This document discusses ABB's solution for electric vehicle charging infrastructure, specifically regarding AC charging poles. It provides an overview of AC charging pole components and functions, including definitions, classifications, product development considerations, standards, and ABB's specific AC charging pole product. The key components and functions of ABB's AC charging pole are described, including the control system integration using ABB PLCs, interfaces and protocols, and the user interface. Images of ABB's AC charging pole product and user interface are also presented.

1. © ABB Group
2009-07-14 | Slide 1
Low Voltage Products
EV charging infrastructure
Solution for AC charging
D. Malacalza, J. Fan, ABB Low Voltage Installation Materials Ltd (Beijing), Aug 2011

2. © ABB Group
2009-07-14 | Slide 2
EV Charging
Content
§ Overview
§ AC charge pole definition
§ AC charge pole development
§ Solution from ABB LV Installation materials,
Beijing

3. © ABB Group
May 6, 2016 | Slide 3
© ABB Group
May 6, 2016 | Slide 3
Background
Environmental concerns
Road transport is an increasing source of CO2 emissions
AnnualemissionofCO2inGigatons
Electricity plants
Industry (excl. cement)
Road transport
Residential and service sector
Deforestation
Others
Refineries etc
International transport
10
9
8
7
6
5
4
3
2
1
0
1970 1980 1990 2000
Source: IPCC “Mitigation
of Climate Change”,
Cambridge University
Press, 2007

4. © ABB Group
May 6, 2016 | Slide 4
Lochner-Porsche 1st PHEV
GM XP883 electric motor powered
the car until it reached 16 km/h, at
which point the gasoline engine
would kick in when running in hybrid
mode.
Esoro H301 by the
Swiss company
Esoro AG. 9 kWh Ni-
Cd battery could be
recharged in 4 h
from a 220v
electrical wall
outlet, or in about 2
h at a steady speed
of 120km/h.
Audi Duo twice
expensive A4 diesel
Renault Kangoo on board
3.5kW charger could charge a
depleted battery pack in about
4 h from 220 volts.
Toyota Prius+ had a 15
km range using Lead-acid
battery pack. Calcars
initiative
Toyota Prius had
a A123 Li-ion pack
for 25 km
Chevrolet Volt
had a 65 km range
using Li-ion battery
pack. Starts 2010
Many car
manufacturers
announced
commercialization of
PHEV in 2009-2010:
Toyota, GM, VW,
Mazda
The electric automobile is
in its heyday. Of the 4,192
cars produced in the US
28% are powered by
electricity, and electric
autos represent about 1/3
of all cars found on the
roads of New York City,
Boston, and Chicago.
The electric car ceases
to be a viable
commercial product.
The electric car's
downfall is
attributable to a
number of factors,
including the desire
for longer distance
vehicles, their lack of
horsepower, and the
ready availability of
gasoline.
1890 1900 1920
Concerns about the soaring price of oil
and a growing environmental
movement result in renewed interests
in electric cars from both consumers
and producers.
Vanguard
CitiCar had a top
speed of 50 km/h
and a reliable
warm-weather
range of 65 km.
19701974
GM EV1 had a
range of 260 km
with Ni-MH battery
1994 1997 1999
REVAi is the best selling EV (lead-
acid battery, top speed 80 km/h,
range 80 km, recharge time 8 h,
price in UK ≈ 12000€
2001 2003 2004 2005 2006 2007 2008 2010
Smart EV (zebra battery,
top speed 120 km/h, range
110 km, recharge time 8 h)
Mitsubishi iMiEV (16 kWh
Li-ion battery, top speed 130
km/h, range 130 km)
Nissan, Toyota,
GM, Mitsubishi
and 11 new
companies
planning to offer
highway-capable
EV within a few
years.
ZENN (lead-acid
battery, top speed
40 km/h, range 60
km, recharge time
8 h, 15000$
Background
Electric vehicles history

