Level 1 and Level 2 Electric Vehicle Service Equipment ...

1 PSUAC Source(110 V 240 V)Terminal BlockMetering and GFCI Current TransformersUCC28910 DAC-DCTPS62063DC/DC5 V 12 V30-A RelayEVJ1772 OutputInput Voltage Signal FilteringStuck Relay Voltage CheckInput Current Signal FilteringLM7321 GFCI DetectionOPA171 Pilot Signal GenerationMSP430F6736SD ADCTLP7407 Relay DriverUser I/OCommunication Option1 tidub87 February2016 SubmitDocumentationFeedbackCopyright 2016,TexasInstrumentsIncorporatedLevel1 and Level2 ElectricVehicleServiceEquipment(EVSE)Ref erenceDesignTI DesignsLevel1 and Level2 ElectricVehicleServiceEquipment(EVSE)Ref erenceDesignDesignOverviewThis verifiedTI Designprovidesan overviewon how toimplementJ1772-compliantlevel1 and level2 electricvehicleserviceequipment(EVSE).Th e designshowcasessafe failuremodesusingTI s peripheraldriversalongwith integratedfault a configurablepowerdeliverycontrolandimple mentsself-meteringto ensuremaximumpowerdeliveryto the electricvehicle(EV).The designalsoincludesa E2E ExpertsDesignFeatures Full Implementationof J1772-CompliantServiceEquipment HighCurrentRelayDriversfor Supportof HighCurrentContactors StandardizedPilotWireSignalingProtocol IntegratedUtilityMeterGradeEnergyMeasure ment GFCIF aultDetectionand Protection Optionfor CommunicationDaughterCardAdd-inFeaturedA pplications Level1 and Level2 ElectricVehicleServiceEquipment(EVSE)An IMPORTANTNOTICEat the end of this TI referencedesignaddressesauthorizeduse, intellectualpropertymattersand otherimportantdisclaimersand ConverterBattery and Charge CircuitryAC PowerDC PowerPilot February2016 SubmitDocumentationFeedbackCopyright 2016,TexasInstrumentsIncorporatedLevel1 and Level2 ElectricVehicleServiceEquipment(EVSE)

2 ReferenceDesign1 SystemDescriptionElectricvehicleshavebee naroundfor overa century,but havehad limitedmarketsuccessuntil batterytechnologydriveefficiencyand marketforceshaveacceleratedthe demandand deploymentratesof electricvehiclesthat can competewith havea requirementof pluggingand unplugginga very high powerdevicetotheirhomeelectricitysystemo n a benefitfroma broadnetworkof gas stationsfor rapidenergydeliveryto the vehicleand technologyis improving,electricvehiclesstill sufferfromslowenergydeliveryrates,whichr equirevehiclesto be stationaryfor long periodsof timeto slowenergydeliverysystemsbehindelectricv ehiclesalso highlightthe shortcomingsofthe gas slowrate of chargingis the resultof usinglow batterychargecurrentsto avoiddamage(a problemthat is constantlybeingimproved),as well as the energycapacityof the localgrid powerconnectioncan createissuesin regardsto safetyand to tap into muchhighercurrentconnectionsavailablein commercialbuildings.

3 However,thesestationsmustbe able to chargeall varietiesof electricvehicles(EVs)on the roadto be beingmitigatedthroughElectricVehicleServ iceEquipment(EVSE),whichcontrolsthepower flow into an J1772 SAEstandardforAC electricalconnectionsto a samespecificationsalso translateinto internationallocalizations,with only standarddesignof EV chargingsystemson the marketat the time of this writinghavethe AC-DCconverterfor the batterychargesystemintegratedinto the Vehicle ,so only AC poweris chargecircuitryis enabledon somevehicles,but this configurationis outsidethe scopeof facilitatethe powerdeliveryto the Vehicle ,the EVSE sits betweena stablegrid connectionandthe Vehicle ,as Figure1 EVSEP ositionin PowerFlowThe coreof the EVSE operationfor AC powerdelivery)is communicationwith the vehicleovera single-line pilot EVSE operationis basedon level1 and level2 devices,for whichTable1 describesthe single-linepilot wire enablesnegotiationwith the vehiclefor powerstatus,availablepower,and addition,the EVSE mustbe able to controlAC powerdeliveryto the plug itself(up to 240-VAC and 80 A in somecases)to necessitaterobustrelayor oftenincludedsuchas ground-faultcircuitinterrupter(GFCI)prot ectionand Level1 and Level2 ChargingStandardsLEVELDEFINITIONENERGYRA TINGL evel1 Alternatingcurrentenergyto the onboardchargerof the Vehicle ; ,commonlyreferredtoas a ; 16 A (= )Level2 Alternatingcurrentenergyto the onboardchargerof the Vehicle ;208 V to240-V, maximumcurrentspecifiedis 32 A (continuous)with a branchcircuitbreakerratedat 40 240-VAC.

