Electric Vehicle

Charging Solutions
Presentation for Bitron

1
Littelfuse, 90 years of growth & innovation

Confidential and Proprietary | Littelfuse, Inc. © 2018 2

Protect Ι Control Ι Sense — A Global Approach
Protect Control Sense
▪ Today’s sophisticated ▪ Safely and efficiently ▪ Sensing technologies are
electronics require control power in even the increasingly used to support
greater protection from harshest environments complex electronic systems
ESD, power surges and ▪ Limit equipment damage ▪ Broad platform of
other occurrences and minimize electrical technologies help improve
▪ Handle more power in hazards product performance,
smaller products ▪ Improve productivity and comfort, convenience and
▪ Innovative circuit reduce costs safety
protection solutions

Confidential and Proprietary | Littelfuse, Inc. © 2018 3

Global Leader in Circuit Protection
Expanding Player in Power Control and Sensing
Electronics (51%)
Passive Products
Semiconductor Products
Sensor products

Automotive (39%)
Passenger Car Products
Automotive Sensor Products
Commercial Vehicle Products

Industrial (10%)
Fuse Products
Protection Relays

Littelfuse serves more than 100,000 customers across three major market segments

Confidential and Proprietary | Littelfuse, Inc. © 2018 4

 Pro Forma
Littelfuse Combination
growth Overview
in power & control
+
Revenue (1) $1,164M $325M $1,489M
Adj. EBITDA Margin(2)
/ Synergized Adj.
EBITDA 23%(2) 14%(2) 21%(2) / 23%(3)
Margin (3)

Electronics Electronics
Electronics
Revenue by
Industrial Auto / Industrial Industrial
Auto /
End Market(4) Transportation
Transportation Auto /
Transportation

Power Power
Revenue by Control Control
Circuit Power Circuit
Product Protection Sensors Control Protection
Technology
Sensors

Europe Europe Europe

Revenue by APAC APAC
Geography APAC
Americas Americas Americas

Notes:
(1) Reflects TTM revenue as of 7/1/17 (Littelfuse) and 6/30/17 (IXYS)
(2) See appendix for Adjusted TTM EBITDA margin calculation
(3) Reflects Adjusted EBITDA after the effect of $30 million in annualized cost synergies Confidential and Proprietary | Littelfuse, Inc. © 2018 5
(4) Electronics: consumer electronics, data/telecom, auto electronics, appliances, and industrial electronics Littelfuse, Inc. © 2017 8
Industrial: motor drives, utilities, industrial power supply, oil & gas, mining and other heavy industrial markets
Global Labs — Designing and Validating Next-
Generation Products and Solutions

▪ Network of 15 global labs and design centers

– High Power Labs
– Semiconductor Application Labs
– Product Evaluation, Reliability and Applications Labs
– Materials Labs
▪ Combine comprehensive testing capabilities with
consultation
▪ Robust circuit protection testing
▪ Simulate harsh environments
▪ Analyze sensing technologies
▪ Assure high performance, reliability, safety and
regulatory compliance

Confidential and Proprietary | Littelfuse, Inc. © 2018 6

Solutions for EV Charging

Confidential and Proprietary | Littelfuse, Inc. © 2018 7

Investing to Drive Cross-Segment Opportunities:
Leveraging Technologies and Customer Relationships

EV is really at the center

with products from all
three segments
Automotive
Electronics Automotive Electronics

EV / Charging

Energy
Conversion / Storage
& Motor Control
Industrial

Confidential and Proprietary | Littelfuse, Inc. © 2018 8

Content

Standards and Definitions

Plug types
AC Charger and DC Charger examples and solutions
Thermal protection requirements and solutions
High Speed overcurrent solutions
Ground fault protection

Confidential and Proprietary | Littelfuse, Inc. © 2018 9

Content

Standards and Definitions

Plug types
AC Charger and DC Charger examples and solutions
Thermal protection requirements and solutions
High Speed overcurrent solutions
Ground fault protection

Confidential and Proprietary | Littelfuse, Inc. © 2018 10

What makes EV charging confusing..

