SAE J1772-2010 EV and PHEV Conductive Charge Coupler

SAE J1772-2010 EV and PHEV Conductive Charge Coupler

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SURFACE
VEHICLE
RECOMMENDED
PRACTICE
 
      J1772™ JAN2010
 
Issued   1996-10
Revised 2010-01
 
Superseding J1772™ NOV2001
 
(R)  SAE Electric Vehicle and Plug in Hybrid Electric Vehicle Conductive Charge Coupler
 
RATIONALE
This recommended practice redefines AC Level 1 and AC Level 2 charge levels and specifies a new conductive charge
coupler and electrical interfaces for AC Level 1 and AC Level 2 charging.  The coupler and interfaces for DC charging are
currently being developed and will be added to this document upon completion.  Adoption of multiple standard charge
couplers based on charge level will enable selection of an appropriate charge coupler based on vehicle requirements thus
allowing for better vehicle packaging, reduced cost, and ease of customer use.
FOREWORD
Energy stored in a battery provides power for an Electric Vehicle (EV) or Plug In Hybrid Electric Vehicles (PHEV). 
Conductive charging is a method for connecting the electric power supply network to the EV/PHEV for the purpose of
transferring energy to charge the battery and operate other vehicle electrical systems, establishing a reliable equipment
grounding path, and exchanging control information between the EV/PHEV and the supply equipment. This document
describes the electrical and physical interfaces between the EV/PHEV and supply equipment to facilitate conductive
charging.  Functional and performance requirements for the EV/PHEV and supply equipment are also specified. This
document contains 51 pages, including this page, and should not be used as a design tool if any of the pages are
missing.
NOTE:   This SAE Recommended Practice is intended as a guide toward standard practice and is subject to change in
order to harmonize with international standards and to keep pace with experience and technical advances.
TABLE OF CONTENTS
1.  SCOPE .......................................................................................................................................................... 4
 
2.  REFERENCES  .............................................................................................................................................. 4
2.1  Applicable Publications ................................................................................................................................. 4
2.1.1  SAE Publications  ........................................................................................................................................... 4
2.1.2  Canadian Standards Association Publication ............................................................................................... 4
2.1.3  Federal Communication Commission Publications ...................................................................................... 4
2.1.4  International Electrotechnical Commission Publication ................................................................................ 5
2.1.5  International Standards Organization Publication ........................................................................................ 5
2.1.6  National Fire Protection Association Publication .......................................................................................... 5
2.1.7  Underwriters Laboratories Inc. Publications ................................................................................................. 5
2.2  Related Publications ..................................................................................................................................... 5
2.2.1  SAE Publications  ........................................................................................................................................... 6
2.2.2  International Electrotechnical Commission Publications .............................................................................. 6
2.2.3  Underwriters Laboratories Inc. Publications ................................................................................................. 6
 
Author:Gilligan-SID:9234-GUID:27482883-155.69.4.4SAE  J1772 Revised JAN2010  Page 2 of 51
 
 
3.  DEFINITIONS ............................................................................................................................................... 7
3.1  AC Level 1 Charging ..................................................................................................................................... 7
3.2  AC Level 2 Charging ..................................................................................................................................... 7
3.3  Charger ......................................................................................................................................................... 7
3.4  Chassis Ground ............................................................................................................................................ 7
3.5  Conductive .................................................................................................................................................... 7
3.6  Connector (Charge) ...................................................................................................................................... 7
3.7  Contact (Charge) .......................................................................................................................................... 7
3.8  Control Pilot ................................................................................................................................................... 7
3.9  Coupler (Charge) .......................................................................................................................................... 8
3.10  DC Charging ................................................................................................................................................. 8
3.11  Electric Vehicle (EV) ..................................................................................................................................... 8
3.12  Electric Vehicle Supply Equipment (EVSE) .................................................................................................. 8
3.13  Equipment Ground (Grounding Conductor) .................................................................................................. 8
3.14  EV/PHEV Charging System .......................................................................................................................... 8
3.15  Insulator ........................................................................................................................................................ 8
3.16  Off-Board Charger ........................................................................................................................................ 8
3.17  On-Board Charger ........................................................................................................................................ 8
3.18  Plug In Hybrid Electric Vehicle (PHEV) ........................................................................................................ 8
3.19  Vehicle Inlet (Charge) ................................................................................................................................... 9
 
