EV Charger Schematic Review

flux

已开始处理你的请求，但现在账户没有可用 ACUs，AI 功能暂时不可用，所以我不能继续调用工具完成修改。
目前本轮已完成：
  • 读取并理解任务：按顺序整理这些 sheet，并加入 K_CHG / K_DIS 硬件互锁后重新 ERC。
  • 检查了当前 K_CHG / K_DIS 线圈驱动相关连接：
    • 两个接触器线圈目前都直接由 24V_RELAY_AFTER_ESTOP 供电；
    • K_CHG_COIL_LOW 和 K_DIS_COIL_LOW 分别由 Q1/Q2 低边 NMOS 驱动；
    • 目前尚未加入真正的硬件互锁触点。
  • 确认当前 schematic 视觉整理还没有实际完成；上一条进度里“cleanup completed”不代表已经完成可视排版。
还需要继续做：
  • 添加 K_CHG / K_DIS 硬件互锁，建议用对方的 NC 辅助触点串入本接触器线圈供电路径：
    • 24V_RELAY_AFTER_ESTOP -> K_DIS_NC_INTERLOCK -> K_CHG coil
    • 24V_RELAY_AFTER_ESTOP -> K_CHG_NC_INTERLOCK -> K_DIS coil
  • 按顺序渲染/展示：
    1. CP_GENERATION_AND_MONITOR
    2. CC_PP_RC_R4_AND_DISCHARGE_IDENTIFICATION
    3. CHARGE_AND_DISCHARGE_CONTACTOR_CONTROL
    4. AC_MAIN_PATH_AND_BIDIRECTIONAL_MEASUREMENT
    5. POWER_MCU_COMMUNICATION
  • 重新运行 ERC，并修复或记录剩余 unresolved items。
H

hanlinzhen

flux

I can’t run analysis, auto-placement, or routing right now because the account has no available ACUs, so AI execution features are unavailable.
What was accomplished so far in this session:
  • The EV charge controller/test board was refined into a review-stage logical schematic.
  • The pilot architecture was corrected to use PILOT_OUT, with CP/CC/PP interpretation notes updated.
  • R1_CP was defined as the mandatory 1.000 kΩ, 0.1%, 0.5 W GB/T control-guide equivalent series resistor, with CP monitoring on the CP_OUT side.
  • Discharge-identification branches and full-board schematic notes were added.
  • A later request to clean schematic sheets and add K_CHG/K_DIS hardware interlock was started conceptually but not completed due to ACU limits.
What remains to be done:
  • Inspect current PCB state to determine whether placement, routing, or both are needed.
  • If placement is incomplete, run auto-layout/component placement.
  • If placement is usable but airwires remain, run routing.
  • Apply the resulting layout/routing changes automatically.
  • Run board checks/DRC afterward.
  • Keep this project marked REVIEW REQUIRED for HV, relay pinout, creepage/clearance, thermal, EMC, protection, and manufacturing readiness.
Manual PCB checklist
Check placement status
Find unrouted nets
Verify HV clearance
Review BOM risks
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Files