Case A

Case B
CharIN

Case C
GB/T 20234.2-2011
IEC 62196-2 ACEA Confidential and Proprietary | Littelfuse, Inc. © 2018 11
What are the different types of EV chargers?
AC Level 1 AC Level 2 DC Fast Charger

▪ 120V AC, 1-phase, 12A or 16A ▪ 208V-240V AC, 1-phase, ≤ 80A ▪ 380V-600V AC, 3-phase
max. continuous current max. continuous current

▪ Delivers AC power from the wall ▪ Delivers AC power from the wall ▪ Delivers DC power, bypassing the
to vehicle’s on-board charger to vehicle’s on-board charger vehicle’s on-board charger

▪ Typically takes 8-12 hours to ▪ Typically takes 4-6 hours to ▪ Typically provides 80% charge of
charge fully depleted battery charge fully depleted battery fully depleted battery within 30
minutes

As defined in Society of Automotive Engineers standard J1772. Primarily applies to North America.
Other regions use differing terminology from other standards (e.g., IEC 61851, GB/T 20234 series).
Confidential and Proprietary | Littelfuse, Inc. © 2018 12
 What are the different types of EV chargers?
- Rest of world terminology
Mode 1 (AC) Mode 2 (AC) Mode 3 (AC) Mode 4 (DC)

▪ 250V AC, 1-phase, 16A max. ▪ 250V AC, 1-phase, 32A max. ▪ 250V AC, 1-phase, 32A max. ▪ AC or DC input supply, cord or
OR OR OR permanently connected with
480V AC, 3-phase, 16A max. 480V AC, 3-phase, 32A max. 480V AC, 3-phase, 32A max. control pilot & shock protection

▪ Cord with no pilot or auxiliary
connections
▪ Delivers AC power from the wall
to vehicle’s on-board charger
▪ Cord with control pilot & shock
protection
▪ Delivers AC power from the wall
to vehicle’s on-board charger
▪ Permanently connected to AC
supply with control pilot & shock
protection
▪ Delivers AC power from the wall
to vehicle’s on-board charger
▪ Delivers DC power, bypassing the
vehicle’s on-board charger
▪ Typically provides 80% charge of
fully depleted battery within 30
minutes*

As defined by International Electrotechnical Commission standard IEC 61851-1. * Charge time dependent on vehicle battery capacity
AC: Alternating Current Confidential and Proprietary | Littelfuse, Inc. © 2018 13
DC: Direct Current
International Standards for EV charging IEC
▪ IEC 61851 covers
– EV supply equipment with a rated supply voltage of up to 1000 Vac or up to 1500 Vdc
– EV supply equipment with a rated output voltage up to 1000 Vac or up to 1500 Vdc
– EV (Electric Vehicle) and PHEV (Plug-in Hybrid Electric vehicles)
– the characteristics and operating conditions of the EV supply equipment;
– the specification of the connection between the EV supply equipment and the EV;
– the requirements for electrical safety for the EV supply equipment
– IEC 61851-23 This part of IEC 61851, together with IEC 61851-1:2010, gives the requirements for d.c.electric vehicle (EV) charging
stations, herein also referred to as "DC charger", for conductive connection to the vehicle, with an a.c. or d.c. input voltage up to 1000
V a.c. and up to 1 500V d.c. according to IEC 60038.
– IEC 61851-23 AA.3.1.2 Automatic disconnection and earth fault monitoring => Important for DC-fast charging. Requires
Isolation Monitor (US IM) Insulation Monitoring Device (IEC/EN IMD)
▪ IEC 62196-1
– Plugs, socket-outlets, vehicle connectors and vehicle inlets-Conductive charging if electric vehicles
– -Part 1: General requirements

▪ IEC 62196-2
– Plugs, socket-outlets, vehicle connectors and vehicle inlets-Conductive charging if electric vehicles
– -Part 2: Dimensional compatibility and interchangeability requirements for a.c. pin and contact-tube accessories

▪ IEC 62196-3 – DC charging

– Plugs, socket-outlets, vehicle connectors and vehicle inlets-Conductive charging if electric vehicles
– -Part 3: Dimensional compatibility and interchangeability requirements for d.c. pin and a.c./d.c. pin and contact-tube accessories

Confidential and Proprietary | Littelfuse, Inc. © 2018 14

International Standards for EV charging GB/T and J1772

GB stands for Guobiao => Chinese for „National Standard“

▪ GB/T 20234.1
– Connection set of conductive charging for electric vehicles—Part 1: General requirements

▪ GB/T 20234.2
– Connection set for conductive charging of electric vehicles—Part 2: AC charging coupler

▪ GB/T 20234.3
– Connection set for conductive charging of electric vehicles—Part 3: DC charging coupler

▪ J1772
– Society of Automotive Engineers Standard
– AC Level 1, AC Level 2, DC Fast Charger