4.  GENERAL CONDUCTIVE CHARGING SYSTEM DESCRIPTION .............................................................. 9
4.1  AC Level 1 and AC Level 2 Interface Functions ........................................................................................... 9
4.2  AC Level 1 Charging ................................................................................................................................... 11
4.3  AC Level 2 Charging ................................................................................................................................... 12
4.4  DC Charging ............................................................................................................................................... 12
 
5.  CONTROL AND DATA ............................................................................................................................... 12
5.1  Typical Control Pilot Circuit ......................................................................................................................... 13
5.2  Equivalent Control Pilot Circuit ................................................................................................................... 13
5.3  Control Pilot Functions ................................................................................................................................ 15
5.3.1  Verification of Vehicle Connection .............................................................................................................. 15
5.3.2  EVSE Ready to Supply Energy ................................................................................................................... 15
5.3.3  EV/PHEV Ready to Accept Energy  ............................................................................................................. 15
5.3.4  Determination of Indoor Ventilation............................................................................................................. 15
5.3.5  EVSE Current Capacity .............................................................................................................................. 15
5.3.6  Verification of Equipment Grounding Continuity ......................................................................................... 17
5.4  Proximity Detection ..................................................................................................................................... 17
5.5  Digital Data Transfer ................................................................................................................................... 18
5.6  Typical Start Up Sequence  ......................................................................................................................... 20
 
6.  GENERAL EV/PHEV REQUIREMENTS .................................................................................................... 21
6.1  EV/PHEV Cable Ampacity Coordination ..................................................................................................... 21
6.2  Environmental ............................................................................................................................................. 22
 
7.  GENERAL EVSE REQUIREMENTS .......................................................................................................... 22
7.1  EVSE Electromagnetic Emissions .............................................................................................................. 22
7.1.1  EVSE Conducted Emissions  ....................................................................................................................... 22
7.1.2  EVSE Radiated Emissions .......................................................................................................................... 22
7.2  EVSE Electromagnetic Immunity ................................................................................................................ 22
7.3  EVSE Electrostatic Discharge  ..................................................................................................................... 24
7.4  EVSE Harmonic Distortion Immunity .......................................................................................................... 24
7.5  EVSE Electrical Fast Transient Immunity ................................................................................................... 24
7.6  EVSE Voltage Dips, Short Interruptions and Voltage Variations Immunity ................................................ 24
7.7  EVSE Magnetic Field Immunity .................................................................................................................. 24
7.8  EVSE Capacitor Switching Transient Test ................................................................................................. 24
7.9  EVSE Voltage Surge Test ........................................................................................................................... 24
Author:Gilligan-SID:9234-GUID:27482883-155.69.4.4SAE  J1772 Revised JAN2010  Page 3 of 51
 
 
7.10  Installation Requirements ........................................................................................................................... 25
7.11  General Product Standards ........................................................................................................................ 25
7.12  Personnel Protection System  ...................................................................................................................... 25
7.13  AC Present Indicator ................................................................................................................................... 25
7.14  Conductor Cord Requirements ................................................................................................................... 25
7.15  Coupler Requirements ................................................................................................................................ 25
 
