High Voltage Systems

This information report provides an overview of a typical high voltage electric propulsion vehicle (xEV) and the associated on-board safety systems typically employed by OEM’s to protect these high voltage systems. The report aims to improve public confidence in xEV safety systems and dispel public misconceptions about the likelihood of being shocked by the high voltage system, even when the vehicle has been damaged. The report will document select high voltage systems used for xEV’s and describe safety systems employed to prevent exposure to the high voltage systems.

This SAE Information Report SAE J2836/2™ establishes use cases and general information for communication between plug-in electric vehicles and the DC Off-board charger. Where relevant, this document notes, but does not formally specify, interactions between the vehicle and vehicle operator.
This applies to the off-board DC charger for conductive charging, which supplies DC current to the vehicle battery of the electric vehicle through a SAE J1772™ Hybrid coupler or SAE J1772™ AC Level 2 type coupler on DC power lines, using the AC power lines or the pilot line for PLC communication, or dedicated communication lines that is further described in SAE J2847/2.
The specification supports DC energy transfer via Forward Power Flow (FPF) from grid-to-vehicle.
The relationship of this document to the others that address PEV communications is further explained in section 5.
This is the 1st version of this document and completes step 1 effort that captures the initial objectives of the SAE task force. The intent of step 1 was to record as much information on “what we think works” and publish. The effort continues however, to step 2 that allows public review for additional comments and viewpoints, while the task force also continues additional testing and early implementation. Results of step 2 effort will then be incorporated into updates of this document and lead to a republished version.

Electric, Fuel Cell and Hybrid vehicles may contain many types of high voltage systems. Adequate barriers between occupants and the high voltage systems are necessary to provide protection from potentially harmful electric current and materials within the high voltage system that can cause injury to occupants of the vehicle during and after a crash. This SAE Recommended Practice is applicable to Electric, Fuel Cell and Hybrid vehicle designs that are comprised of at least one vehicle propulsion voltage bus with a nominal operating voltage greater than 60 and less than 1,500 VDC, or greater than 30 and less than 1,000 VAC. This Recommended Practice addresses post-crash electrical safety, retention of electrical propulsion components and electrolyte spillage.