standard for installing and maintaining electric vehicle
TRANSCRIPT
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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
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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)
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NECA 413-201X
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, self-propelled 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
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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 625.
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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.
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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.
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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.
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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.
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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”
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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
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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
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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
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Introduction
Society of Automotive Engineers (SAE) and EV Manufacturers have standardized the charge coupling for AC Level 1 and AC Level 2 charging (SAE J1772TM Connector)
SAE continues to work to standardize the DC Fast Charging coupling
SAE J1772TM 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 J1772TM Connector
Common EV conductive charging system architecture
Standard EV coupler (inlet and connector)
Communication protocol
Performance requirements
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SAE J1772TM 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 J1772TM 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 J1772TM Connector
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SAE J1772TM 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 J1772TM Connector
Designed to withstand 10,000 connection/disconnection cycles
Resistant to contamination (dust, salt, water)
Withstand EV driving over it
SAE J1772TM 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
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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
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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
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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 lead-acid 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
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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”
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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-of-
use (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
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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)
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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
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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
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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
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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 J1772TM) 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)
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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
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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
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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
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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
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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
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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.)
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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
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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 210.19(A)(1))
INSTALLATION
Branch Circuit Limitations l NEC limits branch circuit current to 80% of the
overcurrent device rating (NEC 210.19(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 625.18, 625.19, and 235.29 are permitted to be cord-and-plug connected
l AC Level 1 and 2 equipment is permitted to be cord-and-plug connected provided it meets the requirements in NEC 625.18 and 625.19 and is Listed and identified for such use
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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
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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
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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
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INSTALLATION
DC Fast Charging l Directly wired to a dedicated branch circuit
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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
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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
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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
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Standard for Installing and Maintaining Electric Vehicle Supply Equipment (EVSE)
Presented by: Gregory W. Massey, P. E.