Schematic

Layout

3D View

Project Specification
Project Overview
  • Name: EV Charge Controller Test Board
  • Status: Review-stage logical schematic only
  • Purpose: Programmable single-phase AC EV charging controller and test board for IEC/GB/T-style control-pilot and cable-coding experiments.
  • Critical limitation: This is not production-ready and not safety-certified. Do not claim compliance and do not generate final manufacturing files from this revision.
Intended Use
  • Bench/review prototype for evaluating EVSE control behavior, CP generation/monitoring, CC/RC/S3 emulation, relay control, and output measurement.
  • External upstream RCD/MCB is assumed.
  • No RCD or MCB is included on this board.
Required Hierarchical Sheets
  • TOP_LEVEL_INTERFACES
  • POWER_MCU_COMMUNICATION
  • CP_GENERATION_AND_MONITOR
  • CC_PP_RC_R4_AND_DISCHARGE_IDENTIFICATION
  • CHARGE_AND_DISCHARGE_CONTACTOR_CONTROL
  • AC_MAIN_PATH_AND_BIDIRECTIONAL_MEASUREMENT
  • REVIEW_AND_TEST_STATE_TABLE
What the Device Should Do
  • Accept an external isolated 24 VDC control supply.
  • Generate IEC/GB/T-style 1 kHz CP signaling in normal and programmable test modes.
  • Emulate CC/PP passive discharge-identification and normal charging RC/R4/S3 conditions through CC_PP_OUT, while active CP waveform generation remains on a separate CP_OUT terminal.
  • Switch both line and neutral simultaneously using the two main poles of K1; do not swap L and N.
  • Keep PE permanently continuous from PE_IN to PE_OUT; PE is never software-switched.
  • Measure output current and voltage after the main relay for monitoring only.
  • Support Ethernet, isolated RS-485, SWD, UART debug, watchdog, and service jumper functions.
Main Features
  • STM32G474RET6 MCU control core.
  • 24 V to 5 V conversion using LMR33630 and 5 V to 3.3 V using AP63203.
  • W5500 Ethernet and ADM2587E isolated RS-485.
  • Isolated ±15 V CP analogue supply using WRE2415S-1WR2.
  • MCP4922 DAC, REF5050 reference, 74AHCT125 logic buffer, OPA197 analogue stages, ADG1419 high-Z CP interruption.
  • HF170F/24-2H1DTF candidate main relay/contactor with auxiliary feedback.
  • 40 A / 20 mA CT current measurement and high-impedance L/N voltage measurement.
System Architecture
Diagram



  
    
  
  
    
  
































