Standard for Installing and Maintaining Electric Vehicle Supply Equipment (EVSE)

Transcription

1 Standard for Installing and Maintaining Electric Vehicle Supply Equipment (EVSE) Presented by: Gregory W. Massey, P. E. Overview Electric Vehicles (EVs) create a need to build an infrastructure that will supply the added load of EV charging Contractors are equipped to manage the installation and commissioning of Electric Vehicle Service Equipment (EVSE) The new EVSE market presents opportunities for electrical contractors The goal of NECA is to assist in the safe, sound, and successful growth of the electric vehicle market Overview NECA 413, Standard for Installing and Maintaining Electric Vehicle Supply Equipment (EVSE) Arrangement of NECA 413 Scope Definitions Overview 1

2 Overview Arrangement of NECA 413 Safety Pre-Installation Considerations Installation Maintenance NECA 413 is currently in the ANSI approval process What are NEIS NEIS - National Electrical Installation Standards A series of installation manuals for electrical products and systems Levels the playing field by establishing minimum quality standards for installing equipment and systems National Electrical Installation Standards NEIS Describe installation practices that go beyond the minimum safety requirements found in the NEC Ensure that electrical installation practices live up to expected professional electrical design and installation integrity. Approved by the American National Standards Institute (ANSI) 2

3 NECA X NECA 413, Standard for Installing and Maintaining Electric Vehicle Supply Equipment (EVSE) (draft) Outlines the NEC requirements for EVSE Provides guidance in selecting, sizing, and installing EVSE Scope Includes AC Level 1, AC Level 2, and DC fast charging Excludes devices other than Code-compliant AC Level 1, AC Level 2, and DC fast charging, as well as off-road, selfpropelled EVs Conforms to NFPA 70, National Electrical Code, NFPA 70E, Standard for Electrical Safety, and other NEIS publications Definitions Define selected terms: l AC Level 1 Charging l AC Level 2 Charging l Electric Vehicle (EV) l Electric Vehicle (EV) Connector l Electric Vehicle (EV) Coupler l Electric Vehicle (EV) Inlet 3

4 Definitions Define selected terms: l Electric Vehicle Supply Equipment (EVSE) l Fast Charging DC l Off-Board Charger l On-Board Charger l Personnel Protection System AC Level 1 Charging Electric vehicle (EV) charging that employs cord-and-plug connected portable electric vehicle supply equipment (EVSE). AC Level 1 EVSE is rated single-phase, nominal 120VAC, with either a 15A or 20A configuration, and is suitable for connection to NEMA 5-15R or 5-20R receptacles. AC Level 2 Charging AC Level 2 EVSE is rated single-phase, nominal 208VAC or 240VAC, 80A maximum, with branch circuit overcurrent protection required. Electric vehicle (EV) charging for indoor use could be cord and plug connected or permanently wired electric vehicle supply equipment (EVSE) operated at a fixed or portable location used specifically for EV charging. An AC Level 2 system may be cord and plug connected if identified as meeting the requirements of NEC

5 Electric Vehicle (EV) An automotive-type vehicle for on-road use, such as passenger automobiles, buses, trucks, vans, neighborhood electric vehicles, electric motorcycles, and the like, primarily powered by an electric motor that draws current from a rechargeable storage battery, fuel cell, photovoltaic array, or other source of electric current. Plug-in hybrid electric vehicles (PHEV) are considered electric vehicles. Electric Vehicle (EV) For the purpose of this Standard, off-road, self-propelled electric vehicles, such as industrial trucks, hoists, lifts, transports, golf carts, airline ground support equipment, tractors, boats, and the like, are not included. Electric Vehicle (EV) Connector A device that, by insertion into an electric vehicle (EV) inlet, establishes an electrical connection to the EV for the purpose of energy transfer and information exchange. This device is part of the EV coupler. 5

