EV Technology Videos – YouTube Links

Toyota Hybrid – How It Works

http://www.youtube.com/watch?v=4CFxQGWAaho

Chevy Electric and Extended Range – How It Works

http://www.youtube.com/watch?v=AX5ZwzNwTc4&feature=related

GE EV Solar Carport EV Charging Station Construction

http://www.youtube.com/watch?v=rPn2pmhvpPo

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Pre-Seminar EV Technology Videos

Formula 1 – KERS (Kinetic Energy Recovery System)

Example = Red Bull Racing Team
http://www.youtube.com/watch?v=VYqhApWgZ74

24 Hours of LeMans – Hybrid

Example = Toyota TS030
http://www.youtube.com/watch?feature=endscreen&NR=1&v=0bFShHZv4wk

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imagination at work

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Basics of Electric Vehicle Charging Stations

Electric cars are here. This introductory course

focuses on the charging stations used to recharge
these vehicles.

Beginning with the various types of vehicles,

continuing to the three levels of charging setups then
detailing exterior/interior functional components and
concluding with infrastructure examples.

This session will provide insight into how this

technology will shape our future in transportation.

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 General Electric
Basics of
Electric Vehicle Charging Stations
8:00pm – 9:00pm
Cocoa Terrace

Dennis Balickie – GE Specification Engineer

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Growth Factors
and
Key Influencers

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Project Get Ready: Electric Vehicles in America

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3 Key Drivers for EV Growth

1. Government Funding and Incentives

2. Auto Manufacturer EV Pipeline

3. Shifting Consumer Mindset

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Government Funding and Support
1. American Recovery and Reinvestment Act (ARRA) Funding – $2.4B for
manufacturing and infrastructure
• $1.5B for US-based manufacturers to produce batteries and EV components
• $500MM to produce other EV components like motors
• $400MM to demonstrate and evaluate PHEV and related infrastructure
2. Auto Manufacturer Incentives - $8B loans for Advanced Vehicle Technologies
• $5.9B to Ford (factories in Ohio, Illinois, Kentucky, Michigan, Missouri, Ohio)
• $1.6B to Nissan (factory in Tennessee)
• $465MM to Telsa (factory in California)
3. Fuel Efficient Vehicles Tax Incentives for Consumers
• Tax credit for EV’s, up to $7,500
• Commercial Infrastructure: Tax credit for 30% of the cost of charging
station installation, up to $30,000
• Consumer Infrastructure: Tax credit of 30% of the cost of charging station
installation, up to $1,000.
• Applies to all equipment installed by the end of 2011
4. Additional EV Infrastructure Incentives in States (CA, MD, WV, DC, HI)
• Handfull of municipalities also offering incentives
• Some Utility Rate Reductions in place
• Check with your state and city government agencies for details
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 Automobile Investment & Production
2009 2010 2011 2012
Sport/Luxury

Tesla Model S
Cadillac XTS PHEV

Tesla Roadster
Volvo V70
Porsche 918 PHEV Audi A1 PHEV Fisker Karma PHEV
Compact

Mini EV Wheego Toyota Prius

LiFe PHEV
Zenn EV Mitsubishi i-MiEV Smart for two Think City Honda insight PHEV
Sedan/SUV

GM Volt Nissan Leaf Coda EV Toyota Rav4 EV BYD e6 EV Ford Focus EV

Light Trucks

Smith Electric Edison Navistar eStar Ford Transit Connect Mercedes Vito E-cell Renault Kangoo Bright Auto Idea

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Auto Manufacturer Activity
Hybrid Vehicles (HV): Battery Electric Vehicles (BEV):
Lexus HS 250h Coda Automotive Sedan
Mercedes E Class Hybrid Mitsubishi iMiEV BEV
Porsche Cayenne S Hybrid Nissan LEAF
Toyota Camry Hybrid Ford Battery Electric Van
Toyota Prius Hybrid Tesla Roadster Sport EV
Chevy Volt Extended Range EV
Audi A8 Hybrid (likely introduction)
BMW 5-Series ActiveHybrid Peugeot Urban EV
Honda CR-Z sport hybrid coupe Renault Kangoo Z.E.
Lexus CT 200h Hybrid Hatchback Renault Fluence Z.E.
Peugeot Diesel Hybrid Tesla Model S
Suzuki Kizashi Hybrid BYD e6 Electric Vehicle
Audi Q5 Crossover Hybrid Ford Battery Electric Small Car
Hyundai Sonata Hybrid Opel Ampera Extended Range
Infiniti M35 Hybrid
Fiat 500 minicar (2012)
Ferrari Hybrid (2014) Renault City Car (2012)
Renault Urban EV (2012)
Audi e-tron (2012)