8.  COUPLER REQUIREMENTS  ..................................................................................................................... 25
8.1  Vehicle Inlet/ Connector Compatibility ........................................................................................................ 25
8.2  Ergonomic Requirements ........................................................................................................................... 25
8.2.1  Ease of Use  ................................................................................................................................................. 25
8.2.2  Indexing ....................................................................................................................................................... 25
8.2.3  Alignment .................................................................................................................................................... 26
8.2.4  Tactile Feel .................................................................................................................................................. 26
8.2.5  Latching ....................................................................................................................................................... 26
8.3  Safety Requirements .................................................................................................................................. 26
8.3.1  Isolation ....................................................................................................................................................... 26
8.3.2  Exposure of Contacts .................................................................................................................................. 26
8.3.3  Sharp Edges ............................................................................................................................................... 26
8.3.4  Touch Temperature .................................................................................................................................... 26
8.3.5  Hazardous Conditions  ................................................................................................................................. 26
8.3.6  Unauthorized Access .................................................................................................................................. 26
8.4  Performance Requirements  ........................................................................................................................ 26
8.4.1  Design Life .................................................................................................................................................. 27
8.4.2  Impact Resistance ...................................................................................................................................... 27
8.4.3  Vehicle Drive-Over ...................................................................................................................................... 27
8.5  Environmental Requirements  ...................................................................................................................... 27
8.5.1  General Environmental Considerations ...................................................................................................... 27
8.5.2  Temperature Range .................................................................................................................................... 27
8.5.3  Temperature Rise ....................................................................................................................................... 27
8.5.4  Insulation Resistance .................................................................................................................................. 27
8.5.5  Fluid Resistance.......................................................................................................................................... 27
8.5.6  Mechanical Requirements .......................................................................................................................... 27
8.5.7  Sealing Requirements ................................................................................................................................. 28
8.6  General Coupler Physical Description ........................................................................................................ 28
8.6.1  Vehicle Inlet General requirements ............................................................................................................ 28
8.6.2  Connector General Requirements .............................................................................................................. 29
8.7  Dimensional Requirements  ......................................................................................................................... 29
8.7.1  Interface Contacts Sizing ............................................................................................................................ 29
8.7.2  Vehicle Inlet Physical Dimensions .............................................................................................................. 29
8.7.3  Connector Physical Dimensions ................................................................................................................. 29
8.7.4  Vehicle Inlet Access Zone  ........................................................................................................................... 29
8.7.5  Contact Sequencing .................................................................................................................................... 29
 
9.  CHARGE STATUS INDICATOR  ................................................................................................................. 30
 
10.  CONNECTOR / VEHICLE INLET OPTIONAL MARKING .......................................................................... 30
 
11.  NOTES ........................................................................................................................................................ 30
11.1  Marginal Indicia ........................................................................................................................................... 30
 
APPENDIX A HISTORY EVSE/VEHICLE INTERFACE.................................................................................................... 31
APPENDIX B AC LEVEL 3 CHARGING ........................................................................................................................... 34
APPENDIX C PREVIOUS CHARGE COUPLER DESIGNS ............................................................................................. 37
APPENDIX D CHARGE COUPLER DIMENSIONAL REQUIREMENTS (NON LOCKABLE) .......................................... 43
APPENDIX E CHARGE COUPLER DIMENSIONAL REQUIREMENTS (LOCKABLE) ................................................... 49
 
Author:Gilligan-SID:9234-GUID:27482883-155.69.4.4SAE  J1772 Revised JAN2010  Page 4 of 51
 
1. SCOPE
This SAE Recommended Practice covers the general physical, electrical, functional and performance requirements to
facilitate conductive charging of EV/PHEV vehicles in North America. This document defines a common EV/PHEV and
supply equipment vehicle conductive charging method including operational requirements and the functional and
dimensional requirements for the vehicle inlet and mating connector.
2. REFERENCES
2.1 Applicable Publications
The following publications form a part of this specification to the extent specified herein.  Unless otherwise indicated, the
latest issue of SAE and other applicable publications shall apply.
2.1.1 SAE Publications
Available from SAE International, 400 Commonwealth  Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside
USA and Canada) or 724-776-4970 (outside USA