6 Electric Vehicle (EV) Coupler A mating electric vehicle (EV) inlet and EV connector set. Electric Vehicle (EV) Inlet The device on the electric vehicle (EV) into which the EV connector is inserted for energy transfer and information exchange. This device is part of the EV coupler. For the purposes of this Standard, the EV inlet is considered to be part of the EV and not part of the electric vehicle supply equipment (EVSE). Electric Vehicle Supply Equipment (EVSE) The conductors, including the ungrounded, grounded, and equipment grounding conductors and the electric vehicle (EV) connectors, attachment plugs, and all other fittings, devices, power outlets, or apparatus installed specifically for the purpose of transferring energy between the premises wiring and the EV. 6

7 Electric Vehicle Supply Equipment (EVSE) Fast Charging DC Electric vehicle (EV) charging that employs permanently wired electric vehicle supply equipment (EVSE) that is operated at a fixed location and is used specifically for EV charging. As of the date of this publication, fast charging DC EVSE ratings are yet to be determined, but can be considered any single-phase voltage or current rating higher than that of AC Level 2, or any three-phase supply voltage configuration. Fast charging DC was initially known in the industry as AC Level 3 charging. Fast Charging DC DC Fast Charging is rated 400A maximum, and 600VAC maximum, with branch circuit overcurrent protection as required for the equipment. 7

8 Off-Board Charger A charger with control and monitoring capabilities built into the electric vehicle supply equipment (EVSE), not on the electric vehicle (EV). Typical of DC Fast Charging On-Board Charging A charger with control and monitoring capabilities built into the electric vehicle (EV), not in the electric vehicle supply equipment (EVSE) Typical of AC Level 1 and 2 charging Personnel Protection System A system of personnel protection devices and construction features that, when used together, provides protection against electric shock of personnel. 8

9 Introduction Historically, EVs have been specialty vehicles, forklifts, golf carts Modern EVs are passenger cars, buses and delivery trucks Electric motor and rechargeable battery pack, fuel cell, photovoltaic (PV) array, or other current source Introduction EV range the distance that the EV can travel before recharging Range varies from vehicle to vehicle Dependent upon the on-board battery system and the hybrid nature of the EV Introduction Larger batteries give extended range Increase size, weight, cost On-board fuel sources give extended range Ability to charge batteries on the road 9

10 Introduction What is a reasonable range? Average daily commute in the United States is 40 miles or less EV target range Introduction Gasoline Hybrid electric motor close-coupled between the gasoline engine and the transmission Captures power that is normally lost to charge on-board batteries Self-contained batteries Honda Civic Hybrid Introduction Plug-In Hybrid On-board electric battery gives a range of approximately 35 miles (Chevy Volt) Gasoline engine-generator to extend range 10

11 Introduction All Electric EV Plug in to charge on-board batteries No other power source to charge batteries Range from 47 to 105 miles before recharge (Nissan Leaf) Introduction EVSE controls the energy transfer between the premises wiring system and the onboard battery system Charging level is determined by the operating voltage and power drawn during energy transfer Function of the battery system Introduction AC Level 1 charging operates on 120V AC with NEMA 5-15R or 5-20R plug configuration Typically takes between 12 and 20 hours for full charge This is a continuous load 11

12 Introduction AC Level 2 charging operates up to 240V single phase and up to 80A Typically takes between 4 and 6 hours for full charge This is a continuous load Introduction DC Fast Charging Conversion from AC to DC takes place off-vehicle DC power is delivered directly to the vehicle Introduction DC Fast Charging operates on other than 240V (max) single phase and three phase Full charge may be made in less than one hour NEC Article 625 considers this a continuous load 12

13 Introduction Society of Automotive Engineers (SAE) and EV Manufacturers have standardized the charge coupling for AC Level 1 and AC Level 2 charging (SAE J1772 TM Connector) SAE continues to work to standardize the DC Fast Charging coupling SAE J1772 TM Connector Society of Automotive Engineers (SAE) developed a standardized (NEC compliant) conductive charge connector Analogous to Henry Ford s standardization of parts and implementation of the assembly line SAE J1772 TM Connector Common EV conductive charging system architecture Standard EV coupler (inlet and connector) Communication protocol Performance requirements 13

