PLC communication description
Powerline communication (PLC) is a communication method that uses the local power grid (230V) to provide internet connection to other Powerline devices (charging stations). The PLC module is thus a communication converter, which converts wired internet connection (network cable) to internet over the local power grid (Powerline).
1. Installation
PLC communication module is mounted on DIN rail. If there is a long distance from the distribution board to the charging stations, it is recommended to install PLC module in a enclosure near the charging stations. But the length of the network cable should not exceed 90 meters.
2. Connected protection
It is recommended to install a 10A fuse before the PLC module. The module is usually mounted after a 63A course, but the connection terminals are 1.5-2.5 mm2.
This also simplifies any troubleshooting and restart of the PLC module.
3. Coupling
IMPORTANT: Only use connection terminals marked L1, N and PE.
Charging stations communicate on PLC over L1 and N, PLC module should therefore not be connected as 3 phase.
It is important that the phase order is the same on the entire charging system.
QR and configuration
Connect the charging stations to the PLC module with QR code.
1. Open the Zaptec App
2. Select wheel at the top left
3. Select "Configure Zaptec Devices"
4. Wait for the Zaptec App to scan for available charging stations via Bluetooth
5. Enter the PIN code of the current charging station.
6. Select "PLC".
7. Select "Scan Network Name".
8. Select "Camera" to scan the QR code from the PLC module.
9. Scan QR code, click "save" in the upper right corner.
10. The charging station will now receive the IP address from the network.
* These steps are repeated for each charging station to be connected to the PLC module
NOTE. PLC module purchased after Nov. 2019 comes pre-encrypted with QR code
Use existing network key for retrofitting if charging station
PLC module purchased before Nov. 2019 is without encryption and without QR code
Copy network key from an online charging station
1. Open the Zaptec App
2. Select "Gear" at the top left
3. Select "Configure Zaptec Devices"
4. Wait for the Zaptec App to scan for available charging stations via Bluetooth
5. Enter the PIN code of the current charging station.
6. Select "PLC".
7. Copy key from charging station
8. Then follow the same procedure on the new charger and paste the network key in the last paragraph under "set network key".
10. Press "save"
Troubleshooting PLC
Factors that can affect the signal strength of the PLC network
1. Total length of cable
Cable length has a direct effect on the signal strength of the charging stations.
In addition to having one PLC per cable run / course, it is important to consider the location of the PLC module.
If the supply from the switchboard is located far away from the charging system, the PLC module should be placed closer to the charging stations.
The charging stations communicate with the PLC only between L1 + N + PE.
Connection on the L2 and L3 terminals will lead to increased cable length the devices are trying to communicate over.
2. Number of connected devices
A PLC module has a limit on the number of devices it can communicate with. Exceeding this number will lead to unstable communication over the PLC. It is therefore important to isolate PLC communication on each course by encrypting the PLC module and associated charging stations.
General recommendation is 20 charging stations per PLC module.
Minimum one PLC unit per cable run / course.
3. Grounding conditions
PLC communication uses the ground connection for positioning the frequency range.
Without a ground connection, the PLC communication range will be significantly reduced.
If the ground connection is insufficient or affected by external factors like ground faults, this may result in the PLC not being able to maintain sufficient signal quality for stable communication.
4. Local power outages
Noise from external sources, like frequency converters, can be difficult to map but this can be limited by installing a filter before the PLC module.