EV SOLUTIONS YOUR COMPLIMENTARY EV CHARGING PRIMER

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1 EV SOLUTIONS YOUR COMPLIMENTARY EV CHARGING PRIMER

2 AV INFORMATION: Unless otherwise noted, these materials contain information prepared by AeroVironment, Inc. ( AV ) for municipal fleet managers, utilities and other commercial enterprises which have an interest in the electric vehicle charging industry. These materials are a summary only, are current as of May 1, 2010, and are subject to change at any time without notice. Use of this information is subject to the provisions of any agreement which a recipient may enter into with AV. Images of AV s EV charging and related equipment are pre-production, prototype models; final production models may vary. AeroVironment, EV Solutions, PosiCharge and the AeroVironment logo are trademarks of AeroVironment, Inc. Other trade names and trademarks shows are the property of their respective owners AeroVironment, Inc. All rights reserved. No portion of these materials may be duplicated, used or disclosed without prior written permission from AeroVironment, Inc.

3 TA B L E O F C O N T E N T S 2 Electric Vehicle Charging Basics 3 Charging Your Electric Fleet 4 Fleet Charging Products 5 Just the FAQs 8 Level 2 Overnight Charging Specifications 9 Level 3 DC Fast Charging Specifications Prototype and pre-production images shown. Production models may vary. 10 AeroVironment s Fleet Solutions 11 Electric Fleet Infrastructure: Getting Started 12 About AeroVironment, Inc. 1

4 E L E C T R I C V E H I C L E C H A R G I N G B A S I C S EVs have been used for years in industrial applications. More than a decade of industrial electric vehicle (EV) charging in the field has proven electric vehicle and fast charge technology, demonstrating that EVs can increase fleet productivity, increase operators safety and decrease operating costs in any number of fleet applications. Charging Speeds. There are three technology classes of EV charging: Level 1, Level 2 Overnight and Level 3 Fast charging. Charge or refill times depend on the charging technology used, the chemistry of the vehicle s battery, and other conditions. LEVEL 1 CHARGING Portable plug 120 VAC standard outlet Delivers power from the wall to the vehicle s on-board charger Time from fully depleted to fully charged: hours LEVEL 2 CHARGING (OVERNIGHT CHARGING) Fixed charging station VAC fixed installation Delivers AC power from the wall to the on-board charger Time from fully depleted to fully charged: 3-8 hours LEVEL 3 CHARGING (DC FAST CHARGING) High powered fast-charge station (like a gas pump ) VAC fixed installation Delivers DC energy, bypassing the on-board charger Time from fully depleted to fully charged: as little as <30 minutes Prototype and pre-production renderings shown. Production models may vary. 2

5 C H A R G I N G Y O U R E L E C T R I C F L E E T EVs and Your Fleet. EV fleet charging requirements will vary depending on a fleet s unique energy and scheduling needs. However, most fleets are optimized by using central or distributed Level 2 (overnight/between shift AC) or Level 3 (fast DC) charging for safe, practical and efficient battery refilling. Many fleet operations with predictable, shorter routes and downtime overnight can take advantage of Level 2 charging stations installed in the parking depot. The stations will allow vehicles to charge opportunistically during non-business hours. Level 2 charging can take approximately 3 to 8 hours depending on battery size, battery chemistry, and the vehicle s state of charge (SOC) when plugged in at the end of a shift. Distributed Level 3 DC charging stations may be necessary for operations with longer, continuous, or unpredictable routes like taxi cabs or rental cars. Level 3 charging stations can augment Level 2 charging by enabling quick on-road battery refueling in approximately 10 to 15 minutes, depending on conditions, allowing vehicles to travel greater distances. Level 3 charging stations are also ideal for large batteries used in vehicles such as buses and trucks. REPLENISHMENT RATE FOR MILES DRIVEN Charge Regimen 30 Miles/ Day 60 Miles/ Day 90 Miles/ Day Level 1 (1.4kW) ~ 5½ Hrs ~ 11 Hrs ~16 Hrs Level 2 (3.3kW) ~ 2½ Hrs ~ 4½ Hrs ~ 6½ Hrs Level 2 (6.6kW) ~ 1 Hr ~ 2½ Hrs ~ 3½ Hrs DC Fast Charger < ½ Hr ~ ½ Hr < 1 Hr *Replenishment rates are approximate. Actual rates may vary. 3