Confidential and Proprietary | Littelfuse, Inc. © 2018 15

 Charging modes according to IEC 61851 - Mode1 -
Definition:
A charging mode is a method for connection of an EV
to the supply network to supply energy to the vehicle
▪ Mode 1 is a method for the connection of an EV
to a standard socket-outlet of an AC supply
network, utilizing a cable and plug, both of
which are not fitted with any supplementary
pilot or auxiliary contacts.
▪ The rated values for current and voltage shall
not exceed:
▪ 16 A and 250 V AC, single-phase,
▪ 16 A and 480 V AC, three-phase.
▪ Prohibited by national codes in US, IL, UK
▪ Prohibited in public areas by national codes
in IT
▪ Without integral ground fault leakage
interruption not permitted in CA
▪ with a plug for household and similar use:
– limited to 6A in DK
– If the charging cycle exceeds 2 hours
max current 10A in NO
– If the charging cycle exceeds 2 hours
max current 8A in FR
– Mode 1 cable assembly without PCRD
shall not be used but only Mode 1 cables
with a PRCD*: DE
*Personal Residual Current Device
Confidential and Proprietary | Littelfuse, Inc. © 2018 16
Charging modes according to IEC 61851 - Mode 2 -

Definition: A charging mode is a method for connection of an EV to the

supply network to supply energy to the vehicle

▪ Mode 2 is a method for the connection of an EV to a standard socket-outlet of an AC supply network

utilizing an AC EV supply equipment with a cable and plug, with a control pilot function and system
for personal protection against electric shock placed between the standard plug and the EV.

▪ The rated values for current and voltage shall not exceed:
– 32 A and 250 V AC single-phase;
– 32 A and 480 V AC three-phase.

▪ EV supply equipment intended for Mode 2 charging shall provide a protective earthing conductor from the
standard plug to the vehicle connector.

▪ Mode 2 equipment that is destined to be mounted on a wall but is detachable by the user, or to be used
in a shock resistant enclosure shall use protection equipment as required by IEC 62752.

Confidential and Proprietary | Littelfuse, Inc. © 2018 17

Charging modes according to IEC 61851 - Mode 3 -

Definition: A charging mode is a method for connection of an

EV to the supply network to supply energy to the vehicle

Mode 3

▪ Mode 3 is a method for the connection of an EV to an AC EV supply equipment

permanently connected to an AC supply network, with a control pilot function that
extends from the AC EV supply equipment to the EV.

▪ EV supply equipment intended for Mode 3 charging shall provide a protective earthing
conductor to the EV socket-outlet and/or to the vehicle connector.

Confidential and Proprietary | Littelfuse, Inc. © 2018 18

Charging modes according to IEC 61851 - Mode 4 -

Definition: A charging mode is a method for connection of an EV to the

supply network to supply energy to the vehicle

Mode 4
▪ Mode 4 is a method for the connection of an EV to an AC or DC supply network utilizing a DC EV supply
equipment, with a control pilot function that extends from the DC EV supply equipment to the EV.

▪ Mode 4 equipment may be either permanently connected or connected by a cable and plug to the supply
network.

▪ EV supply equipment intended for Mode 4 charging shall provide a protective earthing conductor or
protective conductor to the vehicle connector.

Confidential and Proprietary | Littelfuse, Inc. © 2018 19

Connection cases according to IEC 61851
Case A
▪ connection of an EV to the supply network with a plug and cable
permanently attached to the EV

Case B
▪ connection of an EV to a supply network with a cable assembly
detachable at both ends

Case C
▪ connection of an EV to a supply network utilizing a cable and vehicle
connector permanently attached to the EV charging station.

Confidential and Proprietary | Littelfuse, Inc. © 2018 20

 Terms and Definitions
EV supply equipment
▪ Equipment or a combination of equipment, providing dedicated
functions to supply electric energy from a fixed wlectrical installation
or supply network to an EV for the purpose of charing

EXAMPLE 1: For Mode 3 case B, the EV supply equipment consists of the charging station and the cable assembly.

EXAMPLE 2: For Mode 3 case C, the EV supply equipment consists of the charging station with its cable assembly.

