EPRI s Utility Direct DC Fast Charger Development, Testing, Demonstration. Arindam Maitra IWC Meeting March 28, 2012
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1 EPRI s Utility Direct DC Fast Charger Development, Testing, Demonstration Arindam Maitra IWC Meeting March 28, 2012
2 Utility Direct Medium Voltage Fast Charger Conventional DC Fast Charger needs a new three-phase service Three-phase transformer Three primary conductors and associated medium voltage fuses Three high-current service conductors 208/480 Vac DC fast charger Overall efficiency (w xfmr) ~88-91% Installation costs Utility Direct Fast Charger Combines service transformer and DC fast charger into one unit Needs only one primary conductor, no isolation transformer and no secondary conductors Overall efficiency >95% Installation costs 2
3 Configuration of Utility Direct Fast Charger 2.4 or M-level AFE 8 kv AC AC-DC & 400-V + Isolated DC DC-DC DC-DC Charger HV components are enclosed within the pad-mounted enclosure AC input can be interrupted with highvoltage vacuum switch DC voltage can be interrupted with a DC circuit breaker Charger output is Chademo compatible 3
4 Pad-Mount Case for Medium-Voltage AFE Converter and Isolated DC-DC Stage (Box-A) Photograph of the case and internal circuits 4
5 Utility Direct Fast Charger with CHAdeMO Interface PC Display Control Console Interface DSP board 1,7 2 GND d1 RDY Vehicle 2.4kV rms I ref V ref CMD Medium Voltage DC-DC Charger PWR+ PWR CAN+ CAN d2 Side Battery Management System 5
6 2.4KV 50kW Medium Voltage IUT Based DC Charger Efficiency Comparisons 6
7 EPRI Web/Mobile Application EPRI Server DC Charging Data Android Tablet Provides user interface to the charger Sends DC charging data to the EPRI Server AC Charging Data Bluetooth Instrumentation CAN Listener 2.4 kv AC Charger CAN Bus 500 VDC 7
8 Demo in 6-7, 2012 Medium Voltage IUT DC Fast Charger Fully functional 1-phase 2.4KV 45KVA IUT DC Fast charger (FC) system with the CHAdeMO communication protocols (CAN) Why is it valuable? Utility owned asset for fast charging Provide customers with a variety of products and services that go beyond the meter Reduced energy losses versus conventional chargers Reduced weight versus fast chargers using conventional transformers 8
9 Installation Options Conventional FC installation Option 1: Underground installation (pad-mount) Option 2: Overhead installation (pole-mount) Medium Voltage FC installation (pad-mount) The objective is to compare cost of installing a 480 Vac fast charger vs an EPRI MV fast charger 9
10 480 Vac Fast Charger vs MV Fast Charger Installations 480 Vac Fast Charger Installation Option Vac Fast Charger Installation Option 2 Medium Voltage Fast Charger Installation 10
11 Key Installation Components 480 Vac FC (Option 1) 480 Vac FC (Option 2) EPRI MVDC FC 3 long primaries (135 ft) 3 short primaries (5 ft) 1 long primary (135ft) 1 three-phase 75 kva padmount xfmr (13.8 kv/480 Vac) Excavation, foundation, concrete pad, MV terminations 4 underground service conductors (10ft) + 2 underground DC service conductors (10 ft) 3 single-phase 25 kva pole-mount xfmrs (7.32kv/277 Vac) overhead service conductors (110 ft) + 2 underground DC service conductors (10 ft) - 2 underground DC service conductors (10 ft) Trenching, conduits Some trenching, conduits Trenching, conduits 480 Vac service panel + Secondary side metering 480 Vac service panel + Secondary side metering Primary side metering 11
12 Installation Cost 480 Vac FC (Option 1) 480 Vac FC (Option 2) EPRI MVDC FC Primaries $3937 $261 $1399 Transformer(s) $14776 $3638 Service conductor $752 $2284 $378 Service Panel $350 $350 Metering $365 $365 $1500 Foundation Cost for FC Main Box $3272 $3272 $3272 Total Cost $23452 $10170 $6549 * Approximate costs these do not include unit price of the fast charger 12
13 Where this Technology Makes Sense Utilities who want to provide fast charging capability directly from their distribution system. This could be especially useful in dense cities where you place fast chargers that aren't hosted by a business Businesses could install Intelligent Universal Transformer (IUT) technology, as their building transformer and conveniently add fast charging service (and also integrate their onsite solar, energy storage, and building energy management system). This would help in managing the high peak loads of the DC charger and the impact both on the utility and to a business' own cost of service, specifically by reducing demand charges DC fast charging technology has the potential to significantly increase the range and versatility of battery electric vehicles, enhancing their commercial appeal 13
14 TVA imiev CHARGING (Charging Event #1) March 6 th,
15 15
16 Charging Power as a Function of Time imiev Charging Power (kw) Time (minute) 16
17 Battery Capacitor and State-of-Charge imiev Battery Capacity (kwh) SOC State of Charge Time (minute) 17
18 Voltage and Current During Charging imiev Charging current (A) Battery Voltage (V) Time (minute) 18
19 EPRI LEAF CHARGING Charging Event #2 March 6 th,
20 20
21 Charging Power as a Function of Time Leaf Charging Power (kw) Time (minute) 21
22 Battery Capacitor and State-of-Charge Leaf Battery Capacity (kwh) State of Charge Time (minute) 22
23 Voltage and Current During Charing Leaf Charging current (A) Battery Voltage (V) Time (minute) 23
24 EPRI LEAF CHARGING Charging Event #3 March 6 th,
25 Charging Power as a Function of Time Leaf Charging Power (kw) Time (minute) 25
26 Battery Capacitor and State-of-Charge Leaf Battery Capacity (kwh) kwh SOC State of Charge Time (minute) 26
27 Voltage and Current During Charing Leaf Charging current (A) Battery Voltage (V) Time (minute) 27
28 EPRI LEAF CHARGING Charging Event #4 March 7 th,
29 29
30 Charging Power as a Function of Time EPRI Leaf Charging Power (kw) Time (minute) 30
31 Battery Capacitor and State-of-Charge EPRI Leaf Battery Capacity (kwh) kwh SOC State of Charge Time (minute) 31
32 Voltage and Current During Charging EPRI Leaf Charging current (A) Battery Voltage (V) Time (minute) 32
33 LEAF CHARGING Charging Event #5 March 7 th,
34 34
35 Charging Power as a Function of Time TVA Leaf Battery Capacity (kwh) kwh SOC State of Charge Time (minute) 35
36 Charging Power as a Function of Time TVA Leaf Charging Power (kw) Time (minute) 36
37 Voltage and Current During Charging - TVA Charging current (A) Battery Voltage (V) Time (minute) 37
38 Together Shaping the Future of Electricity 38
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