6 F L E E T C H A R G I N G P R O D U C T S The optimal charging solution will depend on your fleet s energy needs, break schedule, and other application-specific requirements. Electric campus and service fleets can be supported by Level 2 or Level 3 charging stations made more powerful by data solutions that deliver real-time intelligence, enabling fleet managers to control and optimize energy use throughout the day. Both Level 2 and Level 3 charging stations are designed for safety, reliability, and battery longevity. Designed with intuitive control displays, both are rated for outdoor use and will offer a number of optional features including: Multiple communication options Payment system option Data management and metering options and compatibility Wired and wireless communication compatibility FLEET SOLUTIONS: Outdoor Level 2 AC Charging Stations Multiport private stations and secure semi-public options available J1772 compatibility supports all SAE compliant EVs Outdoor Level 3 DC Charging Stations Fast charging in minutes, not hours High power levels support large batteries JARI/TEPCO compliant connector availability EV charging services Site assessments and application studies Installation services and post-install on site service Data Services Industry software Customizable solutions LEVEL 2 CHARGING STATIONS LEVEL 3 CHARGING STATIONS Prototype and pre-production images and renderings shown. Production models may vary. 4

7 J U S T T H E FA Q S WHY DO I NEED A CHARGING STATION? Electric vehicles carry rechargeable batteries that supply their energy. When you drive an electric vehicle it consumes electricity from the battery. The charging station refills your battery with electricity from, for example, your home, just like filling your current car with gas. Charging stations come in several types including those designed for use at home or work, for installation on the street and eventually, those designed to deliver a fast charge. HOW DOES THE CHARGING STATION WORK? The home charging station is typically mounted on your garage wall and connected to your home s electrical system. You plug it into your car when you get home, and unplug it when you re ready to drive. Commercial charging station for fleets and the public are usually mounted outdoors, where vehicles can stop for a charge. Fleet charging stations replenish energy either during a several-hour shift change or shutdown, or in minutes during a break. HOW WILL I KNOW IF MY CAR IS CHARGED UP? Lights on the charging station will let you know your charging status. DOES IT STOP AUTOMATICALLY? The charging station knows when it s done charging and will stop automatically. WHERE WILL I PUT IT? The charging station is typically mounted near where you park your car, such as on your home s garage wall. WHO WILL INSTALL IT? Only a professional, licensed electrician is authorized to install your charging station to ensure that it works properly and meets code requirements. WILL IT WORK WITH ANY ELECTRIC VEHICLE? Because the home charging station s connector (the plug) is standard for most EVs, the charging station is compatible with most EVs from major automakers. Similarly, Level 2 commercial fleet charging stations will use the same standardized connector as home charging stations and will work with most EVs from major automakers. Level 3 DC fast charging stations, which feature a different architecture than Level 2 charging stations, are currently the subject of a process to reach standardization as well. CAN I STOP THE CHARGING STATION BEFORE IT S AT 100%? Just as you can stop refueling a gasoline car before the tank s filled, you can also safely stop charging your EV before the battery is fully recharged. 5

8 J U S T T H E FA Q S ( C O N T. ) WILL IT WORK WITH PLUG-IN HYBRID VEHICLES (PHEVS)? The Level 2 EVSE is compatible with most PHEVs and can reduce PHEV charge times considerably. A Level 2 EVSE can also make PHEVs more environmentally friendly by making charging easier and faster. HOW FAR WILL A FULL CHARGE GET ME? Driving distance depends on the vehicle s range. If a vehicle s battery has a stated 100 mile range, a full charge is expected to deliver 100 miles; however, this can vary based on a number of conditions. HOW FAST DOES IT CHARGE? Depending on the battery size and the design of the vehicle, in many situations the home charging station can fully charge an EV in as little as four hours, depending on conditions. DC fast charging stations can provide an appreciable charge in a matter of minutes. IS IT SAFE? The home charging station is designed with safety and reliability in mind, and will be listed by the Underwriter s Laboratory, the same people who certify other electric appliances found in most homes and businesses. Commercial fleet and public chargers will also incorporate the same rigor and safety-focused design as the home charging line. WHAT IF IT RAINS? AeroVironment s home and commercial charging stations are rated for outdoor use and are able to withstand various weather conditions. WHEN IT STOPS CHARGING, DOES IT STOP DRAWING POWER? AeroVironment s charging stations are energyconscious and stop drawing all but minimal power when not charging. WHAT S DIFFERENT ABOUT AV S CHARGERS? AV has been on the leading edge of electric vehicles since the 1990s, when we played a key role in developing the prototype of the first mass market EV (GM s EV1). AV also has a line of testing and simulation systems used by automakers and battery manufacturers to test EVs, as well as a broad line of chargers used to charge heavy-duty industrial forklifts across North America and the world. AV s upcoming line of passenger EV charging stations are based on this heritage and fielded technology making it a proven solution with a truly reliable track record. WHAT IF I LIVE IN AN APARTMENT? Various charging configurations for apartment garages and other multi-family housing situations will be available from AV. These same configurations, as well as higher-powered models, can also be used for commercial fleets. 6