Volkswagen E-Up (2013)

Tesla EV (2016)

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Shifting Consumer Mindset

Hybrid & EVs as a Tangible Symbol Environmentally

Conscious
37%

Technology
Frugal
and Car
Desire for Fuel Efficiency Travelers
Driven
26%
37%

Expression of Personal Politics

New group of conscientious consumers is emerging

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Terminology, Standards
and
LEED Points

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Electric Vehicle Terminology
Hybrid or Standard Hybrid:
A vehicle with a gasoline engine and an electric motor, each of
which can propel it. Traditionally the gasoline engine is the
primary propelling component and the electric motor servers
as an assisting/supplementary propelling component.
Gasoline is the only fuel.
Not really an Electric Vehicle.
Doesn’t require a charging station.

VIDEO
http://www.youtube.com/watch?v=4CFxQGWAaho

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Electric Vehicle Terminology
EV:
Electric Vehicles – The generic name for PHEV & BEV & REEV.
EVs are equipped with charging ports to recharge the battery
packs.

Range Anxiety:
Fear of running out of charge.
Similar to now when you are on a long trip in your gasoline powered vehicle
and you see the “Last Fuel Stop for XX Miles” sign and you start doing the
mental MPG math.

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Electric Vehicle Terminology
Plug-in Hybrid (PHEV):
A vehicle that has a battery bank that can be re-charged by
plugging in to normal household current as well as using the
on-board charging capabilities of normal hybrids.

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Electric Vehicle Terminology
Battery Electric Vehicle (BEV):
A vehicle that uses chemical energy stored in rechargeable
battery packs. BEV’s use electric motors and motor
controllers instead of internal combustion engines for
propulsion.

BATTERY PACK

ELECTRIC
MOTOR

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Electric Vehicle Terminology
Range Extended Electric Vehicle (REEV):
A vehicle that uses chemical energy stored in rechargeable
battery packs. REEV’s use electric motors and motor
controllers instead of internal combustion engines for
propulsion. A gasoline engine powers an electric generator to
recharge the batteries and provide electric power directly.

VIDEO
http://www.youtube.com/watch?v=AX5ZwzNwTc4&feature=related

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Comparision
of Vehicles

Plug-in Hybrid Battery Range Extended

Vehicle
Petrol Hybrid Electirc Vehicle Electic Vehicle Electirc Vehicle
Power:
PHEV BEV REEV
40 E-miles
Range: 400 miles 400 miles 400 miles 100 E-miles
(300 RE-miles)
4 – 8 hrs
Refuel <1 hr 4 – 8 hrs
5 min 5 min Level 2 Charge
Time: Level 2 Charge Level 2 Charge
(5 min)

1st car 1st car 1st car 2nd car 1st car
Usage:
Familiy car Family car Family car City car Family car

Energy Most Efficient

Not Efficient Efficient More Efficient Most Efficient
Efficiency: with Range

Customer
Benchmark + Electric motor + Charging + 100% Battery + Generator
Mind:

1st Year
Early 1900’s 2001 2012 2010 2010
USA:
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Electric Vehicle Terminology
EVSE:
Electric Vehicle Supply Equipment or charging station

Level 1 (Slow Charging or “The Overnight Charge”)

• 120VAC, 15A, compatible with the most commonly available
grounded electrical outlet (Usually provided with the car)
• Typical charge time: 8 - 10+ hours

Level 2 (Faster Charging or “At the Office Charge”)

• 208-240VAC, up to 80A (Standard Current is 30A)
• Typical charge time: 4 - 8 hours

Level 3 (DC Charging)

• Typical charge time: 15 - 30 minutes

Note: actual charge time depends on a number of factors

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Charging Options – Why use Level 2?