Confidential and Proprietary | Littelfuse, Inc. © 2018 21

 Organizations which are involved in standardizations and
definitions in regard to EV charger infrastructure
▪ ACEA (Europe)
– Association des Constructeurs Européens d'Automobiles
– https://www.acea.be/
▪ CharIN (Europe)
– Charging Interface Initiative e.V.
– The CharIN Vision: Developing and establishing the
Combined Charging System (CCS) as the global standard
for charging battery powered electric vehicles.
▪ IEC
– International Electrotechnical Commission
– Defines charging modes (IEC62196) Mode 1, Mode 2,
Mode 3 and Mode 4
– Defines three connection cases, Case A, Case B, Case
C
▪ SAE (US)
– Society of Automotive Engineers
– Defines the charging in Levels Level 1, Level 2, Level 3

▪ CHAdeMO
– Japanese Association formed 2010
– CHAdeMO is an abbreviation of “CHArge de Move“ or the
Japanese phrase “O cha demo ikaga desuka“ „How about a
cub of tea?, referring to the time it would take to charge a
car. Source:wikipedia.org

Source Wikipedia: CHAdeMO Source: Phoenix Contact

(IEC 62196 type 4, DC), IEC 62196
combo2 (DC only), and IEC 62196
type 2 (AC).

Confidential and Proprietary | Littelfuse, Inc. © 2018 22

Content

Standards and Definitions

Plug types
AC Charger and DC Charger examples and solutions
Thermal protection requirements and solutions
High Speed overcurrent solutions
Ground fault protection

Confidential and Proprietary | Littelfuse, Inc. © 2018 23

 Plug types Japan / US
Type 1 („J1772“) CHAdeMO Combo (Type 1) Tesla
Slow (AC) Fast (DC) (Slow AC Supercharger
and Fast DC)

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Plug types Europe

Type 2 Combo
(„Mennekes“) Slow (AC) (Slow AC and Fast DC)

Confidential and Proprietary | Littelfuse, Inc. © 2018 25

AC Plug Type 2 Europe
CP PP ▪ CP Control Pilot
▪ PP Proximity Pilot
▪ PE Prodective Earth
▪ N Neutral
N L1 ▪ L1 Phase 1
▪ L2 Phase 2
▪ L3 Phase 3
L3 L2
PE
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CCS Plug Type 2 Europe
CP PP ▪ CP Control Pilot
PE ▪ PP Proximity Pilot
▪ PE Prodective Earth
▪ N Neutral
N L1
▪ L1 Phase 1
▪ L2 Phase 2
L3 L2 ▪ L3 Phase 3
▪ DC+ Fast Charging DC+
▪ DC- Fast Charging DC-
DC+ DC-
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EV charging WW What is used where?

Source: www/charinev.org

Confidential and Proprietary | Littelfuse, Inc. © 2018 28

CharIN Specification Info

Source: www/charinev.org
Confidential and Proprietary | Littelfuse, Inc. © 2018 29
CharIN Specification Info

Source: www/charinev.org

Confidential and Proprietary | Littelfuse, Inc. © 2018 30

Content

Standards and Definitions

Plug types
AC Charger and DC Charger examples and solutions
Thermal protection requirements and solutions
High Speed overcurrent solutions
Ground fault protection

Confidential and Proprietary | Littelfuse, Inc. © 2018 31

On-Board vs. Off-Board Charger
On-Board Charger Off-Board Charger

AC/AC
Charging Station + AC/DC
Converter
AC/DC
Charging Station
Bypass
On-Board Charger
Power
~22kW ~50kW ~350kW and +
Battery charge is managed by BMS High power transfer – due to fewer space constraints
Low power transfer – mostly limited by space More complex BMS to ensure battery thermal management
Less concern on Battery thermal management Removes weight from vehicle
Adds weight to vehicle Fast charge
Slow charge

Demand for faster (higher power) charging is driving DC charger growth.

Confidential and Proprietary | Littelfuse, Inc. © 2018 32
 AC Chargers (Level1, Level2, Mode 2, Mode3)
– Off-Board (~1.9 kW to 19.2 kW / 1 Phase)
1
110Vac -240Vac

110Vac -240Vac

or

1 Technology Series 2 Technology Series 3 Technology Series

UL Listed AC JLLS, JLLN, KLKD AC Fuse 314/324 series TVS Diode SMF, SMAJ, SAC
Fuse series
MOV TMOV, UltraMOV series Diode Array (Wired Comms) SEP0xx series

