epri’s utility direct dc fast charger – development, testing,...
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Arindam MaitraIWC Meeting
March 28, 2012
EPRI’s Utility Direct DC Fast Charger –Development, Testing, Demonstration
2© 2012 Electric Power Research Institute, Inc. All rights reserved.
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
3© 2012 Electric Power Research Institute, Inc. All rights reserved.
Configuration of Utility Direct Fast Charger
M-level AFEAC-DC &Isolated DC-DC
DC-DC
Charger400-V
DC
2.4 or8 kV AC +
–
• HV components are enclosed within thepad-mounted enclosure
• AC input can be interrupted with high-voltage vacuum switch
• DC voltage can be interrupted with a DCcircuit breaker
• Charger output is Chademo compatible
4© 2012 Electric Power Research Institute, Inc. All rights reserved.
Pad-Mount Case for Medium-Voltage AFE Converter and Isolated DC-DC Stage (Box-A)
Photograph of the case and internal circuits
5© 2012 Electric Power Research Institute, Inc. All rights reserved.
Utility Direct Fast Charger with CHAdeMOInterface
DSP
board
Medium
Voltage
DC-DC
Charger
Vehicle
Side
Battery
Management
System
Interface
PC Display
Control
Console
1,7
2
4
GNDd1
d2
RDY
8
9
10
CAN+CAN–
5
6
PWR+
PWR–
IrefVref
CMD
2.4kV
rms
6© 2012 Electric Power Research Institute, Inc. All rights reserved.
2.4KV 50kW Medium Voltage IUT Based DC Charger –Efficiency Comparisons
7© 2012 Electric Power Research Institute, Inc. All rights reserved.
EPRI Web/Mobile Application
CAN Listener
EPRI Server
Charger
Android Tablet
• Provides user interface to the charger
• Sends DC charging data to the EPRI Server
Bluetooth
Instrumentation
2.4 kV AC
500 VDC
CAN Bus
AC Charging Data
DC Charging
Data
8© 2012 Electric Power Research Institute, Inc. All rights reserved.
Demo in Knoxville @March 6-7, 2012
• Medium Voltage IUT DC Fast Charger
– Fully functional 1-phase 2.4KV 45KVA IUT DC Fast charger (FC) system with the CHAdeMOcommunication 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
9© 2012 Electric Power Research Institute, Inc. All rights reserved.
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
10© 2012 Electric Power Research Institute, Inc. All rights reserved.
480 Vac Fast Charger vs MV Fast Charger Installations
480 Vac Fast Charger Installation – Option 1 480 Vac Fast Charger Installation – Option 2
Medium Voltage Fast Charger Installation
11© 2012 Electric Power Research Institute, Inc. All rights reserved.
Key Installation Components
480 Vac FC (Option 1) 480 Vac FC (Option 2) EPRI MVDC FC3 long primaries (135 ft) 3 short primaries (5 ft) 1 long primary (135ft)1 three-phase 75 kVA pad-mount xfmr (13.8 kV/480 Vac)
3 single-phase 25 kVA pole-mount xfmrs(7.32kv/277 Vac)
-
Excavation, foundation, concrete pad, MV terminations
- -
4 underground service conductors (10ft) + 2underground DC service conductors (10 ft)
4 overhead service conductors (110 ft) + 2underground 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
12© 2012 Electric Power Research Institute, Inc. All rights reserved.
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
13© 2012 Electric Power Research Institute, Inc. All rights reserved.
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
14© 2012 Electric Power Research Institute, Inc. All rights reserved.
TVA iMieV CHARGING (Charging Event #1)March 6th, 2012
15© 2012 Electric Power Research Institute, Inc. All rights reserved.
16© 2012 Electric Power Research Institute, Inc. All rights reserved.
Charging Power as a Function of Time – iMieV
Time (minute)
Cha
rgin
g P
ower
(kW
)
17© 2012 Electric Power Research Institute, Inc. All rights reserved.