Level 1 Charging Level 2 Charging

Power Source 110 VAC, 15 A (16A peak), 208 – 240 VAC, 30 A, Dual Pole
Household Wall Outlet Dedicated Circuit
Max Charging
Up to 1.65 KW Up to 7.2 KW (240V @ 30A)
Power Output
Speed 8 – 10+ hours 4 – 8 hours

Installation Plug-in wall outlet connector Electrician Installation Needed

Safety Household Circuit Breaker, UL, Household Circuit Breaker, UL,

Ground Fault, Cable only Ground Fault, Cable only
energized when charging energized when charging
Accesibility Accessible everywhere Dedicated equipment and cable

Procurement Typically included w/car After-Market Purchase

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Level 3 Charging Station Overview
Current Status of Level 3 Charging
• Only Nissan, Mitsubishi, and smaller OEMS have a Level 3 Port
– Chevy and Ford can NOT be charged via DC fast charger.
– Society of Automotive Engineers has not standardized on a plug
– You will probably not see American car companies adopt level 3
charging until SAE develops the Level 3 plug (~late 2012).

Nissan Leaf Charging Ports Excerpt from Nissan Manual on L3 Charging

Level 3 Plug Level 2 Plug SAE

CHAdeMO J1772

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Cost of charging an EV BEV battery capacity
Nissan LEAF 24kWh
GM Volt 16kWh
CODA sedan 34kWh
Tesla model S 56kWh

Level 1 … 120Vac, 15A Level 2 … 240Vac, 30A

Charge Total % of Retail Charge Total % of Retail
time kWh capacity electricity time kWh capacity electricity
(hrs) (LEAF) cost* (hrs) (LEAF) cost*

1 2.9 12% $0.35 1 6.6 28% $0.80

2 5.8 24% $0.69 2 13.3 55% $1.60

3 8.6 36% $1.04 3 20.0 83% $2.40

4 11.5 48% $1.38 4 26.6 100% $3.19

5 14.4 60% $1.73

6 17.3 72% $2.07 * at avg retail rate of $0.12kWh

7 20.2 84% $2.42

$3.00 per charge equates to
8 23.0 96% $2.76
100 miles for BEV (max)
9 25.9 100% $3.11
40 miles for REEV (max)

Retail electricity cost is ~$3 per full charge

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U.S. Electric Vehicle Standards
UL 2594, for EVSE
UL 2594 covers electric vehicle (EV) supply equipment, rated a maximum of 250 V ac, with a frequency of 60 Hz, and intended to
provide power to an electric vehicle with an onboard charging unit. The products covered by UL 2594 include EV Power Outlets,
EV cord sets and EV charging stations, Level 1 & 2.

UL 2231, the Standard for Safety of Personnel Protection Systems for EV

Supply Circuits
This Standard covers devices and systems intended for use in accordance with the National Electrical Code® (American National
Standards Institute/National Fire Protection Association 70), to reduce the risk of electric shock to the user from accessible parts,
in grounded or isolated circuits for charging EVs.

NEC Article 625, Electric Vehicle Charging System

The provisions of this article cover the electrical conductors and equipment external to an electric vehicle that connect an
electric vehicle to a supply of electricity by conductive or inductive means, and the installation of equipment and devices related
to electric vehicle charging.

SAE (Society of Automotive Engineers) J1772, Electric Vehicle and Plug in

Hybrid Electric Vehicle Conductive Charge Coupler
This SAE Recommended Practice covers the general physical, electrical, functional and performance requirements to facilitate
conductive charging of EV/PHEV vehicles in North America. This document defines a common EV/PHEV and supply equipment
vehicle conductive charging method including operational requirements and the functional and dimensional requirements for
the vehicle inlet and mating connector.

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EV-Related LEED Status Points

LEED-NC: Sustainable Sites Credit 4.3

3 points available if 5% of parking is made
available for low-emission & fuel efficient
vehicles

LEED-EB: Sustainable Site Credit 4.0

3 to 15 points available for the reduction in
conventional commuting trips from 10-75%

For more information on LEED, please visit www.geelectrical.com/energy

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 Level 2
Charging Station Details
and
Power Requirements

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Overview
EVSE electric vehicle supply equipment

Power EV electric vehicle

Pilot Inverter
AC charging plug
AC charging cable On board charger

Protections

Motor
AC Power Supply Battery

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Interior System Components
LED
Controller Light Bar
Smart features
for control, communication and safety VFD
Vacuum Fluorescent
Display
Ground Fault CT
Protection against Ground Fault
Control Lines
Control and Communications Signals
within EVSE
Current Transformer
One phase metering / Overload