GDT CG3, CG2 series Polymer ESD (Wireless Comms) XGD series

SCR SJ series Confidential and Proprietary | Littelfuse, Inc. © 2018 33

 AC Chargers (Mode 2, Mode3)
– Off-Board (~1.9 kW to 43 kW / 2 Phase)
1
400 Vac
400 Vac

or

2
3

1 Technology Series 2 Technology Series 3 Technology Series

UL Listed AC JLLS, JLLN, KLKD AC Fuse 314/324 series TVS Diode SMF, SMAJ, SAC
Fuse series
MOV TMOV, UltraMOV Diode Array (Wired Comms) SEP0xx series
series
Polymer ESD (Wireless Comms) XGD series
GDT CG3, CG2 series
Confidential and Proprietary | Littelfuse, Inc. © 2018 34
SCR SJ series
 2 Auxiliary (AC/DC) Power Supply
Provides power to user interface, control circuits, communications, etc.
3.3V / 5V / 12V / 24Vdc
b

e
d
a c

a Technology Series Technology Series c Technology Series Technology Series

b e
AC Fuse 314/324 series SCR for active SJ series MOSFET PolarTM Power TVS diode SMBJ series
rectification series,
MOV TMOV, UltraMOV CPC37xx series PPTC miniSMD series
Diode for DPG series, (near
GDT CG3 series (high V) passive VBExx connectors)
CG2 series rectification series d Technology Series

Optical LOC11x series

isolator

Confidential and Proprietary | Littelfuse, Inc. © 2018 35

DC Fast charger Block Diagram

Confidential and Proprietary | Littelfuse, Inc. © 2018 36

State of the art system architecture

Topologies AC/DC: Topologies DC/AC: Topology AC/DC:

▪ Symmetric Boost PFC
▪ Neutral Boost PFC
▪ Advanced Neutral Boost PFC
▪ Vienna Rectifier
▪ Full Bridge hard ▪ Active Rectification
switching
▪ Resonant LLC
– Single
– Series Connected

Confidential and Proprietary | Littelfuse, Inc. © 2018 37

DC fast charging modular architectures

Confidential and Proprietary | Littelfuse, Inc. © 2018 38

DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

Confidential and Proprietary | Littelfuse, Inc. © 2018 39

DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
AC Input Power protection
AC Input Power

1
Technology Series
AC fuse (cabinet JLS, JLLS, LDC
level) series
AC fuse (PCB 606, 504, 505
level) series
GDT CG3 series (high V)
CG2 series
MOV AUMOV, TMOV

Confidential and Proprietary | Littelfuse, Inc. © 2018 41

DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Residual Current Device (RCD)

Technology Series
Current transformer SE-CS30 series

AC ground-fault SE-704 series

relay

Confidential and Proprietary | Littelfuse, Inc. © 2018 44

DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Input rectification and Power Factor Control (PFC)
3
Technology Series
Standard rectifier (parallel DMA200X1600NA
legs)
3-phase rectifier bridge MDNA240U2200ED
Discrete diode SONIC-FRDTM series
4
Technology Series
Si or SiC diode for modular FRED DSE series
architecture LSIC2SD series
IGBT discrete or module XPTTM series
(for low frequency) MG12 series
Si or SiC MOSFET X-Class HiPerFETTM series
(for high frequency) LSIC1MOS series
Gate driver IX44** series,
IXD*6** series
High-speed DC fuse L70QS, PSR series
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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Galvanic isolated DC/DC Conversion

Technology Series
SiC MOSFET LSIC1MO series
(for high
frequency)
MOSFET X-Class & X2-Class
HiPerFETTM series,
VKM 40-06P1
Gate driver IXD*614 series

Confidential and Proprietary | Littelfuse, Inc. © 2018 50

DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
DC Output Power

6
Technology Series
Ground/Earth-Fault SE-601, SE-GRM
Protection
DC Fuse L70QS, PSR series
505 and 525 series for
Modular Topology

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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 DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Auxiliary Power Supply
7
3.3V / 5V / 12V / 24Vdc
b

e
d
a c

a Technology Series Technology Series c Technology Series Technology Series

b e
AC Fuse 314/324 series SCR for active SJ series MOSFET PolarTM Power TVS diode SMBJ series
rectification series,
MOV TMOV, UltraMOV CPC37xx series PPTC miniSMD series
Diode for DPG series, (near
GDT CG3 series (high V) passive VBExx connectors)
CG2 series rectification series d Technology Series

Optical LOC11x series

isolator

Confidential and Proprietary | Littelfuse, Inc. © 2018 56

DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Controls, Displays and Communications

8
Technology Series
TVS Diode SMF, SMAJ, SAC
Diode Array (Wired SEP0xx series
Comms)
Polymer ESD (Wireless XGD series
Comms)

Confidential and Proprietary | Littelfuse, Inc. © 2018 59

DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC Fast Charger – Off-Board (~ 100kW+ / 3 Phases)
Single 1x 100kW or modular structure 4x 15-30kW
380Vac -480Vac 2 750Vdc 400Vdc to 1000Vdc
5

