DC

Charging
Fast Charging
 DC Charging Technology

Learning Types of DC Charging Technology

Objectives Components of DC Charging

Working of DC Charging Technolgy

What is Direct
Current Charging
What is Direct
Current Charging
 Types of DC Charging

Combined Charging System CCS

Charge De More CHADEMO

TESLA

GB/T
DC Charging
Concept
DC Charging
Process
Step – I
DC Charging
Process Step –II
DC Charging Video
 • Then, the power control unit appropriately adjusts the voltage and current
STEP - III of the DC/DC converter inside the charging station to control the variable
DC power delivered to charge the battery.
 • The battery management system or BMS plays the key role of
communicating with the charging station to control the voltage and current
Step - IV delivered to the battery and to operate the protection circuits in case of an
unsafe situation.
 • Once the vehicle is charged there is an error signal shared via BMS & the charger. The AC
Step – V relay is disconnected de-energizing the system with input power , and a reminder to
disengage the charging gun with the vehicle is sent to the EV driver thus completing the
charging process
 Service Panel

Electrical Distribution
Components User Interfaces
of DC Auxiliary Power Supply
Charging
Communications
Stations
Power Module

Charging Plug
Service Panel

• The role of the service panel is to protect the charger during charging. Access to the panel is denied
during charging, and when full charging is forced, charging stops when there is no charge, allowing
access to charger maintenance.
 Electrical Distribution

• Electricity is core to the charging process and electricity is a commodity that can
create security risks to overcome and secure electricity distribution.
User Interface
• This is the on-board
communication system
through which EV Driver can
access the EVSE for
Authorization and Charging of
their Vehicles
Auxiliary
Power Supply
• This Part of the Charging
system is always on and
supports the communication
system with DC Power so that
they can operate as the AC
Mains only comes into the
picture when there is a
vehicle to be Charged
Power Module

• This Unit is the most important part of a DC Charger as This Unit Converts
AC into DC as per the requirement or communication between the BMS of
the vehicle & DC Charger
 This Unit initiates the
charging as per the connector
system enabled in the Electric
Vehicle
Charging
Plug They are different as per
vehicle support and different
Charging Technologies
 There are 4 Types of Communication in a DC
Charger

The First Communication is between the

charger & the vehicle

Communication The Second is between the charger and EV

in DC Chargers Driver

The Third is between Charger & the Grid

The Fourth is between the Charger & the

back-end servers
Conclusion
• In DC Charging we surpass the on-Board charger limits to enhance the
charging Capacity of the Electric Vehicle
• Conversion of AC to DC is achieved in the DC Chargers
• DC Charger has a Handshake process , where the EV Driver authorizes
the charger to access vehicle information and lithium ion battery pack
information
CCS Charging Technology
 Defining Combined Charging System

Learning Connectors of Combined Charging

Systems
Objectives (CCS-I) , (CCS-II )

Charging Process of CCS

Combined Charging System

• A combined charging system is a universal

charging system for electric vehicles that
supports which all the available AC charging
solutions with DC charging through
theconnector only. One charge port is
required in red in the vehicle for single-phase
AC charging, three-phase AC charging as well
as DC charging.
Combined Charging
System I & II
The difference between the two is connector of CCS I & CCS II
CCS I CONNECTOR
It was the First to Arrive
CCS I CONNECTOR
Pin Configuration 2 Pins for DC Charging, one
protective earth, 2 Communication Pins for
Communication Proximity Pilot & Communication
Pins

Maximum voltage and current ratings: In

general, CCS charger can deliver up to 350
Amps at a voltage of between 200 to 1000V
giving a maximum power output of 350 KWH
 A combined charging system connector is used as a single
connector for both AC phase-i & phase-iii and DC charging
by using separate pins within the same connector. The
combo AC and DC charging connector comply with the IEC
62196-1, IEC 62196-2, and IEC 62196-3 standards.