4 12 A to 80 A(= kW to )UnifiedClockSystem128kB96KB64KB32KB16 KBFlashMCLKACLKSMCLKCPUXV2andWorkingRegi sters(25 MHz)EEM(S: 3+1)XINXOUTJTAG/SBWI nterface/Port PJeUSCI_A0eUSCI_A1eUSCI_A2(UART,IrDA,SPI )SD24_B3 Channel2 ChannelADC10_A10 Bit200 KSPSLCD_C8 MUXUp to , , DVSSAVCCAVSSPAI/O PortsP1/P22 8 I/OsInterrupt& WakeupPA1 16 PortsP7/P82 8 I/OsPD1 16 I/OsI/O PortsP91 4 I/OPE1 4 PortsP5/P62 8 I/OsPC1 16 PortsP3/P42 8 I/OsPB1 16 (SPI, I2C)RTC_C(32kHz)AUX1 AUX2 AUX3TA1TA2TA3 Timer_A2 CCRegistersTimer_A3 February2016 SubmitDocumentationFeedbackCopyright 2016,TexasInstrumentsIncorporatedLevel1 and Level2 ElectricVehicleServiceEquipment(EVSE)Ref erenceDesignThis implementationof an EVSE containsa basicset of features,whichare expandableto primaryfunctionalityincludes: Level1 and level2 operation(120V to 240 V) Powerdeliveryup to 30 A (expandablewith largerrelays) Pilotsignalwire communicationsupport GFCI monitoring Latchedrelaydetection s (TI) MSP430 familyof microcontrollers(MCUs)offersa widerangeof devicesthatcan be usedto fulfillthe requirementsof an MSP430F6736microcontrollerhas beenspecificallychosenfor this applicationbecauseof its integrateddeltasigma( ) converters,whichcan beleveragedto addition,the devicefeaturesa powerful16-bitreducedinstructionset computing(RISC)CPU,16-bitregisters,and constantgeneratorsthat MSP430F6736has a highlyaccuratetimermodulewhichcan be usedtogeneratethe specificpulsewidthmodulation(PWM)and duty cyclesrequiredof the pilot wire carriergeneration,a successiveapproximationregister(SAR)anal og-to-digitalconverter(ADC)to readtheresponseof the vehicleon the pilot wire,an interruptiblegeneralpurposeinput/output( GPIO)

5 Pin for rapidresponseto GFCI events,and severaluniversalserialcommunicationinter face(USCI)modulesto enablefeature-richcommunicationin the designsthat only requirea subsetof thesefeatures,theseMCUsalso providea simple,code-compatiblepathto deviceswith reducedflash,RAM,and showsa functionalblockdiagramof the FunctionalBlockDiagram, February2016 SubmitDocumentationFeedbackCopyright 2016,TexasInstrumentsIncorporatedLevel1 and Level2 ElectricVehicleServiceEquipment(EVSE) J1772compliantEVSE(detailedfurtherin ) requiresa 12-VDC powersupply,in additiontothe powerrequiredfor normalsystemICs, suchas the simplifythis designto focuson moreapplicationspecificfunctionality,a preexistingdesignfromthe TI PowerLab AC-DCdesignwith 12-Voutputswas chosenfor simplicity,with the additionaloutputsprovidinga bonusfor the rest of the PMP10299devicefit all of the deviceis basedaroundthe UCC28910 PSRcontroller,has 12- and 5-V outputs,and has beendesignedwith automotivequalityin extra5-V rail can be usedto powerthe MCUand otherICs on the board,as well as and 5-V outputsallowsfor a widerangeof relayselection, TPS62063buckconverteris usedto bringthe 5-V rail downto the V requiredby mostof the converterhas an inputrangeof V to 6 V, whichmakesit idealfor bringingdowna pre-regulated5-V rail to a systemvoltageof pilot signalinterface,whichSection3 coversin furtherdetail,requiresa 1-kHz.