External isolated 24 VDC
LMR33630 5 V
AP63203 3.3 V
STM32G474RET6
W5500 Ethernet
ADM2587E Isolated RS-485
CP DAC / Buffer / OPA197 Stages
ADG1419 CP High-Z Switch
CP_OUT active CP terminal
RC / R4 / S3 and Discharge Identification Network
CC_PP_OUT passive CC / PP terminal
Main Relay Coil Driver
L/N Two-Pole K1 Switching
Output Voltage and Current Measurement
PE_IN
PE_OUT Continuous
Hardware Subsystems
TOP_LEVEL_INTERFACES
  • Named sheet boundary nets and test points for 24V_IN, 5V, 3V3, +15V_ISO, -15V_ISO, CP_OUT, CC_PP_OUT, PE_IN/PE_OUT, L_IN, N_IN, L_OUT, N_OUT, RS485_A/B, Ethernet, SWD, UART, K1 control/feedback, ADC inputs, and service/watchdog signals.
  • Correct external vehicle-side terminals: PE_OUT, CP_OUT, and CC_PP_OUT.
  • CC_PP_OUT silkscreen text: “CC / PP”.
  • Do not use a separate PP_OUT terminal.
POWER_MCU_COMMUNICATION
  • External isolated 24 VDC input.
  • 24V input protection placeholders: fuse, reverse-polarity protection, and TVS. Ratings/coordination are REVIEW REQUIRED.
  • STM32G474RET6 MCU.
  • LMR33630 24 V to 5 V buck; AP63203 5 V to 3.3 V buck.
  • W5500 Ethernet with generic RJ45 placeholder marked VERIFY FOOTPRINT / PINOUT BEFORE RELEASE.
  • ADM2587E isolated RS-485 with TVS and selectable 120 ohm termination.
  • SWD, UART debug, watchdog, and service jumper.
CP_GENERATION_AND_MONITOR
  • 1 kHz CP signal.
  • Normal mode: +12 V / -12 V.
  • Test mode: independently programmable +11 V to +13 V and -11 V to -13 V platforms.
  • WRE2415S-1WR2 isolated ±15 V supply.
  • MCP4922 + REF5050 + 74AHCT125 + OPA197 + ADG1419.
  • 1.000 kOhm 0.1% CP series resistor.
  • Mandatory R1_CP = 1.000kΩ, 0.1%, 0.5W series resistor between the CP source switching circuit and CP_OUT.
  • R1_CP is the GB/T control-guide equivalent resistor R1; it is not optional and is not merely a protection resistor.
  • CP voltage monitor is connected on the CP_OUT side of R1_CP, relative to PE_OUT, and feeds the MCU/control domain through a review-required protection/isolation boundary.
  • Physical CP output disconnect/high-Z control is provided for test and engineering modes.
  • CP_OUT and PE_OUT test points are required.
  • In GB CP mode, the active CP waveform source may connect through the protected 1k output resistor to CP_OUT.
  • In EU/US PP mode, the active ±12 V CP generator must be physically disconnected/high impedance.
  • Never connect the CP waveform generator to CC_PP_OUT.
  • The PE-referenced CP analogue monitor domain and MCU/control domain require isolation/protection review.
CC_PP_RC_R4_AND_DISCHARGE_IDENTIFICATION
  • External vehicle signal terminal for passive resistance identification: CC_PP_OUT, silkscreen “CC / PP”, plus PE_OUT.
  • No S2 detection/connection.
  • Supersedes earlier terminal interpretation: PILOT_OUT is obsolete. The schematic has been revised to use CP_OUT for active CP waveform generation and CC_PP_OUT for passive CC/PP resistance networks.
  • Normal charging RC/R4 path topology: PE_OUT -> [selected R4 path OR S3 bypass switch across selected R4] -> selected RC -> RC enable switch -> CC_PP_OUT.
  • R4 and RC are series elements in the normal charging route.
  • R4 selection and RC selection are independent; do not force value pairing.
  • S3 bypass switch is connected in parallel across the selected R4, so closing S3 bypasses R4.
  • The normal RC/R4 path is one complete selectable route.
  • RC values: 1.500k, 680R, 220R, with ±3% boundary test selections.
  • R4 values: 1.8k, 2.7k, 3.3k.
  • External-discharge identification paths are independent direct PE-to-CC_PP_OUT paths and do not pass through RC or R4:
    • PE_OUT -> K_DIS_GB -> R_DIS_GB -> CC_PP_OUT, with R_DIS_GB = 2.00kΩ, 0.5W axial flameproof.
    • PE_OUT -> K_DIS_EU -> R_DIS_EU -> CC_PP_OUT, with R_DIS_EU = 50Ω, 1W axial flameproof.
    • PE_OUT -> K_DIS_US -> R_DIS_US (DNP) -> CC_PP_OUT, vehicle-specific reserve with 1W axial-compatible through-hole footprint.
  • No universal US/J1772 discharge resistance is claimed.
  • Interlocking: the complete normal RC/R4 route must be mutually exclusive with every discharge-identification route.
  • Only one of K_DIS_GB, K_DIS_EU, and K_DIS_US may be active.
  • RC and R4 remain independently configurable within the normal charging route.
  • All passive resistance routes released must leave CC_PP_OUT open circuit.
  • CC_PP_OUT is used only as a passive resistance network for the vehicle to detect. The board does not measure CC/PP-to-PE voltage and must not include CC/PP voltage sensing.
CHARGE_AND_DISCHARGE_CONTACTOR_CONTROL
  • Candidate: Hongfa HF170F/24-2H1DTF.
