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Testing Basic and Advanced

Written By: Christopher Howell (and 2 other contributors)
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    • Testing is an important part of the OpenEVSE build process. This guide provides testing recommendation both for the user and those developing hardware and software.

    • OpenEVSE performs extensive self test during boot, before closing relays/contactors and while operating.

    • Basic Testing is recommended for all builders after building your charging station and whenever maintenance is performed.

    • Advanced testing shall be performed by hardware and software developers before releasing "Stable" firmware or a new hardware revision.

    • For builders wishing to better understand how a charging stations work, Advanced Testing may be performed.

    • Advanced Tests require live AC Power. Use extreme caution when working near energized high voltage components.

    • During the boot process OpenEVSE will run a Power on Self Test (POST).

    • If the POST fails by indicating any Error condition or a RED LED/LCD please refer to the Troubleshooting guide before proceeding.

    • EVSE states can be tested with a few resistors and a diode, and EV Simulator or an EVSE Tester.

  4. Power on OpenEVSE Charging Station with the GFCI coil with self test loop disconnected.

    • Power on OpenEVSE Charging Station with the GFCI coil with self test loop disconnected.

    • The OpenEVSE Charging Station should fail the boot process with "Error GFCI Self Test Failed" and indicate red on the LED/LCD.

    • If the Power on Self Test deos not fail with the coils disconnected, check that GFCI Self Test is enabled in the Service Menu.

    • If GFCI self check is enabled and the test does not fail please refer to the Troubleshooting guide.

    • The following tests are intended for Hardware and Software developers to validate hardware revisions and validate production software.

    • Builders who wish to better understand the safety features of OpenEVSE Charging Stations may proceed if desired.

    • Advanced Tests require live AC Power. Use extreme caution when working near energized high voltage components.

    • GFCI must trip between 15ma and 20ma.

    • Using Ohms Law select to correct 5 watt resistors to draw 15ma and 20ma. Alternatively, a 5 watt resistor selected for 12ma plus a 5k 5w pot can be used to determine the exact trip point.

    • US - 120v line to ground 8k = 15ma and 6k = 20ma

    • Europe 230v line to ground 15.3k = 15ma and 11.5k = 20ma

    • While the EVSE is in State C "Charging" connect a wire with the 15ma resistor in parallel through the GFCI coil from one hot to ground. The Charging Station should not trip.

    • While the EVSE is in State C "Charging" connect a wire with the 20ma resistor in parallel through the GFCI coil from one hot to ground. The Charging Station should trip this time.

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Christopher Howell

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