The signaling and communication for AC charging is

CCS I compliant with IEC 61851-1, 61851-22, and for DC charging
with IEC 61851-1, 61851-23, ISO/IEC 15118, the german
CONNECTOR DIN SPEC 70121 and the SAE J2847/2 standards

The control pilot has both low-level communication using

PWM and high-level communication using power line
communication (PLC).
CCS II CONNECTOR
CCS II CONNECTOR
Pin Configuration 2 Pins for DC Charging , one
protective earth , 2 Communication Pins for
Communication Proximity Pilot & Communication
Pins

Maximum voltage and current ratings: In

general, CCS charger can deliver up to 350
Amps at a voltage of between 200 to 1000V
giving a maximum power output of 350 kW
CCS II CONNECTOR
Combined Charging System is used as a single connector for both AC Phase I , AC Phase
- III and DC charging by using separate pins within the same connector. The Combo AC
and DC charging connector comply with the SAE J3068, IEC 62196-2 Type 2 Connector
and GB/T 20234.2 Making it Universal for Charging Technologies for AC

. The signaling and communication for AC charging is compliant with IEC 61851-1,
61851-22, and for DC charging with IEC 61851-1, 61851-23, ISO/IEC 15118, the
German DIN SPEC 70121 and the SAE J2847/2 standards

The control pilot has both low-level communication using PWM and high-level
communication using power line communication (PLC).
CCS Charging
Step –I

Standard by IEC
Step –II

Standard by IEC
Step –III

Standard by IEC
Step –IV Compatible
• DC supply can check internal isolation if no voltage
is applied to the connector
• The vehicle will not be in a ready state if the EV
and DC power sources are incompatible. It will
enter a normal shutdown sequence.

Standard by IEC
Step - V
• EV responds to the value by issuing a ready
signal that ends the initialization phase.
• Once the connector lock is confirmed the EV
request cable and isolation check to the charger.
• DC Supply starts checking HV System Isolation
and continuously reports the Isolation stage to
the Vehicle

Standard by IEC
Step - VI
• DC Supply determines that
the isolation resistance of
systems is above 100 ohms
• If the insulation test
completes successfully, DC
power is valid, and a follow-
up message is displayed.
• DC Supply status changes to
ready with 'vehicle
check' response
Standard by IEC
 Step- VII

• At initial pre-charge phase, EV sends pre-charge

request which contains both requested DC
current 2A maximum inrush current and
requested DC voltage
• DC supply adopts DC OUTPUT voltage to the
requested value by the vehicle while limiting
current to a maximum value of 2A (maximum
inrush according to CC

Standard by IEC
Step- VIII

• EV is initiating message cycles by

requesting voltage/current. Supply
is responding with voltage/current
adjustment as well as present limit
and status values (voltage, current,
isolation, …).
• Continuous monitoring of lock,
isolation, voltage, current, and
temperature.
Standard by IEC
STEP – IX

• EV Reduces the current request to

complete the energy transfer. The
DC supply follows the current
request with a time delay and
reduces the output current to less
than 1A before disabling its output

Standard by IEC
STEP X

Standard by IEC
USP of CCS
Charger
Conclusion
• Concept & Connectors of CCS Charging Technology
• Handshake Process and charging process of CCS CHARGING
Technology
CHADEMO
CHARGEDEMOVE
 Concept of CHAdeMO
Charging System

Learning Connectors of CHAdeMO

Objectives
Charging Process of
CHAdeMO
CHADEMO

CHAdeMO is a DC charging standard for electric

vehicles. It enables seamless communication
between the car and the charger. It is developed by
CHAdeMO Association, which also monitors and
certify compatibility between the car and the
charger.
CHADEMO CONNECTOR

CHAdeMO Connector have a standard form IEC & IEEE for Their Connectors &
Chargers
IEC standard (IEC 61851-23, -24, as well as 62196-3)
IEEE standard (IEEE Standard 2030.1.1TM-2015).
CHADEMO CONNECTOR
• CONNECTORS
CHADEMO CONNECTOR
• Pin Configuration: It is a 10 Pin connector with 3 Power pins and 6 signal pins
as shown in the figure & one Earthing Pin.
• CHAdeMO uses the Controller Area Network or CAN protocol in the
communication pins for signaling.
• Maximum voltage and current ratings
• Voltage 50 Volt – 500 Volt
• Current 80 A- 400A
• Maximum Power 200kW.
CHADEMO
CHARGING PROCESS

Standard By CHAdeMO
CHADEMO
CHARGING PROCESS

Standard By CHAdeMO
CHADEMO
CHARGING PROCESS

Standard By CHAdeMO
CHADEMO
CHARGING PROCESS

Standard By CHAdeMO
CHADEMO
CHARGING
PROCESS
When the insulation
test is completed, by
closing the ‘d2’relay,
the charger lets the
vehicle know that
preparations for
charging have been
completed through
the analog pin
No.10.
Standard By CHAdeMO
CHADEMO
CHARGING
PROCESS
The vehicle recognizes
this via the photo-
coupler ‘g’, and finally
charging is commenced.