14 SAE J1772 TM Connector Coupler is round, 43mm diameter, with five contacts or pins: l Two contacts for power (AC Line 1 and AC Line 2/Neutral) l One contact for ground connection SAE J1772 TM Connector l One contact for proximity detection to prevent the car from moving while charging l One contact for control pilot, last to engage, first to disengage, communicates charge rate available to determine amount of current allowed for the vehicle being charged SAE J1772 TM Connector 14

15 SAE J1772 TM Connector Connector supports communication over power lines Identifies the vehicle and control charging rate Permits the EVSE to adjust charging rate to the battery system SAE J1772 TM Connector Designed to withstand 10,000 connection/disconnection cycles Resistant to contamination (dust, salt, water) Withstand EV driving over it SAE J1772 TM Connector Rated for single phase EV charging up to 240V and 80 A load current This is the Industry Standard for AC Level 1 and 2 EV connectors 15

16 SAFETY General l EV batteries are a potential energy source. Disconnect the EV when working on or near EVSE components l Stop the EV charging cycle prior to disconnecting the connector. Do not disconnect the EVSE to stop the charging cycle using the connection interlock l Do not disassemble EVSE SAFETY NEC-Required Interlocks: l Connection interlock l Charge circuit interrupt device l Automatic de-energization device l Ventilation interlock SAFETY Connection Interlock l Ensure adequate contact pressure between the connector and the inlet l Prevents energization when the connector is not connected to the inlet l When properly connected, connection interlock permits a system check and permits the transfer of energy across the coupling 16

17 SAFETY Charge circuit interrupt device l Personal Protection System is required for shock protection, and includes: Ground fault protection Service ground monitor Isolation monitor Circuit interrupting device Electrical insulation SAFETY Charge circuit interrupt device l UL Product Safety Standards specify combinations of these devices can be used l Systems approach to shock protection SAFETY Automatic de-energization device l Connection interlock l De-energizes EVSE due to strain on the cable or coupling, exposed live parts, partial disconnection l Aborts the charging cycle 17

18 SAFETY Ventilation Interlock l Modern EV batteries (sealed lead-acid, nickel-metal hydride or lithium) do not emit hydrogen gas during charging and can be safely charged in a non-ventilated, indoor environment. l Batteries that require ventilation, such as flooded leadacid or nickel-iron batteries, have become the exception, not the norm SAFETY When ventilation is required: l EV charge connector receives a signal from the EV, which identified its need for ventilation l Suitable EVSE controls a ventilation system l Turns on ventilation when required l Stops charging when the ventilation system fails SAFETY NEC Article 625 ventilation requirements include: l Suitable EVSE must be marked Ventilation Required and mechanical ventilation must be provided. l Mechanical ventilation must include both supply and exhaust equipment. l Mechanical equipment must be permanently installed and located to intake from and vent directly to the outdoors 18

19 SAFETY NEC Article 625 ventilation requirements include: l Positive pressure systems are permitted only in buildings or areas specifically designed and approved l Mechanical ventilation rates can be determined from Tables in Article 625, calculated using general formulas in Article 625, or calculated by qualified personnel as part of a ventilation engineering study SAFETY NEC Article 625 ventilation requirements include: l Mechanical ventilation equipment supply circuits must be electrically interlocked to the EVSE l Mechanical ventilation equipment must remain energized during the entire EV charging cycle and is recommended to operate for 5 minutes after completion of the charging cycle l EV ventilation loads are considered continuous SAFETY When ventilation is not required: l Modern sealed batteries l No mechanical ventilation l EVSE will not charge EV batteries that require ventilation l EVSE must be marked Ventilation Not Required 19