9 J U S T T H E FA Q S ( C O N T. ) WHO WILL SERVICE MY CHARGER? Only professional electricians are certified to service your charger. WILL THE CHARGER COMMUNICATE WITH THE SMART GRID? Some versions of the AV home charger will communicate with the smart grid, optimizing your energy usage and further reducing your carbon footprint. We also feature fleet and public chargers with robust communication capability, so that you can get smarter about your fleet s energy usage, and how it impacts your bottom line. HOW DO I KNOW IF IT S CHARGING? An LED will let you know when it s charging. It ll turn off when it s done charging. WHAT ARE MY OPTIONS FOR CHARGING AT HOME? Trickle Charging is when you plug your EV into a regular 120V wall socket and trickle charge your car this will most likely take longer than ten hours for most electric vehicles. Opportunity Charging is accomplished with the AV Home Charger, which requires a 240V connection and is designed to fully charge a vehicle in four hours, depending on conditions. We call this opportunity charging because you will probably use the Home Charger while sleeping or enjoying dinner, for example. Remember, you won t need a full charge from 0 to 100% every time. You will probably get into the habit of charging opportunistically whether you are at a half tank, low, or nearly full, just because it s easy. WHAT OTHER KINDS OF CHARGING OPTIONS ARE THERE, BESIDES HOME CHARGING? Opportunity Charging in Public. Versions of the 240V home chargers are planned for installation at certain workplaces, as well as shopping malls, retail stores, private fleet yards and other places where drivers have planned stops for a few hours and can charge while taking care of other business. Fast Charging. The last type of charging is planned for installation at public charging locations similar to gas stations for the rare occasion when you need to fill up in the middle of a long trip, or find yourself low on energy. These chargers are designed to get energy to your battery quickly as fast as ten minutes, depending on conditions, using a DC fast charger. Some fleets will also use fast charging to support extra large batteries, or if the fleet has very little available downtime for charging. 7

10 L E V E L 2 O V E R N I G H T C H A R G I N G S P E C I F I C AT I O N S LEVEL 2 CHARGING STATIONS (AC to AC) Specification EVSE-RS EVSE-RS Dual EVSE-RS Quad EVSE-LS EVSE-CS Connector SAE J1772 SAE J1772 SAE J1772 SAE J1772 SAE J1772 Voltage 208VAC to 240VAC 208VAC to 240VAC 208VAC to 240VAC 208VAC to 240VAC 208VAC to 240VAC Frequency 50/60 Hertz 50/60 Hertz 50/60 Hertz 50/60 Hertz 50/60 Hertz Current 30A max 30A max 30A max 30A max 30A max Operating Temperature -30 C to 50 C -30 C to 50 C -30 C to 50 C -30 C to 50 C -30 C to 50 C Storage/Transit Temperature Humidity -40 C to 60 C -40 C to 60 C -40 C to 60 C -40 C to 60 C -40 C to 60 C Cord Length Up to 25 available Up to 25 available Up to 25 available Up to 25 available Up to 25 available Enclosure NEMA 4 NEMA 4 NEMA 4 NEMA 4 NEMA 4 * Information and specifications subject to change Prototype and pre-production images and renderings shown. Production models may vary. 8