  • K_CHG: two-pole L/N charge contactor candidate HF170F/24-2H1DTF.
  • K_DIS: independent two-pole L/N discharge-output contactor placeholder.
  • K_CHG and K_DIS must never be closed simultaneously.
  • E_STOP_NC hardwired in series with the 24 V coil supply for both contactors.
  • =100 V NMOS drivers, gate protection, flyback suppression, and optocoupler-isolated auxiliary feedback.
  • Relay pinout/footprint marked VERIFY AGAINST SUPPLIER DRAWING OR SAMPLE.
AC_MAIN_PATH_AND_BIDIRECTIONAL_MEASUREMENT
  • Charge path: L_IN/N_IN -> K_CHG -> L_VEH/N_VEH.
  • Discharge path: L_VEH/N_VEH -> K_DIS -> L_DIS_OUT/N_DIS_OUT.
  • PE_IN, PE_OUT, and PE_DIS_OUT are permanently continuous; never switch PE.
  • CT placeholder on vehicle-side L conductor for bidirectional current polarity.
  • Vehicle-side L/N voltage measurement on L_VEH/N_VEH using symmetric high-impedance divider and differential AFE.
  • Report RMS voltage/current and signed real power direction in firmware/reporting.
  • Heavy 32A copper routing requirements are documentation only, not PCB layout.
REVIEW_AND_TEST_STATE_TABLE
  • Captures normal charge, test, engineering, GB/EU/US discharge candidate modes, normal stop, emergency stop, relay interlock, all-open safe state, and unresolved safety/thermal/isolation/creepage/EMC/manufacturing review items.
Power and Runtime Expectations
  • Powered from external isolated 24 VDC source.
  • On-board rails: 24V_IN, 5V, 3V3, +15V_ISO, -15V_ISO, 1V65_BIAS, REF_5V.
  • No battery/runtime requirement.
Physical Design Expectations
  • PCB size target: 260 mm x 180 mm.
  • 4-layer, 2.0 mm FR-4, 4 oz outer copper.
  • 15 mm is the minimum continuous width target for the narrowest L/N heavy-copper path on the outer layers; it is not a thermal parameter.
Important Design Decisions
  • Do not include RCD; rely on external upstream RCD/MCB.
  • Switch both L and N with K1; PE must remain permanently continuous.
  • Vehicle-side L/N may see reverse AC voltage up to normal input voltage for up to 30 seconds with relay open.
  • Use generic mechanical placeholders for HF170 relay, M6 AC terminals, RJ45, CT, and small relays.
  • Correct terminal ownership: CP_OUT is for active CP waveform generation and CP-to-PE monitoring only; CC_PP_OUT is for RC, R4/S3, and GB/EU/US passive discharge-identification resistors only. Never connect the CP generator to CC_PP_OUT, and never connect RC/R4/discharge resistors to CP_OUT.
Review Required / Open Safety Checks
  • High-voltage safety and creepage/clearance.
  • Relay/contactor pinout, footprint, contact rating, auxiliary contact mapping, and coil behavior.
  • M6 terminal footprints and current/thermal rating.
  • Copper width, bottleneck, via stitching, and temperature rise at 32 A.
  • EMC, surge, ESD, transient, and protection strategy.
  • CT accuracy, voltage AFE safety, and measurement calibration.
  • Regulatory/safety compliance review by qualified personnel.
Change Notes
  • Initial project specification created from user-provided requirements and corrected follow-up attachment.
  • Added CC/PP discharge-identification branch requirements and interlock constraints for GB, EU, and US/J1772 reserve branches.
  • Corrected terminal architecture again: PILOT_OUT is superseded. The board has three external vehicle-side terminals: PE_OUT, CP_OUT, and CC_PP_OUT with silkscreen “CC / PP”. No CC/PP-to-PE voltage sensing is required or allowed.
  • Clarified CP output resistor: R1_CP is mandatory GB/T control-guide equivalent R1, 1.000kΩ / 0.1% / 0.5W, and CP voltage monitoring is on the CP_OUT side of R1_CP.
  • Schematic revised to restore CP_OUT for active CP waveform generation/CP-to-PE monitoring and CC_PP_OUT for passive RC/R4/S3 and discharge-identification resistors, without PCB placement/routing/footprint work.
  • Full-board component-level schematic pass added the requested sheet groups, discharge-output terminals, K_DIS contactor path, 24V input protection placeholders, and bidirectional measurement documentation without PCB placement/routing/footprint work.

  • Project Overview

  • Intended Use

  • Required Hierarchical Sheets

  • What the Device Should Do

  • Main Features

  • System Architecture

  • Hardware Subsystems

  • TOP_LEVEL_INTERFACES

  • POWER_MCU_COMMUNICATION

  • CP_GENERATION_AND_MONITOR

  • CC_PP_RC_R4_AND_DISCHARGE_IDENTIFICATION

  • CHARGE_AND_DISCHARGE_CONTACTOR_CONTROL

  • AC_MAIN_PATH_AND_BIDIRECTIONAL_MEASUREMENT

  • REVIEW_AND_TEST_STATE_TABLE

  • Power and Runtime Expectations

  • Physical Design Expectations

  • Important Design Decisions

  • Review Required / Open Safety Checks

  • Change Notes