May 20, 2016
Dear California Energy Commission,
The U.S. Green Vehicle Council project is a project to complete CHAdeMO DC fast charging by the end of 2016 on a route that includes Santa Nella, Stockton, Coalinga Merced, Fresno, Tulare, Lost Hills, Lebec, Castaic and Oceanside, in our beautiful state of California.
The very first installation on this CEC grant in Santa Nella has a lot of shortcomings that I hope were addressed in the original contract. I have to assume the grant recipient plans to install the same unit at all other locations along the route. Since the actual unit that they installed at Santa Nella does not currently work, now is a good time to make sure all the ducks are in order on this contract.
My purpose of the below data is not to glaze your eyes over with a bunch of technical mumbo-jumbo, but this data is instructive. As I suggested at the California Energy Commission (CEC) workshops late last year and early this year, state money should only be issued when we know exactly what we are getting. There is one specification that is very difficult for less than fully honest vendors to fudge for DC charging, and that is the "Output DC Amps - Continuous Duty ". Obviously, fully compliant units for the applicable DC charge protocols PLUS the applicable UL certification would also be paramount.
"Continuous Duty" is particularly important. It should be rated at the ambient temperatures that the unit will be exposed to, and in the central California valley, that could be up to 50C / 122F. Many chargers, like the Nissan "44kW" units that are popular, can only output their full power for a relatively short period of time in a hot environment. Units like the new Tritium Veefil and Tesla Superchargers are liquid cooled to mitigate high temperature. We have NO IDEA yet how well this air cooled unit in Santa Nella will handle heat, should it ever become operational.
My belief is that this unit in Santa Nella is from the following vendor:
[EDIT: the vender is apparently different, per CEC]
SHENZHEN SETEC POWER CO., LTD
Add: #199, Setec Industrial Park, Dakan, Xili Town, Nanshan District, Shenzhen , China
Mobile: +86-13925204306
Tel : 0086-755-26527137 Fax : 0086-755-26527104
Web: http://www.setec-power.com
This unit was offered to me from the vendor in China at a sale price of $2999 in January 2016. I believe what follows are the technical specifications for the unit in Santa Nella. You'll note that it is not compliant with the CHAdeMO specification:
250-450 VDC output (CHAdeMO requires 50-500VDC)
208VAC * (58a * 1.73) = 21kW AC input maximum input power
93% efficiency from AC to DC (my guess) equals 19.5kW output MAXIMUM
Now, we can calculate the MAXIMUM amps into a typical LEAF at 396 VDC maximum battery voltage is 50 amps DC at 19.5kW. It may be lower, which our company can (and will) test for in the near future (again, assuming this unit becomes operational). Since the unit is advertised as "25kW", this is precisely why kW is almost meaningless to specify charger performance in terms of grant language.
The CHAdeMO specification is 200 amps DC maximum "100kW", with plans for 300 amps DC "150kW". Currently, virtually all DC chargers that are advertised as "50 KW" are between 120 or 125 amps DC. The Nissan "44kW" units are 115 amps DC. For comparison, all Tesla Superchargers operate today at up to 370 amps (an actual power output of about 120kW in most Tesla cars).
Any DC charger (not just this one) operating at 50 amps DC Continuous Duty will charge the following cars from 10% to 80% (70% net charge) as follows with "new condition" batteries. All battery capacities are the manufactures published size, or best guess for the "LEAF 2.0":
51 minutes minimum - 16.8kWh is 70% of 24kWh LEAF
58 minutes minimum - 18.9kWh is 70% of 27kWh Soul EV
64 minutes minimum - 21.0kWh is 70% of 30kWh LEAF
90 minutes minimum - 29.3kWh is 70% of 41.8kWh Toyota RAV4 EV
120 minutes minimum - 39.2kWh is 70% of 56kWh Tesla Roadster
129 minutes minimum - 42.0kWh is 70% of 60kWh future LEAF 2.0
180 minutes minimum - 49kWh is 70% of 70kWh Tesla Roadster
193 minutes minimum - 63kWh is 70% of 90kWh Tesla Model X
The above assumes that I have identified this charging unit at Santa Nella properly, but the issues remain nonetheless, even if I misidentified it.
Slow charging will not get the mass market out of their oil burning cars to drive along corridors, and further, the lowest end of income level drivers don't have money to buy a car for each specific need (longer range corridor travel and short range commuting).
Here are the specific potential grant issues that I see so far:
1) The Santa Nella unit does not yet work (always a bad sign)
2) The grant recipient appears to be inflating the actual PERFORMANCE of the unit, by suggesting that a LEAF needs only 12.5kWh to fill the battery from 10% to 80% and that their "25kW" charger can do that in 30 minutes. That is categorically not possible.
3) Any charger that has a power rating below "44kW" (115 amps DC) is grossly inadequate for corridor travel for current cars, and that will only become more acute / inadequate with "200 mile" range cars that are right around the corner with 60kWh batteries (Nissan LEAF version 2.0, GM Bolt, Tesla Model 3). Even Mercedes and BMW are increasing the size of the batteries in their EVs, and of course, our own world class California company Tesla already has 100kWh batteries planned.
4) Any charger that doesn't meet the basic DC charging protocol should not receive grant money
5) I believe that an approved list of DC chargers should be compiled by CEC, either through demonstrated past performance or through CEC specified testing, to verify good performance.
Thanks,
Tony Williams
R&D Manager
Quick Charge Power LLC