NEMA Contactor
Energize or de-energize
Cable & SAE J1772 Connector
Attaches to Electric Vehicle
Fuse
Overload and short circuit protection
AC Power
208-240 VAC / 30 Amps
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Protection
Level 2 Electric Vehicle Supply Equipment
(EVSE)
Overload and short circuit protection
Primary Dedicated 40A Circuit Breaker in the
Distribution Panel
Secondary Controller and current transformer
Inside EVSE
Personel protection
CCID20 15-20 mA Ground Fault Protection

SAE J1772 Pilot function de-energizes connector when

not attached to vehicle
Energize/De-energize
Contactor 2-pole 90 A
Auxiliary Contact
Proximity Proximity function controls presence of EV

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Connection
Power
Single Phase Metering, Standby Power 5W Typical
Random start up between 0 and 15 minutes to avoid overload

Interface
Standard interface across North America
Level 2 Charging -> 208-240 VAC, up to 30A logical requirements (up to 80 A possible)
Control & Pilot Function

Socket
SAE J1772 Connector – Standard Across North America
•L1 & L2 – Hot Voltage for two pole circuit
•CP – Control Pilot Signal – provides communication between vehicle and charger to coordinate charging
•PD – Proximity Detector - Allows vehicle to determine if EVSE is connected
•GND – Ground / Common

L1 L2

CP PD

GND

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Connection
Pilot function
EV connected
EV determines available current
EV ready to charge
EVSE energizes
EVSE alters available current
EV stops charging
EV disconnected
+ 9V

Pilot

Power

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Typical Commercial EVSE Unit
GREEN = Ready
GREEN-BLINKING = Connected
YELLOW = Charging
LED Bar Charger Status RED = Error / Not Authenticated

Operations Instructions
VFD Screen Status Details

RFID (optional) Controlled Access / Usage

Plug Holder

Power Cord Holder

Access Panel (right side)

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Typical Mounting Configurations
Single Double
Wall mount Pole mount
Pedestal Pedestal
No. Connectors 1 1 1 2
Dimensions (in) 31.52"H x 31.52"H x 51.1"H x 51.1"H x
11.82"W x 11.82"W x 14.9"W x 14.9"W x
11.16"D 11.16"D 13.8"D 13.8"D
Weight (lbs) 75 75 140 175
Form Factor

Outdoor rated NEMA – 3R

Material Hot rolled, low carbon steel

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Typical Commercial EVSE Specifications
• Supply Needs: 208-240VAC @ 30A with 40A overload (2 pole)
• GF Protection with Ground Monitor (UL 2231)
• Charger & Vehicle Communication (NEC 625)
- Connection Interlock
- Personnel Protection
- Automatic De-Energizing Device
- Ventilation Interlock
• Connection for Plug & Cord (SAE J1772)
• LED Lights & Display
• Indoor & Outdoor Enclosure (NEMA 3R)
• RFID User Authorization (Optional)
• Network Communications (Optional) – Ethernet CAT5, RS232
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Typical Light Commercial EVSE Unit
Level 2 Unit
Residential EVSE Unit - Wall Mount Only
Charging Icon Weatherized Case
GREEN = Charging Molded Lightweight Plastic
Nema 3R / IP54
Fault Icon
RED = Error / Fault

Power Button
OFF / Standby Button Charging Cable
Socket with interlock
SAE J1772

LED Ring Charger Status

Visualization of station status Power Cord Plug-In Option
WHITE = Ready / Standby Mode Plug option for easy install / removal

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Typical Light Commercial
EVSE Specifications (Level 2)
• Supply Needs: 208-240VAC @ 30A with 40A overload (2 pole)
• GF Protection with Ground Monitor (UL 2231)
• Safety Protections
- Ground Fault
- Overload
• Connection for Plug & Cord (SAE J1772)
• Meets UL Standards Compliance
• Wrap Around Cord Management
• 2 piece mounting bracket for easy installation
• Lockable mounting brackets to prevent theft
• Indoor & Outdoor Enclosure (NEMA 3R)
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 Connections
and
Infrastructure Examples

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Typical EV Infrastructure

Switchboards
Utility Supply Utility Transformer Switchgear And Panelboards

General Purpose
Transformers
Power Panel
Sub-metering
Ltg/Appl Panels
Load Centers EV Charging Stations