6 12-VPWM signaltobe transmitteddownthe lengthof the chargercableto the duty cyclecommunicatesthepowercapabilityof the EVSEto the EV returnsits currentstateby placinga load on the line,whichcausesa facilitatethis, the designrequiresan amplifierwith a widedual-railvoltageinputand sufficientdrivestrengthto facilitatethe variousline designhasselectedthe OPA171amplifierbasedon its inputrangecharacteristics(up to 18 V) and abilityto handlevariousline impedancechanges,evennon-resistivechange sin the eventof currentflowsthrougha pathotherthanthe primaryconductors,usuallyas aresultof a passingbothconductorsthrougha ring-typecurrenttransformer,the currenttransformer(CT)mustbe ratedfor the full ampacityof the line in the eventof massivecurrentinstability,but mustbe sensitiveto evena burdenresistoron the transformerhas a voltagecorrelatedto the measuredcurrent,so aGFCI eventwouldhavea very low differentialvoltage,but standardmethodof measuringcurrentis to use a one-secondwindowof measurementin anelectricitymetering(e-meter)solution,o n whichthe EVSE-coreMCUin is is tooslowof a responserate for properGFCI fault specificGFCI detectioncircuithas beenbuilt,whichtriggersan interruptiblepin on the MCUduringan designrequiresa rapidtransmissionto VCCwith simpleinvertingintegratorarchitecturewit h the LM7322accomplishesthis transmissionand a secondstageis usedto ensurea solidrail voltagefor the Source(110 V 240 V)

7 Terminal BlockMetering and GFCI Current TransformersUCC28910 DAC-DCTPS62063DC/DC5 V 12 V30-A RelayEVJ1772 OutputInput Voltage Signal FilteringStuck Relay Voltage CheckInput Current Signal FilteringLM7321 GFCI DetectionOPA171 Pilot Signal GenerationMSP430F6736SD ADCTLP7407 Relay DriverUser I/OCommunication February2016 SubmitDocumentationFeedbackCopyright 2016,TexasInstrumentsIncorporatedLevel1 and Level2 ElectricVehicleServiceEquipment(EVSE)Ref erenceDesign2 BlockDiagramFigure3. TIDA-006637 BlockDiagramUnifiedClockSystem128kB96KB6 4KB32KB16 KBFlashMCLKACLKSMCLKCPUXV2andWorkingRegi sters(25 MHz)EEM(S: 3+1)XINXOUTJTAG/SBWI nterface/Port PJeUSCI_A0eUSCI_A1eUSCI_A2(UART,IrDA,SPI )SD24_B3 Channel2 ChannelADC10_A10 Bit200 KSPSLCD_C8 MUXUp to , , DVSSAVCCAVSSPAI/O PortsP1/P22 8 I/OsInterrupt& WakeupPA1 16 PortsP7/P82 8 I/OsPD1 16 I/OsI/O PortsP91 4 I/OPE1 4 PortsP5/P62 8 I/OsPC1 16 PortsP3/P42 8 I/OsPB1 16 (SPI, I2C)RTC_C(32kHz)AUX1 AUX2 AUX3TA1TA2TA3 Timer_A2 CCRegistersTimer_A3 February2016 SubmitDocumentationFeedbackCopyright 2016,TexasInstrumentsIncorporatedLevel1 and Level2 ElectricVehicleServiceEquipment(EVSE)Ref erenceDesign3 HighlightedProductsThe TIDA-00637referencedesignfeaturesthe followingdevices: MSP430F6736:Mixed-signalmicrocontroller( MCU) UCC28910D:700-Vflybackswitcherwith a constant-voltageconstant-currentand primary-sidecontrol TPS62063:3-MHz, OPA171.

