EPRI Truck & Bus Meeting SAE Medium and Heavy Duty Vehicle Conductive Charging Task Force Rodney McGee Chairman University of Delaware March 29, 2016 Tempe, AZ SAE TEVHYB13

Current Documents Under Development EV Power Transfer using Three-phase Capable Coupler (J3068) Three-phase AC on-board or integrated chargers EV Power Transfer using Overhead Coupler (J3105) Overhead DC charging Wireless charging Covered by sub-group under J2954 SAE TEVHYB13

Scope of J3068 SAE has authorized a document for three-phase AC power transfer for electric vehicles Scope This document covers the general physical, electrical, functional, testing, and performance requirements for conductive power transfer to an electric vehicle using a coupler capable of, but not limited to, transferring three-phase AC power. It defines a conductive power transfer method including the digital communication system. It also covers the functional and dimensional requirements for the vehicle inlet, supply equipment outlet, and mating housings and contacts. Targeted towards charging at commercial and industrial locations or other places where three-phase power is available and preferred. SAE J3068

J3068 EVSE Evaluated to UL-2594, UL-2231 Cordset / Coupler Based on IEC Type-2 Drawling referred to by reference Evaluated to UL-2251 Includes drive-over test specified in UL-2251 Section 39 Power levels and voltage USA 208/120Y & 480/277Y VAC Canada 208/120Y & 600/347Y VAC NEC and UL documents are in place for the above scenarios SAE J3068

J3068 IEC 62196 (Type 2) For comparison J1772 (Type 1) Interlock required to prevent connector removal during charging L1,L2,L3,N,GND: 6mm conventional contacts ~ 63A* advanced contacts ~ 120-160A† For comparison J1772 (Type 1) L1,L2/N: 3.6mm conventional contacts ~ 30A advanced contacts ~ 80A Combo: DC+/-: 8mm ~ 200A-350A Type-2 Inlet L1,L2,L3,N,GND,CP,PP Type-1 Inlet L1,L2/N,GND,CP,PP *IEC only defines the Type 2 to 63-amp SAE 3068 would extend that rating †Current limit based on designs from two coupler manuf. SAE J3068

Example – Power Table Continuous (A) 277VAC 1Φ (kW) 208VAC 3Φ Breaker (A)* [NEC] 16 4.4 5.8 13.3 20 5.5 7.2 16.6 25 32 8.9 11.5 26.6 40 63 17.5 22.7 52.4 80 22.2 28.8 66.5 100 27.7 36.0 83.1 125 120 33.2 43.2 99.8 150 140 38.7 50.4 116.4 175 160 44.3 57.6 133.0 200 *NEC 240.6 Fuses and Fixed-Trip Circuit Breakers. The standard ampere ratings for fuses and inverse time circuit breakers shall be considered: 15, 20, 25, 30, 35, 40, 45, 50, 70, 80, 90, 100, 110, 125, 150, 175, 200, … *NEC 625, EV loads are considered continuous loads and the breakers rated at 125%. Breakers in other counties are differently rated. SAE J3068

J3068 Testing at NREL for J3068 Energy Systems Integration Facility (ESIF) at the U.S. Department of Energy’s National Renewable Energy Laboratory in Golden, CO SAE J3068

J3068 Transpower school bus Type-2 three-phase AC inlet Integrated motor inverter/charger (EPC Power) Charges and discharges into grid up to 70kW Test with EVSE shown below (shown case-less during EMI testing) SAE J3068

Joining the Task Force (TEVHYB13) Two documents are being developed under the SAE Medium and Heavy Duty Vehicle Conductive Charging Task Force EV Power Transfer using Overhead Coupler (J3105) EV Power Transfer using Three-phase Capable Coupler (J3068) Download the form to join the task force http://bit.ly/sae-join Return to SAE Staff: pebejer@sae.org SAE TEVHYB13

Backup SAE J3068

Three-phase Power System in the US Other variants include 240 delta and 480 delta which either have no neutral or mid-point neutral, while delta is are common for the high/mid voltage electrical distribution system, these systems are less common for installs on the LV side. Split-phase 120/240 is used for US residential Canada uses 347/600Y instead of 277/480Y SAE J3068

NFPA 70 – NEC Current definitions and scope for NEC 2014 “625.4 Voltages. Unless other voltages are specified, the nominal AC system voltages of 120, 120/240, 208Y/120, 240, 480Y/277, 480, 600Y/347, and 600 volts.” NEC 2017 – 1st and 2nd Draft Add support for 1000V supplies (modifies section above) But still a few issues No output EV cord-set markings for 1000V (example, EVE and EVT only go to 600V Table 400.4) SAE J3068

UL 2594 1st edition Need to review this document for needed changes So far so good; needs a more careful read through Scope: 1.1 This Standard covers conductive electric vehicle (EV) supply equipment with a primary source voltage of 600 V ac or less, with a frequency of 60 Hz, and intended to provide ac power to an electric vehicle with an on-board charging unit. This Standard covers electric vehicle supply equipment intended for use where ventilation is not required. Electric vehicle supply equipment covered by this Standard includes: … f) Permanent EV Charging Station – Rated 600 Vac maximum, intended for indoor or indoor/ outdoor use; or g) Permanent EV Power Outlet – Rated 600 Vac maximum, intended for indoor or indoor/ outdoor use. 6.2 EV charging stations 6.2.1 EV charging stations shall be provided with an EV receptacle or an EV connector on the vehicle side of the device. SAE J3068

UL 2202 2nd edition Need to review this document for needed changes From section 11.7: Identification a) 120 volts, 2-wire; b) 120/240 volts, single-phase, 3-wire; c) 208Y/120 volts, two-phase, 3-wire; d) 208Y/120 volts, three-phase, 4-wire; e) 480Y/277 or 600Y/347 volts, three-phase, 4-wire in which the neutral is used as a circuit conductor; f) 240/120 volts, three-phase, 4-wire in which the midpoint on one phase is used as a circuit conductor; or g) 240 or 480 volts, three-phase, 3-wire, corner-grounded delta; SAE J3068

Example – EPC Power Integrated 3-phase system Single device for driving and charging modes 400 kW motor inverter Up to 70kW charger Water cooled 208 and 480 VAC versions Front of class 8 truck SAE J3068

Example – EDN Group On-board Charger Model CMP460-01 16kW 480 (400-550) VAC three-phase supply 350-1022 VDC battery back Ideal for 20A continuous / 25A breaker Water cooled SAE J3068

Example – Tesla charger topology Each “box” is ~3.6kW is a phase board Three phase boards form a 10/11kW module Up to 2 modules installed in vehicle give 20/22kW 85-318* VAC full operating range Grid 3-phase WYE N Grid single-phase L2 L3 L1 L2/N Same on-board chargers with different hook up in inlet wiring box Three-phase on-board configuration 11/22 kW (Also used in supercharger stack-up) Single-phase on-board configuration 10/20 kW * 277VAC used in supercharger installs with 480/277Y; Vehicles are currently configured for 85-265 VAC limits SAE J3068