at 18 VAC and record resistance / voltage 3. With Ground Wire connected, engage S2 to apply AC at vehicle plug. Disconnect ground and record pilot signal duty cycle during fault. If not immediate, wait up to 15 minutes and note if unit trips and the time required. 4. While the unit is in a fault state with S2 not applied, reconnect a proper ground connection. Does normal operation resume? If not immediate, wait up to 15 minutes and note if unit trips and the time required. 5. Repeat the sequence in line 4 up to 5 times to determine if there is a limit on retry attempts. 240 VAC Instruction: 1. With AC power removed from EVSE, the disconnect ground wire between the EVSE and the AC source. Verify Unit enters a fault state. 2. Reconnect AC Ground. Apply AC power. Engage S2 to apply AC at vehicle plug. Disconnect ground and record pilot signal duty cycle during fault. 3. While the unit is in a fault state with S2 not applied, reconnect a proper ground connection. Does normal operation resume? If not immediate, wait up to 15 minutes and note if unit trips and the time required. 4. Repeat the sequence in step 3 up to 5 times to determine if there is a limit on retry attempts. Test Description Result 120 VAC VAC Ground Disconnection Fault. Time to fault? 120 VAC 2 For 120 VAC, EVSE to GND Voltage to trip diagnostic Resistance to trip diagnostic 120 VAC 3 Pilot signal duty cycle during a fault? 120 VAC 4 Automatic fault reset? 120 VAC 5 Number or retries allowed 240 VAC VAC Ground Disconnection Fault. Time to fault? 240 VAC 2 Pilot signal duty cycle during a fault? 240 VAC 3 Automatic fault reset? 240 VAC 4 Number or retries allowed

6 Ground Fault Circuit Interrupter performance Instruction: 1. Plug EVSE into a non GFCI protected outlet. 2. Use breakout box to apply S2 and engage AC relays. 3. With breakout box, introduce a leakage current beginning at 0 ma. Observe the fault current reported on the meter. Increase the leakage current until the EVSE enters a fault state. a. Record the trip current threshold b. Verify the AC relays opened c. Record the Pilot Duty cycle and Voltage d. Disengage S2 and wait for duty cycle to resume, note time up to a max of 15 minutes. 4. With the EVSE in a non faulted state, attempt to close S2 with the leakage resistance in place. a. Verify EVSE enters a fault state b. Disengage S2, but maintain pilot voltage at State B (9.0V). Does the EVSE remain faulted? c. If unit remains faulted, does it clear if pilot voltage is restored to 12V? Test Description Result 3 a Leakage current on Line 1 to cause fault. Leakage current on Line 2 to cause fault. (240 VAC) 3 b Did the AC relays open? 3 c What is the Pilot Signal Voltage and Duty Cycle during the fault? 3 d Does the EVSE perform a self reset? If yes, what is the time delay. 4 b Does GFCI fault latch when S2 is applied into a fault? 4 c Does the GFCI fault clear when the Pilot voltage returns to 12V (unplugged)?

7 Application of AC energy to the vehicle Instruction: This test is in place to evaluate the performance of the EVSE relative to the amount of time required to actually show energy is available as well as the time to switch energy to the vehicle. In addition, this should help identify potential diagnostic issues. Please monitor the following signals. On Board Charger AC Input Voltage On Board Charger AC Input Current High Voltage Charger Coupler Proximity Voltage Control Pilot Voltage Control Pilot Duty Cycle Please embed an.mdf data file and attach screenshot of the plug in. Test How long does it take from the time of plug insertion to an amber Charge Status Indicator (valid pilot signal)? How long does it take after S2 is applied (6.0V pilot signal) until there is AC voltage at the OBCM? During the first 5 seconds that the pilot voltage is at State C level (6.0V), does the duty cycle toggle to any no power available regions (<10% or >90%)? During the first 5 seconds that the pilot voltage is at State C level (constant 6.0V), does the AC voltage cycle as part of an EVSE diagnostic? During the first 30 seconds that the pilot voltage is at State C level (6.0V), does the duty cycle ramp to a different value? Result Insert screen shot here.

8 Miscellaneous Input Power Test Cases For a 240 VAC station, check operation with both 240 VAC split phase and 208 VAC derived from a three phase source. Does the unit charge if plugged into the car before the wall? If there is a power up delay, please comment. Does the EVSE re initiate charging if power is quickly switched via a circuit breaker or external switch? Remove AC power from the EVSE. Ensure the Loss of AC feature works. Ensure Cordset Theft Alarm is not activated until cord is removed from car. Miscellaneous Charge Initiation Test Cases Initiate charging after the car has been at rest for 5 minutes. Verify vehicle starts charging. Verify no DTC s are set. Initiate a remote start. Verify AC energy transfer. Verify no DTC s. Cycle EVSE 5 times while in the CSI in the amber state. Leave handle in vehicle following last cycle. Verify vehicle charges at conclusion. Verify no DTC s. Plug EVSE into vehicle very slowly. Verify vehicle charges. Verify no DTC s. Miscellaneous functions while plugged in Using the Variac on the bench, raise and lower the AC voltage level to create line transients where charging stops and starts. Ensure the vehicle resumes charging, and no DTC s are set. Consider transients that capture the operating regions of the EVSE, min AC level for charging, transition voltages for high and low tap modes. (85 VAC +/ 20 VAC and 180 +/ 20 VAC are initial suggestions) If equipped, does the Charge Rate button work when EVSE is attached to vehicle? Does it retain its state over power cycles For a travel EVSE, what happens if the EVSE is dropped while charging? Start with 6 then 12 and then 24. Please comment on observations. Verify vehicle motion is inhibited when EVSE is not plugged into AC power.

9 Time of Day Charging Interaction Set vehicle departure time to enable a delayed charge. Verify vehicle will enter the delay mode. Does the unit work with a double pump to override time of day charging. Plug EVSE into vehicle very slowly. Verify vehicle charges and retains the delay mode. Verify no DTC s. GM Vehicle Interaction with Unique EVSE Features Set vehicle departure time to enable a delayed charge. Please note any additional tests or condition looked at with regard to unique EVSE features not covered in this test procedure. EVSE Stress Tests Does the unit survive opening line 1 and line 2 or neutral separately? Does the unit survive a short circuit on its output? Instructions: IMPORTANT: DO NOT EXCEED RATED VOLTAGE OF EVSE FOR THIS TEST. Use the Lab Variac to increase the voltage to the EVSE to a point where the EVSE indicates a fault. Then lower the voltage and record where the EVSE clears its fault. Over Voltage threshold to set fault lamp Over Voltage threshold to clear fault lamp

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