5. © ABB Group
May 6, 2016 | Slide 5
Description Installation
Slow charging
(on-board)
Individual poles at home or at parking
lots
Full battery charge >6 hours
2 - 4 kW, normal residential & office
installations
Small converters
Fast charging
(on-board)
Special charging stations / special
equipment at home
Now fastest charge ca. 30 min, typical
1 hr
7.2 - 43 kW
Onboard converter becomes
expensive component for higher
powers
Fast and Ultra-
fast charging
(off-board)
Special charging stations (option:
integration of energy storage)
Concept to reduce charging time to ca.
6 minutes – near parity with ICE
refueling
50 - 250 kW+
Off-board DC converters
Improved performance, lower system
costs
Battery
replacement
Stations for replacement of depleted
batteries Main application: highways
Larger stations on the MW range
MV installations and larger
converters
Vision: robotic solution to replace
batteries
Background
Charging methods

6. © ABB Group
2009-07-14 | Slide 6
EV Charging
Charging station scheme
Power Line
Data Line
Company
server
server
Charging station
Charge
pole(s)

7. © ABB Group
May 6, 2016 | Slide 7
Our offering
EV charging infrastructure solution
Substation Network mngt,
authentication &
billing
Renewable
energy
sources
Public AC
charging pole
3-20kW
Domestic
AC wallbox
3 - 4 kWPublic DC
charging station
50 - 300 kW
Energy
storage &
power quality
Battery swap
stations for public
transportation
Linking charging
infrastructure to
Building-Energy-
Mgmt-Systems
Used car batteries
as central storage
capacity
Storage of peak
supply power in car
batteries (V2G)

8. © ABB Group
2009-07-14 | Slide 8
EV Charging
Content
§ Overview
§ AC charge pole definition
§ AC charge pole development
§ Solution from ABB LV Installation materials,
Beijing

9. © ABB Group
2009-07-14 | Slide 9
EV Charging pole
Car Charging Outlet Unit (charger) - Definition
§ A charger is an access point to electric power.
§ The access is provided through a plug and socket combination.
§ The energy consumption is measured by an electric meter function.
§ The energy flow is controlled by a switching device (on/off)
§ The charger (socket) is protected by short circuit, overload and residual
current protection.
§ Overvoltage protection by surge protection devices can be provided if
required.
§ Authentication devices (RFID transponder/tag, credit card reader)
§ A communication function (eg. GPRS) exchanges information between
charger and system.
§ A control function does:
§ authentication (in interaction with the management system),
§ provides the measured/consumed charged electricity to the
management system,
§ provides monitoring/diagnostics of the charger
§ Above components are housed in a charge pole

10. © ABB Group
2009-07-14 | Slide 10
EV Charging pole
Classification of Charge spots
§ Home/residential
§ In-house (garage) or outdoor (street parking, car port)
§ No authentication necessary
§ Energy measurement (sub-metering) and control part of
the SmartHome
§ Few charge points per home / flat
§ Business, Public (outdoor, indoor)
§ Company parking
§ Public building, stores, malls
§ Car parks

11. © ABB Group
2009-07-14 | Slide 11
EV Charging
Content
§ Overview
§ AC charge pole definition
§ AC charge pole development
§ Solution from ABB LV Installation materials,
Beijing

12. © ABB Group
2009-07-14 | Slide 12
The product structure of a charge pole can be broken down in the
following functional areas:
§ Standard components for electrical distribution (RCBO, MCB,
etc)
§ Standard components for automation/communication (PLC,
Meter, KNX modules, etc.)
§ Socket outlet / Coupler
§ Additional functions (authentication, communication, HMI, etc)
§ System Integration level 1: communication with PLC
§ System Integration level 2: user interface, billing
§ External case
Development of a charge pole is organized accordingly
AC Charging pole
Charge pole structure