The charger supplies an

electric current that
meets the value from
the vehicle via constant
current control

Standard By CHAdeMO
CHADEMO CHARGING
PROCESS

Standard By CHAdeMO
CHADEMO
CHARGING
PROCESS

Standard By CHAdeMO
Components of DC Charger
Interlock of connector

• Given that the control power is supplied to EV contactors via a charger, EV contactors never close and
there is zero voltage unless a vehicle coupler is connected to the vehicle.
• Pre-charge Automatic Safety Check is a test conducted before each charge to check the circuit insulation
and the short circuit between the charger and EV contactors.
• During charging, the vehicle coupler is locked to the vehicle inlet via a mechanical latch, and the
mechanical latch is locked by an electrical lock. Once charging is completed, the electric lock is released
after confirming the voltage on a vehicle connector. If the voltage does not drop to a safety level, the
lock will not be released.

Standard By CHAdeMO
Fail-safe of charging control

• In some cases, a malfunction may occur during charging at the vehicle and charger monitor level.
• Two communication lines (CAN signal and Pilot signal) from the vehicle to the charger are in place to
send a signal in case a malfunction is detected on the vehicle side. This way, charging will stop even if
one communication line is broken.
• When the vehicle coupler is dropped, the disconnection of the grounding wire and the pilot wire cause
each Pilot signal to turn OFF, which puts a halt to the DC output immediately, so that the electrical arcing
stops.

Standard By CHAdeMO
 Protection from
electrical shock
• The isolation transformer inside the charger
separates the AC system at the input side and the DC
system at the output side, therefore, the output side
is a non-earthed system, and the electric shock can
be avoided if an earth leakage fault occurs on one of
the DC lines.
• A leakage current monitoring device is installed at
the DC side as well as the AC side and it shuts down
input power to the charger as soon as leakage
current is detected. The electrical shock protection in
the DC-2 zone stipulated under IEC60479-1 was
realized by combining the leakage current monitoring
and immediate automatic disconnection.
Battery protection

• The current is controlled by the vehicle ECU. Fast charger controls the output current according to the
charging current request from the EV through CAN communication on a real-time basis. This
mechanism allows for different fast charging based on battery performance and usage environment.
To do so, CHAdeMO specifies the requirements for response performance, current ripple, voltage
ripple, and measurement accuracy of the current and voltage.
BENIFTS OF CHADEMO
• SAFETY CHAdeMO mandates strict guidelines in
designing chargers to guarantee electrical safety in
any operating conditions.
• FUTURE-PROOF CHAdeMO is Smart Grid-ready
through its bi-directional charging capability. It is also
compatible with any local or optional functions
beyond charging.
BENIFTS OF CHADEMO
• EASE OF APPLICATION the protocol works with CAN
communication, onboard communication network for
all EVs, making its integration with the rest of the car
easy and reliable.
• UNIFORMITY CHAdeMO connector is identical across
the globe and is a stand-alone plug that can be with or
without an AC connector. It saves costs for EV makers
and enables cross-continental EV travels.
Conclusion
• Connectors of CHAdeMO Charging Technology
• Working & Charging Process of CHAdeMO
• Safety Features of CHAdeMo
 Defining Tesla Super
Charging

Learning Connectors of Tesla

Objectives Super Charging

Super Charging Process

Tesla DC Charging
Concept
• There are Basically 2 Types of
Charging Supported by Tesla
• A/C CHARGING or Home
Charging up to17.2 kw On-
Board Charging
• D/C CHARGING or Fast Charging
up to 180 KWH Off-Board
Charging
TESLA CONNECTOR