3 4

1
6
4
5
7

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DC/DC Converter
IGBT / MOSFET Gate Driver Protection
5 Technology Series
Diode Array SPx series
c a (input logic
b
protection)
TVS diode TPSMx series
b Gate protection
b
and negative bias
voltage
d
c TVS diode(s) SMx series
c
Active clamping P6SM series
d Gate driver IX21xx series
b

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Content

Standards and Definitions

Plug types
AC Charger and DC Charger examples and solutions
Thermal protection requirements and solutions
High Speed overcurrent solutions
Ground fault protection

Confidential and Proprietary | Littelfuse, Inc. © 2018 63

CHAdeMO 200 kW Specification (pub. 2017)
Requires thermal sensing & protection for cable/coupler

Pt1000 RTDs

NTC Thermistors

Image Source: CHAdeMO Association, www.chademo.com setPTM

Confidential and Proprietary | Littelfuse, Inc. © 2018 64
Combined Charging System (CCS)
Requires thermal sensing & protection for cable/coupler

Source: CharIN Design Guide for Combined Charging System, June 2, 2015 Confidential and Proprietary | Littelfuse, Inc. © 2018 65
Project Fast Charge => Cable and plug cooling
▪ Funding project BMVI Germany 7.8 M€
▪ FastCharge project for charge currents
up to 500 A and 1000V => 450 kW
▪ Members:

– BMW
– Porsche
– Allego
– Phoenix Contact
– Siemens

▪ „technical and physical boundries of all

components and systems“ for DC
charging up to 450 kW
Immage Source: www.phoenixcontact.com

Source https://www.electrive.net Confidential and Proprietary | Littelfuse, Inc. © 2018 66

Content

Standards and Definitions

Plug types
AC Charger and DC Charger examples and solutions
Thermal protection requirements and solutions
High Speed overcurrent solutions
Ground fault protection

Confidential and Proprietary | Littelfuse, Inc. © 2018 67

Failure modes of Power Semiconductors warrant
High-Speed overcurrent protection
Power Semiconductor Devices

DIODE MOSFET THYRISTOR IGBT GTO

What happens during a fault?

Case Rupture of IGBT Insulation Failure or Capacitor

Diode Internal Failure,
Resulting in Line to Line Arcing Fault Bank Failure, resulting in DC
resulting in Line-Line Fault
(Explosion) Line to Line Fault

High-Speed Fuses prevent catastrophic damage and case rupture of Power Semiconductor devices!

Confidential and Proprietary | Littelfuse, Inc. © 2018 68

 PSR Series High-Speed Power Fuses
Product Series PSR03_ PSR07_
Voltage Rating AC: 690/700Vac or less AC: 1250/1300Vac or less
DC: 600Vdc or less DC: 1000Vdc or less
Ampere Rating 125A to 2000A 160A to 630A
Interrupting Rating AC: 200kAIC AC: 100kAIC
DC: 150kAIC DC: 150kAIC
Case Size 30, 32 and 33 71 and 72

Material Body: Ceramic

Terminals: Silver plated Brass
Filler: ‘Stone-Sand’
Agency Approvals C-UL-US, IEC 60269-4, CCC, CE

Mounting Options Flush End - Direct Bus-bar

Mounting Studs: Metric, Inches Thread Options Available
Typical Application Power Converters, Soft Starters, DC Systems, UPS,
Variable Speed Drives MS3H100C MS7H1500C
(Case Size: 30 to 33) (Case Size: 70 to 73)

Confidential and Proprietary | Littelfuse, Inc. © 2018 69

Differentiating DC Performance
DC Voltage Rating (Vdc) DC Interrupting Rating (kA)
Ease of product design
1200 200
Best-in-Class DC performance readily
available for design engineers 1000
Up-to 20% 150
800
Up-to 70%
600 100
400
50
200
0 0
Case Size 3X Case Size 7X Case Size 3X Case Size 7X
Littelfuse Comp1* Comp2* Littelfuse Comp1* Comp2*

* Based on limited published DC information, available on public domain

Competition
missing DC rating
information on their
DC rating information available on products and on Only AC rating
product label and on datasheet datasheet published

Confidential and Proprietary | Littelfuse, Inc. © 2018 70

High-Speed Fuse Selection Criteria
High-Speed Fuse Selection Parameters Remarks

Voltage Rating VFUSE ≥ VSYSTEM Rated Voltage of the fuse selected should be equal-to
or higher than system voltage

Rated current of the fuse selected should be higher

Ampere Rating IFUSE ≥ ISYSTEM RMS than System RMS Load Current – Minimum Fuse
Rated current sizing should be 125% of load current

Interrupting Rating I.R.FUSE ≥ ISYSTEM FAULT Interrupting Rating of fuse selected should always be
higher than the available system fault current.