13. © ABB Group
May 6, 2016 | Slide 13
§ IEC Standards:
§ IEC 61851-1/2
§ IEC 62196-2
§ China:
§ China: GB/T XXXX – 201X Electric Vehicle Conductive Charge
Coupler (draft version).
§ China: GB/T XXXX – 201X Communication Protocols between
Battery Management System and Off-board Charger for Electric
Vehicles (draft version)
§ ……
§ America/Japan:
§ SAE J1772 (medium on-board: 3-4 h)
§ CHADEMO (TEPCO/Japan: fast off-board: <30 min)
EV Charging Pole
Standardization issue

14. © ABB Group
2009-07-14 | Slide 14
N
L3
L2
L1
AC charge pole
Block diagram
MCB = Miniature CircuitBreaker
RCBO = Residual Currentoperated circuitBreakers with Overcurrent protection
PWR = Power Supply 230 V AC / 24 V DC
Socket outlet
PE
P
P
N
N
PE
P
P
P
N
N
N
RFID tag, credit card, etc.
GPRS, Power Line, etc.
Sensors, cooling, heating
car communication
Connector
MainSwitch
MCB1ARCBO10A
/16A,30mA
RCBO32A,
30mA
Electricity
Meter
Electricity
Meter
ContactorContactor
Control
Authentication
Communication
PWR
Auxiliary

15. AC500-eCo PLC
§ Authentication of the user by
RFID-chip, verification with
service provider, allow or
refuse charging
§ Read out of charged electricity
and communicate it with the
service provider using wireless
GPRS communication or build-
in Ethernet (cable) or other
fieldbus
§ Load control and charger
status (available, occupied, out
of service, charge current)
§ Communication with the
Electric Vehicle for safe
connection and correct
charging
§ Allows remote diagnostic of
charger
GPRS-modem
AC500-eCo
RFID authentication
RCD automatic
reset and remote
DS200 RCD with automatic reset
and remote control
§ Either resets automatically in a
defined sequence or controlled
by the AC500
§ Monitoring if tripped
Electricity meter
§ Measures the charged electric
power (single phase or 3-
phase)
§ Measures actual line voltage
and actual charge current
Electricity meter
AC Charge pole
Distribution/automation components

16. § Electronic meter with four quadrant metering
meaning that the meter can measure both
imported as well as exported energy for active or
active and reactive energy
§ Type approved according to international
standards. Approved according to MID
§ Class B and A according to EN 50470-1, -3, Class
1 and 2 according to IEC
§ Remote reading via pulse output or
communication
§ Communication via infrared port or via built-in
interface Communication modules that connect
via infrared port to the meter for remote reading
and setting of data in the meter
AC Charge pole
Electricity meter

17. User identification and authorization to charge could
be managed through:
§ Sinopec card (中国石化加油卡)
§ ATM card (connection to the bank server
required)
§ Beijing “all-in-one” card (市政交通一卡通)
§ Credit card (VISA, AMEX, etc)
§ Any other system to be defined according to
the local habits/needs
AC Charge pole
Authentication (example)

18. AC500 PLC
§ Scalable control
§ Wide choice of communication and field bus
couplers
§ User-selectable coupler types for simultaneous
operation
§ Fast replacement thanks to plug-in modules
§ A single software package for the entire range
§ Seamless integration of control system and field
devices
AC Charge pole
Automation/control

19. © ABB Group
2009-07-14 | Slide 19
Highlights in AC charge pole product development
§ Current market evolution doesn’t allow to define a
specific charge pole suitable to any installation
§ Functional areas are well identified
§ The type of component suitable to satisfy the specific
function can change according to the needs of the
installation under consideration
§ All the charge pole components are available on the
market
AC Charge pole
Product Development

20. © ABB Group
2009-07-14 | Slide 20
AC Charge pole
Product Development
Reference standards
§ IEC 62196 (Plugs, socket-outlets and vehicle inlets –
Conductive charging of electrical vehicles)
§ IEC 61851 (Electrical Vehicle Conductive Charging
System)
§ China: GB/T XXXX – 201X Electric Vehicle
Conductive Charge Coupler (draft version).
§ China: GB/T XXXX – 201X Communication Protocols
between Battery Management System and Off-board
Charger for Electric Vehicles (draft version)
§ Other standards (i.e. SAE, UL where required)