8 36-V,low-power,rail-to-railoutput(RRO),g eneralpurposeoperationalamplifier(op amp) LM7322:Highoutputcurrentand unlimitedcap load 15-Vop amp TPL7407:40-V,7-channelNMOS array,low-sidedriverFor moreinformationon eachof thesedevices,see the respectiveproductfoldersat MSP430F6736 FunctionalDiagram Low V downto V Ultralowpowerconsumption Activemode(AM):All systemclocksactive265 A/MHzat 8 MHz, V, flashprogramexecution(typical)140 A/MHzat 8 MHz, V, RAMprogramexecution(typical) Standbymode(LPM3):Real-timeclockwith crystal,watchdog,and supplysupervisoroperational,full RAMretention,fastwake- A at V, A at V (typical) Off mode(LPM4):Full RAMretention,supplysupervisoroperational ,fast wake- A at V (typical) ShutdownRTCmode( ):Shutdownmode,activereal-timeclock(RTC) with A at V (typical) Shutdownmode( ):78 A at V (typical) February2016 SubmitDocumentationFeedbackCopyright 2016,TexasInstrumentsIncorporatedLevel1 and Level2 ElectricVehicleServiceEquipment(EVSE)Ref erenceDesign Wake-upfromstandbymodein 3 s (typical) 16-bitRISC architecture,extendedmemory,up to 25-MHzsystemclock Flexiblepowermanagementsystem FullyintegratedLDOwith programmableregulatedcoresupplyvoltage Supplyvoltagesupervision,monitoring,and brownout Systemoperationfromup to two auxiliarypowersupplies Unifiedclocksystem Frequency-lockedloop (FLL)controlloop for frequencystabilization Low-powerlow-frequencyinternalclocksourc e(VLO) Low-frequencytrimmedinternalreferencesou rce(REFO) 32-kHzcrystals(XT1) One 16-bittimerwith threecaptureand compareregisters Three16-bittimerswith two captureand compareregisterseach Enhanceduniversalserialcommunicationinte rfaces eUSCI_A0,eUSCI_A1,and eUSCI_A2.

9 Enhanceduniversalasynchronousreceiver/tr ansmitter(UART)supportsauto-baudratedete ction,IrDAencoderand decoder,synchronousSPI eUSCI_B0:I2C with multi-slaveaddressing,synchronousSPI Password-protectedRTCwith crystaloffsetcalibrationand temperaturecompensation Separatevoltagesupplyfor backupsubsystem 32-kHzlow-frequencyoscillator(XT1) Real-timeclock Backupmemory(4 bits x 16 bits) Three24-bit ADCswith differentialPGAinputs Integratedliquid-crystaldisplay(LCD)driv erwith contrastcontrolfor up to 320 segmentsin 8-muxmode Hardwaremultipliersupports32-bitoperatio ns 10-bit200-kSPSA-D converter Internalreference Sample-and-hold,auto-scanfeature Up to six externalchannels,two internalchannels,includingtemperaturesen sor Three-channelinternalDMA Serialonboardprogramming,no externalprogrammingvoltagerequired Availablein 100-pinand 80-pinLQFP packagesTPS62060V= Vup to AOUTR360 k1 R180 k2 V = V to 6 VINC10 OUT FC10IN FPVINAVINENMODEAGNDPGNDSWFBC22 H February2016 SubmitDocumentationFeedbackCopyright 2016,TexasInstrumentsIncorporatedLevel1 and Level2 ElectricVehicleServiceEquipment(EVSE) UCC28910 DSimplifiedSchematic Constant-voltage(CV)and constant-current(CC)

10 Outputregulationwithoutoptical-coupler 5% outputvoltageregulationaccuracy 5% outputcurrentregulationwith AC line and primaryinductancetolerancecompensation 700-Vstart-upand smartpowermanagementenables< 30-mWstandbypower 115-kHzmaximumswitchingfrequencydesignfo r high-powerdensity Valleyswitchingand frequencyditheringto easeelectromagneticinterference(EMI)comp liance Thermalshut down Low line and TPS62063 TypicalSchematic 3-MHzswitchingfrequency V to 6 V Up to 97%efficiency Powersavemodeand 3-MHzfixedPWMmode Outputvoltageaccuracyin PWMmode Outputdischargefunction Typical18- A quiescentcurrent 100%duty cyclefor lowestdropout Voltagepositioning Clockdithering Supportsmaximum1-mmheightsolutions Availablein a 2 mm 2 mm WSONOUT B12345678 OUT A-IN A+IN AV-V+-IN B+IN B-+-+ February2016 SubmitDocumentationFeedbackCopyright 2016,TexasInstrumentsIncorporatedLevel1 and Level2 ElectricVehicleServiceEquipment(EVSE) V to 36 V, to 18 V Low nois