11 L E V E L 3 D C FA S T C H A R G I N G S P E C I F I C AT I O N S LEVEL 3 CHARGING STATIONS (AC to DC) Specification EV-30 EV-60 EV-125 EV-250 Power Rating 30kW 60kW 125kW 250kW Power Factor Input Power 480V, 3 Phase AC (Other inputs available) 480V, 3 Phase AC (Other inputs available) 480V, 3 Phase AC (Other inputs available) Input Current 42A 84A 165A 330A Connector AV or JARI/TEPCO AV or JARI/TEPCO AV AV 480V, 3 Phase AC (Other inputs available) Voltage 50VAC to 600VAC 50VAC to 600VAC 50VAC to 600VAC 50VAC to 700VAC Frequency 50Hz / 60Hz 50Hz / 60Hz 50Hz / 60Hz 50Hz / 60Hz Efficiency Rating >90% >90% >90% >90% Current 100A 200A 275A 550A Operating Temperature -30 C to 50C -30 C to 50C -30 C to 50C -30 C to 50C Storage/Transit Temperature -40 C to 60 C -40 C to 60 C -40 C to 60 C -40 C to 60 C Humidity Cord Length Up to 25 available Up to 25 available Up to 25 available Up to 25 available Current Accuracy (Lesser of the two).5a or 5%.5A or 5%.5A or 5% 4A > 100A Duty Cycle rating 100% 100% 100% 100% Charger Shutdown Time 15 ms 15 ms 15 ms 15 ms Voltage Accuracy 1% 1% 1% 1% * Information and specifications subject to change Prototype and pre-production images and renderings shown. Production models may vary. 9

12 A E R O V I R O N M E N T S F L E E T S O L U T I O N S AV will offer support for your fleet equipment and installation with a team of trained, experienced licensed installers and service providers. With AV s proprietary service testing and simulation tool, our network of electricians can confirm the proper installation of charging equipment -- and troubleshoot problems on the spot. Our developing nationwide network of licensed electricians is knowledgeable of local codes and permitting procedures and are just a phone call away. FLEET SERVICES HIGHLIGHTS INSTALLATION Site assessments and application services Service upgrades (trenching, panel upgrades) EVSE installation On-site user training POST INSTALLATION Call center and help desk support Full 3-year warranty on parts with on-site service On-site troubleshooting Proprietary service tool for easy inspection, verification, vehicle simulation, and troubleshooting Prototype and pre-production images shown. Production models may vary. 10

13 E L E C T R I C F L E E T I N F R A S T R U C T U R E : G E T T I N G S TA R T E D AeroVironment offers a range of customized turnkey solutions that will make charging your EV fleet easy and convenient. Highlights include: 1. SITE ASSESSMENT Work schedule application study Review charging needs and locations Review building loads and utility service availability Review local codes 2. QUOTATION Provide a comprehensive quotation for hardware and installation Include options for future Level 2 or Level 3 additions based on fleet growth or duty cycle changes 3. DESIGN & PERMITTING Prepare the necessary drawings Work directly with city planning, permitting departments and utilities Pull the necessary permits Facilitate application for special utility pricing programs if available 4. INSTALLATION Trenching and conduits electrical preparation upgrade / downgrade Install charging stations Certify installation using proprietary Service Tool 5. COMPLETION & HANDOVER Have units and installation signed-off and approved by inspector Use Service Tool to demonstrate operation of charger to Inspector Provide operation and troubleshooting training Review warranty and service process 6. GENERAL Provide post installation support and training Warranty service and extended maintenance plans 11

14 A B O U T A E R O V I R O N M E N T, I N C. More than 20 years ago the idea of a practical electric car was a twinkle in the eye of Paul MacCready, AV s founder and inventor of the first successful human powered airplane. After developing the Sunraycer, a solar-powered race car that beat its competitors in a race across Australia by more than 2 days, Dr. MacCready and his team proposed a radical idea to General Motors: develop an electric car that was a practical alternative to gas-powered cars. GM liked the idea, and hired AV to develop a prototype. Soon after, the first practical electric car, the GM Impact, was born. AV spent the next two decades developing electric and hybridelectric vehicle concepts for customers, and creating charging systems and test systems designed to make EVs more practical. Today AV is a leading supplier of high power test systems used by automakers and advanced battery manufacturers to develop the next generation of electric vehicles. AV s industrial charging systems reliably power thousands of heavy-duty electric forklifts every day, making workplaces safer and more productive. We also supply portable, electric-powered unmanned aircraft that have changed the way military ground forces operate. Our Small Role in a Powerful Transportation Revolution 1987 GM Sunraycer solar vehicle 1989 GM Impact electric vehicle 1999 EV charger for USAF 2000 #1 EV test system in US 2005 Enterprise-wide EV charger implementation at Ford Motor Company 2009 EV home charger development 2010 First planned deliveries of EV home charging stations At AV, we believe that innovative new ideas can help improve people s lives. Built on a history of practical innovation, our EV charging solutions represent an important contribution to a cleaner, brighter future. 12

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16 AeroVironment, Inc. EV Solutions Electric Vehicle Charging Products and Services 181 W. Huntington Drive, Ste. 202 Monrovia, CA AeroVironment, Inc. 0510