20 PRE-INSTALLATION Basic Steps in the EVSE Installation Process l Electrical contractor site assessment for EVSE installation l Obtain electrical wiring permit(s) and coordination of the inspection and approval processes l Coordinate with local electric utility company for time-ofuse (TOU) meters, off-peak metering, etc. PRE-INSTALLATION Basic Steps in the EVSE Installation Process l Facilitate the installation of the EVSE and branch circuit wiring l Inspection, start-up, and commissioning of the completed EVSE installation PRE-INSTALLATION Electrical Contractor Responsibilities l Communication with EV dealer, coordinator, owner, inspector, supplier, others l Understand the types of EVSE and which type(s) are to be installed l Perform an accurate site assessment of existing power service 20

21 PRE-INSTALLATION Electrical Contractor Responsibilities l Provide accurate and clear estimate of necessary power upgrades, if applicable l Coordinate with the electric utility service company and Authority Having Jurisdiction (AHJ) l Use expertise to ensure a positive customer experience PRE-INSTALLATION Battery Operating and Charging Temperature Limitations l Battery capacity, charging voltage, and life expectancy are temperature dependent l Battery capacity is proportional to temperature l Charging voltage and battery life expectancy are inversely proportional to temperature l EV batteries tend to average out, but continuous operation at elevated temperature is a concern PRE-INSTALLATION Smart Chargers l Programmable l Permits EVSE to be controlled and managed as a block Load Shifting Load Shaping Ancillary Services Vehicle-to-Grid (V2G) 21

22 PRE-INSTALLATION Communication and Data Between EV and EVSE l EV and charging system identification l Interlocks and safety (Connection interlock, personnel protection, EV immobilizer system, service ground continuity) l Activation of mechanical ventilation system, if applicable l Acceptance of interlocks and initiation and termination of charging cycle PRE-INSTALLATION Communication and Data Between EVSE and Power Supplier l Control of energy transfer l Provision for monitoring of tariff l Billing of power delivered PRE-INSTALLATION Comply with all local, state, and national codes and regulations Check local planning department requirements Typically requires a permit 22

23 PRE-INSTALLATION The Electrical Permit Process l Determine and contact the applicable Authority Having Jurisdiction (AHJ) l Determine the applicable NEC edition and other Codes adopted and enforced by the AHJ l Verify if there are specific local amendments to the NEC rules PRE-INSTALLATION The Electrical Permit Process l Verify the specific installation procedures and processes l Verify utility company requirements Separate revenue meter is required Different rate tariff applies Application forms and fees are required PRE-INSTALLATION The Role of the Inspector l Issuing construction/installation permits l Enforcement of the NEC and other Codes adopted within their jurisdiction l Review of plans and specifications for Code compliance 23

24 PRE-INSTALLATION The Role of the Inspector l Conduct field inspections l Issuing of non-compliance reports/inspectors notices l Notifying utility for connection or meter clearances l Issue approvals upon completion of project PRE-INSTALLATION Electrical Inspection Process l Coordinate and schedule the rough-in and final inspections l NECA recommends setting up an on-site inspection meeting to assist the inspector and to directly address any issues or concerns to expedite the inspection process l Address all deficiencies that are identified by the inspector l Maintain records of the inspection and approval process CODES AND STANDARDS Codes and Standards l NEC rules (Chapters 1 through 4, Article 625, 230, others) l Applicable IBC (Building Codes) l Equipment Product Listing and Certification 24

25 CODES AND STANDARDS Codes and Standards l NECA National Electrical Installation Standards (NECA 1, NECA 413) l Requirements in EVSE product standards l ADA (other than dwelling units) l OSHA l NFPA 70E, Standard for Electrical Safety in the Workplace CODES AND STANDARDS Electric Vehicle Charging Systems (Article 625) Hazardous (Classified) Locations (Articles 500 through 516) NEC Requirements (Article 625) Wiring Methods EV Coupler (SAE J1772 TM ) l Polarized unless part of a system identified and listed as suitable for the purpose l Configuration must be non-interchangeable l Constructed and Installed to prevent inadvertent contact with live parts l Positive means to prevent unintentional disconnection (interlock) l First-make, last-break grounding pole (NEMA) 25