Total Clearing I2t of the fuse selected should always be

Total Clearing I2t I2 t < I2t SEMI. DEVICE less than the melting/explosion I2t of the semiconductor
FUSE (Terminals or case) device terminals or case

Arc Voltage of the fuse selected at operating voltage

Peak Arc Voltage VARC FUSE < VSEMI. DEVICE should be less than the semiconductor device peak-
(Peak Inverse Voltage) inverse (reverse breakdown) voltage

Apart form these basic selection parameters, considerations should be given to Ambient Temperature,
Cycling Current, Cooling Conditions, Bus-Bar dimensions, Frequency and regenerative conditions

Confidential and Proprietary | Littelfuse, Inc. © 2018 71

Design Tools
Comprehensive Product Datasheet with extensive DC Data

Detailed TC Curves Peak Let-thru

Dimensions Curves

Microswitch for PSR Series

I2t Curves Arc-Voltage Curves Temp. De-rating &

Watt Loss Curves

Confidential and Proprietary | Littelfuse, Inc. © 2018 72

Also Available…
North American Round Body High-Speed Fuses

Product Series L15S L25S L60S, KLC L50S L70S L50QS L70QS
150Vac/dc 250Vac/dc
(1A to 60A) (1A to 200A)
150Vac 250Vac 600Vac
Voltage Rating 500Vac/ 450Vdc 700Vac/ 650Vdc 500Vac/500Vdc 700Vac/700Vdc
(70A to 1000A) (225A to 800A) (all amperages)
100Vdc 200Vdc
(70A to 1000A) (225A to 800A)
1A to 1000A 1A to 800A 1A to 800A 10A to 800A 10A to 800A 35A to 800A 35A to 800A
Ampere Rating
(36 SKUs) (37 SKUs) (37 SKUs) (30 SKUs) (27 SKUs) (22 SKUs) (22 SKUs)

AC: 100kAIC; AC: 200kAIC; AC: 200kAIC; AC: 200kAIC; AC: 200kAIC; AC: 200kAIC; AC: 200kAIC;
Interrupting Rating
DC: 20kAIC DC: 20kAIC DC: 20kAIC DC: 20kAIC DC: 20kAIC DC: 50kAIC DC: 50kAIC

Materials Melamine Body and Silver-plated Copper Terminals

Agency Approvals UL Recognized, CSA, CE, RoHS
Operating Temperature -55°C to +125°C
Mounting Options Direct Bus-bar and Fuseblock (1LFS and LSCR Series)
Typical Applications Power Converters, Soft Starters, DC Systems, Battery Chargers

Confidential and Proprietary | Littelfuse, Inc. © 2018 73

 Miniature High Voltage DC Fuse Solutions
Suitable for supplemental overcurrent protection in modular designs
Fuse Type Series Form Factor Voltage (V) Current (A)
606 10x32mm 500Vac 40A – 63A
505 6x32mm 500Vac, Vdc 15A – 30A
504 6x32mm 420Vdc, 500Vac 25A – 30A
506 6x32mm 600Vdc 15A – 20A
507 6x32mm 650Vdc 1A – 8A
Through Hole
508 6x32mm 1000Vac, Vdc 0.315A – 1A
477 5x20mm 400Vdc, 500Vac 0.5A – 16A
977 5x20mm 450Vdc, 500Vac 0.5A – 16A
487 5x20mm 420Vac, Vdc 8A – 20A
808 4.65x8.9mm 250/350/450Vdc 2A – 5A
Surface Mount 885 4.78x10.86mm 450/500Vdc 1A – 5A

504/505/506/507/508 Series 477/977/487 Series 808 Series 606 Series 885 Series (4.78x10.86mm)
6x32mm 5x20mm 4.65x8.9mm 10x32mm Confidential and Proprietary | Littelfuse, Inc. © 2018 74
 New!
April 4
606 Series Fuse
What is it?
~32 mm
▪ 500Vac 10x32mm Cartridge Fuse

▪ 40A – 63A Current Rating

~10 mm ∅
▪ 2kA@500Vac Interrupting Rating

▪ Through-hole version

▪ Operating temperature: -55C to 125C

▪ Ideal for high voltage power supplies & EV charging stations

Confidential and Proprietary | Littelfuse, Inc. © 2018 75

Content

Standards and Definitions

Plug types
AC Charger and DC Charger examples and solutions
Thermal protection requirements and solutions
High Speed overcurrent solutions
Ground fault protection