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Electrical Example – Individual Unit
Home – 1 EVSE unit – Wall mount

Domestic
Service
Line

Single EVSE
30A Total
#8 AWG Cu THWN
Conduit

2 pole 40A 120/240 Utility Meter

Breaker
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Electrical Example – Small Installation
Retail / Commercial / Office – 3 Pedestal EVSE units

Commercial
Service
Three EVSE
90A Total
Line

#8 AWG Cu THWN Three 2-pole 40A

Conduit 120/240V Breakers Utility Meter

Ensure that capacity of panel board and service are not exceeded.
Select conductor size according to the NEC. 40
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Electrical Example – Larger Installation
Car Group – Hotels, Parking Garage, etc – 12 Pedestal EVSE units

From
Power Panel Board
Twelve EVSE Switchboard
360A Total MCC
Switchgear

175AT/250AF Breaker

400AF/400AT MCB Panel

...
112.5kVA
x 12 Dry Transformer

#8 AWG Cu THWN Twelve 2-pole 40A 2 – 250 AL kcmil THWN

Conduit 120/240V Breakers

Ensure that capacity of panel board and service are not exceeded.
Select conductor size according to the NEC. 41
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 Present
and
Future Technologies

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Where are we today?
Global unit sales Battery cost/kwh curve

2,400 Charging
Stations High cost
2,000
Units in thousands

Electric
1,600 Vehicles

1,200 Medium
cost
800
Low cost
400

2006 2010 2015 2020 2025 2030

2010 2011 2012 2013 2014 2015
Source: Pike Report Source: McKinsey.

EV Production Start Big disruptive market

• 1st USA mainstream sales in late 2010 . . . • Total EV cost of ownership improves as battery
Before that the industry was a specialty market costs decrease
• Most manufacturers launching in 2011 … 3-5%
California Estimates of global production by 2015
• Typical early market issues – complexity,
• 250,000 to 275,000 PEVs by 2015 confusion, dynamic environment

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EV Ecosystem Community Deployment

Office Parking
3-5 Chargers
Hotel
15-20 Chargers

Public Parking
15-25 Chargers

Shopping Mall
10-20 Chargers

For the Home

1 Charger

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Worse Case Driving Distance - 12 mile Radius
Either Winter with Heater On OR Summer with AC On

BEV REEV
- -
Here & Back Here & Back

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Worse Case Driving Distance - 25 mile Radius
Either Winter with Heater On OR Summer with AC On

BEV REEV
- -
Here & Back Here ONLY
-
Gas
Generator
for Return
OR
Recharge at
the Lodge

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Worse Case Driving Distance - 50 mile Radius
Either Winter with Heater On OR Summer with AC On

BEV REEV
- -
Here Only Here on
- Battery
Recharge at Power 1st
the Lodge then on
Gas
Generator 2nd

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New Business Opportunities

On Site Services via EVSE Interface

• Advertisements and Commerce Options
• Reservations for other services
• Information on local events, advisories

Mobile Phone Services for Consumers

• Real-Time Charging Status/Updates
• Promotions
• Social Networking

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Sample App Screens

Login Screen Application Selection Screen

Search for available charging stations by
provider, address, service group, etc.

Admin view of Station utilization and Detailed view of station performance, Flex Charging configuration and
flex charging reporting revenues, etc. reporting
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Differentiate to Attract
Business and Individuals
as a Free Service / Pass-Thru Service / Revenue Service
• Corporate Citizenship
• Meet Present Employee Needs
• Attract New and Retain Existing
Employees

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There will be a time in the future when Electric Vehicles
will be as common as Hybrid Vehicles are now
And so will the charging stations that support them
Hybrid Auto
Technology is
only 10 years
old in the US
-
Seeing a Prius
on the road is
commonplace
now

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Next Generation EVSE Unit
Modular Design to integrate new technology

Indoor & Outdoor

Interactive Display Panel Enclosure (NEMA 4)

LED Ring Charger Status

Protected Plug Holder

Access Panel (on rear)

Base to accept power

and fasten to concrete
Retractable Power Cord

Options:
• Wireless Communications
• Point of Sale (Credit Card kiosk) 52
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Solar Carport EV Charging Stations

VIDEO

http://www.youtube.com/watch?v=rPn2pmhvpPo

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Thank You for Your Time

Q&A
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imagination at work

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