26 CODES AND STANDARDS National Electrical Code l Chapters 1 through 4, Article 625, 220, 230, and others Article 110 Requirements for Electrical Installations Article 210 Branch Circuits Article 220 Branch-Circuit, Feeder and Service Calculations Article 230 Services Article 240 Overcurrent Protection Article 250 Grounding and Bonding CODES AND STANDARDS l National Electrical Code, Chapter 3, Wiring Methods and Materials Article 300 Wiring Methods Article 310 Conductors for General Wiring Applicable Chapter 3 Wiring Methods 26

27 PRE-INSTALLATION Check local electric utility requirements Is the existing service adequate? Utility may offer an off-peak or time-of-use (TOU) meter option, which may require an additional revenue meter Utility will not energize without an approved building inspection 27

28 NEC REQUIREMENTS EVSE must be certified (Listed) and marked by a NRTL EV charging cord may be a tripping hazard. Maximum of 25 feet in length unless equipped with a cable management system (overhead support or trolley system) Locate away from significant pedestrian traffic NEC REQUIREMENTS Check ventilation requirements when installing EVSE indoors Comply with NEC requirements for mechanical ventilation and interlocks LOAD CALCULATIONS Electrical Load Calculations l EVSE and associated equipment, such as mechanical ventilation equipment, are continuous loads l Minimum ampacity of branch circuits, feeders, services, overcurrent protection, etc., is 125% of the maximum current in accordance with the NEC l Distance to utility service voltage drop 28

29 LOAD CALCULATIONS Electrical Load Calculations l Review electric utility bills to determine maximum facility demand l Include future expansion and additional EVSE in commercial calculations l Consult electric utility planners for fleet applications LOAD CALCULATIONS Electrical Load Calculations l Consider a load control strategy in lieu of upgrading the existing service or installing additional capacity, such as : Program the EVSE to only perform off-peak charging Install time clock or timer UTILITY INTERCONNECTION Electric Utility Interconnection Requirements: l Utility rate structure may provide different tariff, such as TOU, DR, RTP, V2G, or off-peak charging (and separate revenue meter) for EVs l Smart grid applications may include vehicle-to-grid (V2G) distributed generation and EV charging control 29

30 SITE SELECTION Site Selection and Preparation l Publicly accessible EVSE should be easy to find and convenient l Provide signage for EVSE-equipped parking spaces l Consider distributing EVSE rather than grouping in large parking lots/facilities l ADA requirements for accessible parking spaces SITE SELECTION Site Selection and Preparation l Provide adequate working space around EVSE for EVs l Provide curbs, wheelstops, setbacks, etc., to properly position EVs, protect EVSE from EVs, minimize cord stretch, etc. l Check that EVSE locations are level and not susceptible to water runoff, such as from roof drainage, standing water, etc., that may indicate that a concrete pad or that cord support above grade is needed SITE SELECTION Site Selection and Preparation l Install concrete pads in accordance with manufacturer recommendations and applicable codes and standards l Ensure that EVSE are not located near potential hazards l Consider locating to discourage vandalism l Provide adequate lighting, signage, safety l Consider providing shade for outdoor EVSE locations 30

31 SITE SELECTION Site Selection and Preparation l Consider precipitation and temperature extremes l Relocate EVSE away from pooling water l Provide cord support where freezing temperatures would cause the cord to freeze to the ground INSTALLATION Installation Instructions l Conformance to all specific EVSE installation instructions (NEC 110.3(B)) l NEC Article 625 requires all materials, devices, fittings, and other equipment for EVSE to be Listed l EVSE nameplates must be used to determine the load being added to the service or system l Location of EVSE will determine any specific installation mounting requirements other than ordinary INSTALLATION Establishing EVSE Locations l Determine the type of occupancy l Determine the overnight EV parking location l Locate the EVSE outlet (minimum 18, maximum 48 AFF) l Verify from the manufacturer what type of connection is required, either receptacle or hard-wired l Determine circuit routing and wiring methods (concealed, fished, surface-mounted, etc.) 31