• Pin Configuration: The Tesla DC chargers like

the AC chargers have two signal pins and three
power pins - two pins for DC power and one
for the earth.
• The unique feature of the Tesla connector is
that same connector and pins can be used for
both AC and DC charging.
• Maximum voltage and current ratings: Tesla
now offers DC charging up to 120 kW and this
is expected to increase in the future.
 Tesla Super Charging Concept

• Tesla Super Charging works on a

concept of conversion of AC to
DC in a combined system. Here
in the Image, You Can See a
Tesla Super Charger.
Components of Super Charging Station

• Tesla Supercharging converts

Gird Power Directly to DC with
High Magnitude and to do this
conversion the components
used are

• Transformer
• Electric Management Unit
• Tesla Super Charger
Charge
Dispenser
• The unit which connects
to the vehicle of TSC acts
as a dispenser of the DC
current in communication
with the vehicle BMS
• Two dispensers' units are
connected to one unit of
135 KWH super
charger with a maximum
output of 99 KWH per
dispenser
Working of Tesla
Supercharger
• EV Driver Connects
the Charger
Connector to the
Vehicle to initiate
Charging Process
Step -II
• EV driver connects to
the servers of TSC by
authorizing through app
TSC dispenser that
initiates hand shaking
process by earthing a
12-volt signal from the
vehicle
Step -III
• Charger communicates
the available current and
after vehicle
confirmation the TSC
energize dispenser with
the DC current
Step -IV
• Charge connector lock
with the EV is confirmed
by the 24-volt earthing
which changes the
colour of the LED from
red to green and the
charging initiates
Benefits of Tesla Super Charging Concept

• The biggest benefits is in terms of

losses as the combine conversion
from AC to DC saves losses of
electric current in the process
• Second benefit is the cost of EVSE
as the conversion unit is outside
the dispenser and have 2
dispenser connected to it , the
cost is reduced nearly to half
• Every TCS has a storage of 400
KWH which creates the buffer
during peak hour charging
Conclusion
• Tesla has a Single connector for AC & DC Chargers
• Working of a Super Charging Station as the Dispenser Out is a Unit
 Concept of GB/T
Charging System

Learning Connectors of GB/T

Objectives
Charging Process of GB/T
GB/T Charging
• GB/T is a type of DC charging
technology developed in
China that supports BEVs and
PHEVs. The GB standard
(Guobiao or "national
standard" in Chinese) was
published by the China
Electricity Council (CEC).
 GB/T
CONNECTOR
GB/T CONNETOR

• China has its own DC charging

connector that is based on the
20234.3-2015 standard and
communicates over a CAN bus.
• The ability of this DC charger to
recharge both the high-voltage
traction battery and the low-
voltage auxiliary battery inside
the electric car makes it special.
GB/T CONNETOR
• Pin Configuration: It has 5
power pins, 2 for DC power,
2 for low voltage auxiliary
power, and one for earth.
• There are 4 signal pins on
this charger, including two
for CAN communication and
two for proximity pilot.
• Maximum voltage and
current ratings: As of now,
this charger can sustain
currents up to 250A at
nominal voltages of 750V or
1000V.
Working of
GB/T
Working of
GB/T
 GB/T Charging Process

• First, the EV driver plugs the

connector into the vehicle's
charging port. At this stage,
GB/T communicates with the
vehicle to confirm the
connection to the vehicle. The
connector is dead here.
Step – I Handshake
Recognition

• In the handshake
recognition phase, the
charger connection check is
completed and general
information such as the
vehicle information along
with Battery capacity is
exchanged with the Charger
.
STEP - II

• Know The Charger

Communicates the Vehicle
about the Available current
in communication with
Vehicle BMS
• The vehicle informs the
charger about the
acceptable current
Step –III

• Once the Vehicle BMS and

Charger communication
reaches to a defined value
of current , the charging
process is started .
• During the charging process,
the vehicle informs the
charger of the current
charge status of the battery
at regular intervals.
Step – IV

• Once the Vehicle Battery

Reaches 90 % an error signal
is sent which terminate the
charging process.
• Charging can be stopped
manually in case the battery
being fully charged or a fault
occurring during the
charging process.
Conclusion
• Connector of GB/T
• Handshake of GB/T Charging Process
• GB/T Low Voltage Advantage
Thanks