Battery Capacitor and State-of-Charge – iMieV
Time (minute)
Bat
tery
Cap
acity
(kW
h)
Sta
te o
f Cha
rge SOC
18© 2012 Electric Power Research Institute, Inc. All rights reserved.
Voltage and Current During Charging – iMieV
Time (minute)
Bat
tery
Vol
tage
(V)
Cha
rgin
g cu
rrent
(A)
19© 2012 Electric Power Research Institute, Inc. All rights reserved.
EPRI LEAF CHARGING – Charging Event #2 March 6th, 2012
20© 2012 Electric Power Research Institute, Inc. All rights reserved.
21© 2012 Electric Power Research Institute, Inc. All rights reserved.
Charging Power as a Function of Time – Leaf
Time (minute)
Cha
rgin
g P
ower
(kW
)
22© 2012 Electric Power Research Institute, Inc. All rights reserved.
Battery Capacitor and State-of-Charge – Leaf
Time (minute)
Bat
tery
Cap
acity
(kW
h)
Sta
te o
f Cha
rge
23© 2012 Electric Power Research Institute, Inc. All rights reserved.
Voltage and Current During Charing – Leaf
Time (minute)
Bat
tery
Vol
tage
(V)
Cha
rgin
g cu
rrent
(A)
24© 2012 Electric Power Research Institute, Inc. All rights reserved.
EPRI LEAF CHARGING – Charging Event #3 March 6th, 2012
25© 2012 Electric Power Research Institute, Inc. All rights reserved.
Charging Power as a Function of Time – Leaf
Time (minute)
Cha
rgin
g P
ower
(kW
)
26© 2012 Electric Power Research Institute, Inc. All rights reserved.
Battery Capacitor and State-of-Charge – Leaf
Time (minute)
Bat
tery
Cap
acity
(kW
h)
Sta
te o
f Cha
rge SOC
kWh
27© 2012 Electric Power Research Institute, Inc. All rights reserved.
Voltage and Current During Charing – LeafB
atte
ry V
olta
ge (V
)C
harg
ing
curre
nt (A
)
Time (minute)
28© 2012 Electric Power Research Institute, Inc. All rights reserved.
EPRI LEAF CHARGING – Charging Event #4
March 7th, 2012
29© 2012 Electric Power Research Institute, Inc. All rights reserved.
30© 2012 Electric Power Research Institute, Inc. All rights reserved.
Charging Power as a Function of Time – EPRI Leaf
Time (minute)
Cha
rgin
g P
ower
(kW
)
31© 2012 Electric Power Research Institute, Inc. All rights reserved.
Battery Capacitor and State-of-Charge – EPRI Leaf
Time (minute)
Bat
tery
Cap
acity
(kW
h)
Sta
te o
f Cha
rge SOC
kWh
32© 2012 Electric Power Research Institute, Inc. All rights reserved.
Voltage and Current During Charging – EPRI Leaf
Bat
tery
Vol
tage
(V)
Cha
rgin
g cu
rrent
(A)
Time (minute)
33© 2012 Electric Power Research Institute, Inc. All rights reserved.
LEAF CHARGING – Charging Event #5 March 7th, 2012
34© 2012 Electric Power Research Institute, Inc. All rights reserved.
35© 2012 Electric Power Research Institute, Inc. All rights reserved.
Charging Power as a Function of Time – TVA Leaf
Time (minute)
Bat
tery
Cap
acity
(kW
h)
Sta
te o
f Cha
rge
SOC
kWh
36© 2012 Electric Power Research Institute, Inc. All rights reserved.
Charging Power as a Function of Time – TVA Leaf
Time (minute)
Cha
rgin
g P
ower
(kW
)
37© 2012 Electric Power Research Institute, Inc. All rights reserved.
Voltage and Current During Charging - TVAB
atte
ry V
olta
ge (V
)C
harg
ing
curre
nt (A
)
Time (minute)
38© 2012 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
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