21. © ABB Group
2009-07-14 | Slide 21
EV Charging
Content
§ Overview
§ AC charge pole definition
§ AC charge pole development
§ Solution from ABB LV Installation materials,
Beijing

22. © ABB Group
2009-07-14 | Slide 22
© ABB Group
2009-07-14 | Slide 22
ABB LV Installation Materials AC charger
Product characteristics
§ Charging voltage: 200-240VAC
§ Charging current:16 / 32A
§ Protection: IP44
§ Charging interface: 7 pins
§ User authentication: RFID
§ Residual current: 30mA
§ Surge protection function
§ Bill printing function
§ HMI display
Function can be specialized according to customer’s requirement

23. © ABB Group
2009-07-14 | Slide 23
© ABB Group
2009-07-14 | Slide 23
ABB LV Installation Materials AC charger
Product appearance

24. © ABB Group
2009-07-14 | Slide 24
© ABB Group
2009-07-14 | Slide 24
n ABB PLC (PM564-T-ETH CPU) act as central control unit
ABB PLC
Phys. interface Protocol
IEEE 802.3 M-Bus
RS485 Proprietary
DO control N/A
RS485 Proprietary
GB/T XXXX-201X 5.2.1 N/A
RS485 Modbus
Authentication (RFID)
Electricity Meter
Communication with
Sever (GPRS/Internet)
Contactor
PWM signal
HMI
Device
ABB LV Installation Materials AC charger
System Integration – Interface and Protocols

25. © ABB Group
2009-07-14 | Slide 25
Main functions of the user interface:
§ User authentication through RFID
§ Lock/Unlock door to access the socket outlet
§ Different charging solutions available for billing: the user
select which charging solution is the most suitable:
§ Power (input of the kWh needed)
§ Time (input of the duration of the charge)
§ Money (input of the amount of money to be charged)
§ Full charging ( Charging until Battery is full)
§ Charging status with posibility to stop the operation
§ Printing of the invoice/result of the charging operation if
requested
ABB LV Installation Materials AC charger
System Integration – Interface and Protocols

26. © ABB Group
2009-07-14 | Slide 26
© ABB Group
2009-07-14 | Slide 26
ABB LV Installation Materials AC charger
System Integration – User interface

27. © ABB Group
2009-07-14 | Slide 27
© ABB Group
2009-07-14 | Slide 27
ABB LV Installation Materials AC charger
System Integration – User interface

28. © ABB Group
2009-07-14 | Slide 28
© ABB Group
2009-07-14 | Slide 28
ABB LV Installation Materials AC charger
System Integration – User interface

29. © ABB Group
2009-07-14 | Slide 29
© ABB Group
2009-07-14 | Slide 29
ABB LV Installation Materials AC charger
System Integration – User interface

30. © ABB Group
2009-07-14 | Slide 30
© ABB Group
2009-07-14 | Slide 30
ABB LV Installation Materials AC charger
System Integration – User interface

31. © ABB Group
2009-07-14 | Slide 31
© ABB Group
2009-07-14 | Slide 31
ABB LV Installation Materials AC charger
System Integration – User interface

32. © ABB Group
2009-07-14 | Slide 32
© ABB Group
2009-07-14 | Slide 32
ABB LV Installation Materials AC charger
System Integration – User interface

33. © ABB Group
2009-07-14 | Slide 33
© ABB Group
2009-07-14 | Slide 33
EV Charging
AC Charge pole – Product Offer
Basic
functionalities
Completepole
Protection
Socket Outlet
Automation/Control
PLC Integration
Authentication/Communication
User Interface Integration
External case
The current product structure will
allow to organize an offer fitting to
all the possible customer needs

34. © ABB Group
2009-07-14 | Slide 34