Confidential and Proprietary | Littelfuse, Inc. © 2018 76

What is a ground fault?
▪ Unintentional connection between energized conductor(s) and earth ground
or equipment frame
▪ Studies have shown that 98% of all electrical faults are ground faults*
▪ Can lead to electric shock on users or fire / property damage!
LEADING INITIATORS OF FAULTS % OF ALL FAULTS

Exposure to moisture 22.5%

Shorting by tools, rodents, etc. 18.0%

Exposure to dust 14.5%

Other mechanical damage 12.1%

Exposure to chemicals 9.0%

Normal deterioration from age 7.0%

* Source: Woodham, Jack, P.E. “The Basics of Grounding Image credit: EC&M Magazine, “High-Tech Training Methods for Learning
Systems” May 1, 2003 Grounding and Bonding Basics,” Hickman, Palmer, Feb 13, 2013
Confidential and Proprietary | Littelfuse, Inc. © 2018 77
CHAdeMO & DC Fast Chargers

CHAdeMO & DC Fast Charger

+ 250 V

AC to DC Ungrounded DC
3-Phase
Converter bus
AC

- 250 V

CHAdeMO Charger Standard:

• Requires two 40-kohm resistors connected between the dc buses
to limit ground-fault current to13 mA on bolted fault at 500 V.

Confidential and Proprietary | Littelfuse, Inc. © 2018 78

CHAdeMO & DC Fast Chargers
DC Ground-Fault Protection

+ 250 V

AC to DC
3-Phase
Converter
AC

SE-601
- 250 V

SE-601 strengths:
- high-quality compared to competition
- microprocessor-based
- programmable output contacts
- CSA, UL, CE, RCM

Confidential and Proprietary | Littelfuse, Inc. © 2018 79

SE-601 DC Ground-Fault Monitor
For Ungrounded DC Systems
▪ Monitors ungrounded DC systems
– Indication of which bus is faulted
+ 250 V ▪ Ground Reference Module
– Limits fault current
▪ No active monitoring signal
– Competitors’ products can interfere
Limits fault with customer equipment
current to 25 S ▪ Self-Test Feature
mA – Ventilation failure, torque-hold, other
applications
▪ Applications:
– EV and other battery charging
systems
– Solar
- 250 V
– Light rail
– Telecommunications buildings
– Datacentres

Confidential and Proprietary | Littelfuse, Inc. © 2018 80

SE-601 on a 500Vdc System
No Ground-Fault Present
+ 250 V

+
I=0
S

- 250 V

• Voltage at point S is zero

• SE-601 sees no voltage or current flow

Confidential and Proprietary | Littelfuse, Inc. © 2018 81

SE-601 on a 500Vdc System
Ground-Fault Present
+ 500 V

I
S

0V X

• Voltage at point S
• SE-601 detects current flow and trips

Confidential and Proprietary | Littelfuse, Inc. © 2018 82

SE-601 DC Ground-Fault Monitor
▪ Universal power supply
▪ -40ºC to 60ºC operating
temperature
▪ Front panel and remote reset
▪ UV or SH trip operation
▪ Latching or non-latching operation
▪ Self-test function
▪ Small footprint

Confidential and Proprietary | Littelfuse, Inc. © 2018 83

DC Fast Charger
AC Ground-Fault Protection

Current Transformer
+ 250 V

AC to DC
3-Phase
Converter
AC

Remote Reset

- 250 V
SE-704
Earth-Leakage Monitor

PGA-0500
Analog Current Meter K1

Confidential and Proprietary | Littelfuse, Inc. © 2018 84

SE-704 – Sensitive Earth-Leakage Detection
▪ 10 to 5000 mA fault level setting range
▪ 30 to 2000 ms time delay setting range
▪ DFT filtering to eliminate nuisance trips
from harmonics/noise
▪ Current sensors capable of high 3-
phase current without nuisance trips
▪ Verification of current sensor connection
▪ Universal power supply
▪ -40ºC to 60ºC operating temperature
▪ Front panel and remote reset
▪ UV or SH trip operation
▪ Latching or non-latching operation

Confidential and Proprietary | Littelfuse, Inc. © 2018 85

SE-704 – Sensitive Earth-Leakage Detection
▪ Uses the SE-CS30 series Current Sensors

Confidential and Proprietary | Littelfuse, Inc. © 2018 86

 Thank You!

PROTECT CONTROL SENSE

Confidential and Proprietary | Littelfuse, Inc. © 2018 87