32 INSTALLATION Branch Circuit Requirements l Typically require new dedicated branch circuits l EVSE is continuous (maximum load for 3 hours or more) l Use manufacturer s nameplate data to determine the minimum conductor size and overcurrent protective device rating 32

33 INSTALLATION Branch Circuit Sizing l Ampacity of not less than the maximum load to be served l Where a combination of continuous and non-continuous loads are served, the conductor size must have an allowable ampacity of not less than the non-continuous load plus 125 percent of the continuous load (NEC (A)(1)) INSTALLATION Branch Circuit Limitations l NEC limits branch circuit current to 80% of the overcurrent device rating (NEC (A)(1)) l Level 1 charging from a NECA 5-15R receptacle is limited to 12A (1,440W supplied at 120V) l Multiple receptacles on a common branch circuit, such as in a residence, can cause nuisance operation of overcurrent protective devices INSTALLATION Cord-and-Plug Connections l EVSE rated 125V, single-phase, 15A or 20A or part of a system identified and listed as suitable for the purpose and meeting the requirements of NEC , , and are permitted to be cord-and-plug connected l AC Level 1 and 2 equipment is permitted to be cord-andplug connected provided it meets the requirements in NEC and and is Listed and identified for such use 33

34 INSTALLATION Adding Circuits to Existing Equipment l Ensure that installers follow all applicable safety-related work practices and contractor safety policies l Requires use of Listed breakers in equipment with space, or Listed tandem or half-sized breakers to create space in a full panelboard 34

35 INSTALLATION Adding Circuits to Existing Equipment l Do not exceed the maximum number of half-sized or tandem breakers in the equipment as specified by the manufacturer l Install a sub-panel when necessary to create space for additional branch circuits in full panelboards INSTALLATION Cord-and-Plug Connections l In dwelling units, cord-and-plug connections are required to be GFCI protected 35

36 INSTALLATION AC Level 1 EVSE Wiring l Portable EVSE that is transported with the EV and is used specifically for EV and is cord-and-plug connected l AC Level 1 EVSE is suitable for connection to NEMA 5-15R or 5-20R receptacles l NECA recommends dedicated branch circuits for all EVSE, including AC Level 1 INSTALLATION AC Level 2 EVSE Wiring l AC Level 2 EVSE can be cord-and-plug connected or directly wired to a dedicated branch circuit 36

37 INSTALLATION DC Fast Charging l Directly wired to a dedicated branch circuit 37

38 INSTALLATION General l EVSE is self-contained equipment l Provide power and communication connections in accordance with manufacturer instructions l Consider spare raceways and conductors l Ground EVSE in accordance with NEC Article 250 INSTALLATION General l Mount EVSE such that wall-mounted outlets are not more than 48 above the ground l Provide a minimum of 24 clearance on all sides of outdoor pedestal-mounted EVSE l Protect EVSE from vehicles using bollards, curbs or wheelstops 38

39 INSTALLATION General l Anchor EVSE in accordance with the manufacturer s instructions l Torque fasteners and connectors in accordance with manufacturer s instructions l Install properly sized and located raceways INSTALLATION General l Continuous load l Conductors and overcurrent protection not less than 125% of the maximum rated load current l EVSE and ventilation systems INSTALLATION Disconnecting Means l Provide a disconnecting means for EVSE rated more than 60A or more than 150V to ground l Readily accessible l Lockable in the open position l Portable means for adding a lock are not acceptable 39

40 INSTALLATION Free-Standing EVSE l Install a grounding electrode when required l When installed, connect the auxiliary grounding electrode to the supply circuit equipment grounding conductor and the frame of the equipment INSTALLATION EVSE Start-up and Commissioning l Follow manufacturer s instructions l Test EVSE using a compatible EV with suitable ratings, connectors, and equipment l Inspect charge connector and user interface display and indictor lights for proper operation l Check for proper operation of mechanical ventilation, when required NECA 413 Questions and Answers 40

41 Standard for Installing and Maintaining Electric Vehicle Supply Equipment (EVSE) Presented by: Gregory W. Massey, P. E. 41