Hi, Brian. Maybe you don't know that I am based in England.
As I understand, you test by producing a 20 mA leakage but the CCID
doesn't always detect it. Is that right? That is not what I first
understood; I though that leakage was occurring in the field, but you
could not reproduce it. I think you have to diagnose the CCID itself,
outside the product. Is it a circuit you have designed and manufactured
or a module that you buy in? If it's your circuit, can you let me see it
by DM to j...@woodjohn.uk? Condensation might desensitize the current
detector, but it seems improbable.
On 2025-03-28 17:20, Brian Gregory wrote:
HI John,
thanks for loaning a few neurons to this. Don't worry, we've got
chargers all over N. America; I'll be I can find one really close if
it comes to that.
> Is the leakage just "from the mains supply to the DC output", or can
you track it down to a specific place in the product?
Yes, we have a CCID circuit, which is required by the safety
standards. The issue is injecting a known value to periodically check
the circuit is working.
The error we're having is a lack of a positive result from the check.
> Do yo have any reports of the leakage current values or the leakage
resistance?
I think we test inject 20mA.
> Have any of the chargers been installed in areas of high humidity?
Yes, all over N. America, including Florida. We have found a small
correlation with temperature: we can increase/decrease somewhat the
likelihood of a failure to detect the test signal in the oven, so
thermal signal drift is a likely candidate. I get a few more details
if you've got a promising approach.
thanks again,
Colorado Brian
---------- Forwarded Message ----------
From: John Woodgate <j...@woodjohn.uk>
To: EMC-PSTC@LISTSERV.IEEE.ORG
Subject: Re: [PSES] Leakage Fault Issue
Date: Wed, 26 Mar 2025 22:46:08 +0000
I am much too far away to access the product, but can you give a bit
more detail, please? Is the leakage just "from the mains supply to the
DC output", or can you track it down to a specific place in the
product? Do yo have any reports of the leakage current values or the
leakage resistance? Have any of the chargers been installed in areas
of high humidity? The leakage could be caused by condensation on
insulating material, including PCB surfaces. I guess condensation
might not occur in your test lab.
On 2025-03-26 22:32, Brian Gregory wrote:
G'day from Colorado,
We have an EV Charger product with a phantom leakage fault issue.
I saw phantom, because nearly 75% of warranty units returned to us
with the problem, show no signs of it when bench tested.
We are looking for an FA team to help us with debugging and
eliminating this issue, which could be fixed in hardware, or firmware.
Please let me know by return post if you know a team or expert who
can make a pitch, and I'll DM you back.
Thank you,
Colorado Brian
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