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Denver Electric Vehicle Council – March Newsletter

We’ve gotten out of the habit of posting the Denver Electric Vehicle Council (DEVC) monthly newsletter. We want to get back in it! You’ll find the pdf below.

There are a couple of interesting articles in this month’s DEVC issue on batteries – new advances in energy density, an update on battery recycling, and a new EV (Lucid Air) which touts a battery with higher energy density than Tesla’s (reprinted from ev4corners!)

For a comprehensive overview of why battery recycling and technology improvements are so important, see David Roberts’ (Volts) story on problems related to minerals needed for the clean-energy transition. You don’t have to be a scientist or economist to understand the information provided in this article. Mr. Roberts does a really good job of breaking it down for those not as technically minded, as well as giving plenty of concise information of interest to those who are.

The DEVC newsletter also includes some articles on changes to the schedule in retiring some of the San Juan Generating Station’s coal-fired generation units, which are relevant to us in the Four Corners area (San Juan Generating Station is located not too far west of Farmington, NM.)

Enjoy the newsletter! Better yet, go to www.devc.info and sign up to receive it yourself. DEVC is the Colorado affiliate of the national Electric Vehicle Association. They are one of the oldest national electric vehicle volunteer organizations. “The Electric Vehicle Association educates and advocates for the rapid adoption of electric vehicles.” To join them, and DEVC, to https://www.myeva.org to become a member. When you sign up, you can choose DEVC as your affiliated chapter.

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Design contest: How best to design an EV from scratch, taking full advantage of the benefits of electrification?

EVs are often designed by the same thinking that turned carriages into “horseless carriages” without fully incorporating the advantages of automobiles. What EV advantages can be improved by redesigning the automobile? Send us your ideas for our design contest.

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Ford F-150 Lightning as Home Backup Generator: The Lowdown on What It Takes (Part 1) and What It Could Give (Part 2)

Word on the internet has it that Ford will open their ordering process for the F-150 Lightning this Thursday, January 6, 2022. It seems a good time to do a deeper dive on Ford’s home backup power option available for their much-awaited electric pickup truck.

Image from Ford

This is Part 1 of a two-part post. Part 1 discusses the specifics how much this option will cost, how it will work, and can it live up to Ford’s promises.

Part 2 will discuss other things you can do with a big electric truck’s battery, to both help your community and save some money for yourself. It’s called Vehicle-to-Grid (V2G) and it could be coming to your neighborhood sooner than you think.

Here’s the home backup promise on Ford’s website:

In Part 1, each part of this promise will be discussed. In Part 2, we’ll learn how one SW Colorado rural electrical co-op plans to work with customers wanting to use the back-up power feature to provide benefits not just to EV owners, but to all co-op customers.

The Three Things You Need to Use the Ford F-150 Lightning as Backup Power For Your Home

Extended Range Battery

The backup power option is not available for all F-150 Lightning models. In particular, it will not be available on their lowest priced PRO model, which has a base price of $40,000. To take advantage of the backup power option, you must purchase an extended range battery model, the lowest cost of which appears to be the $74,000 XLT.

80-amp Ford Charge Station Pro

Ford’s website indicates the 80-amp Ford Charge Station Pro comes standard with extended range battery models. The Charge Station Pro is an extra piece of equipment which will allow your F-150 Lightning to both draw electricity FROM the power lines feeding your house to fill up the truck’s battery AND allow it SEND electricity INTO your house when those power lines are down. It is what’s known as a bi-directional charger. It allows peak charging power of 19.2 kW, much higher than the typical 7 kW a home Level 2 charger provides.

The 32-amp mobile charger which comes with all the F-150 Lightning models will also be included. This charger sends electricity in just one direction: from a power outlet to the truck’s battery. The charger is delivered, coiled neatly in a canvas travel case, as an electrical cord with a charge plug on one end. At the other end there is a choice of two adapters, one you can use to plug into a regular 120V outlet and another you can plug into a 240V outlet.

Good for emergencies away from home, too.

You can use the 32-amp charger wherever there is an outlet, from a regular 120V outlet on a friend’s porch to an electrical hook-up at an RV campground, which delivers as much power as a Level 2 charger.

Carrying this mobile charger in the truck with you could come in handy if you wind up stuck on any road that has closed due to winter storm conditions (as recently happened in Virginia) or an accident. If you can get off the highway, you could plug into any wall outlet (120 V) and heat your vehicle without running down the battery until traffic was able to move again. If you have an F-150 and a full battery, other EVs could plug into your truck’s 120V outlets to run their heaters until traffic gets moving again.

Electrical work done at your house

To use the home backup feature, you will need to get a professional electrician to install the 80-amp Ford Charge Station Pro and an automatic transfer switch at your house. The transfer switch automatically disconnects your home from the grid when the power goes down. That is necessary so your F-150 does not feed battery power back out on the power lines at your house during a power outage, which could cause a severe hazard to power company workers working on the lines.

You will need an 80-amp circuit installed to serve the Charge Station Pro. This won’t be a problem for most homes, but some with older electrical systems may need to upgrade their service with their electric company to carry that many amps.

In May 2021, Ford announced they had partnered with a company called Sunrun to:

facilitate the installation of Ford’s charging stations and energy integration system for residential customers.

https://www.pv-tech.org/ford-selects-sunrun-as-installation-partner-to-make-new-f-150-lightning-backup-power-source/

At Sunrun’s website, they list all of the Four Corners states except Utah as states where they operate. I am not aware if Sunrun currently operates in the Four Corners area. Before your F-150 Lightning order goes to production, you’ll want to confirm what company, Sunrun or a solar contractor local to you, would be able to work with you to install the 80-amp Charge Station Pro and install a new, or modify an existing, home solar system.

Does your electric company get involved in any of this?

No. It is basically the same as if you were adding a new electric appliance to your home. You usually don’t have to notify your electric company to do that. However, the electrician who does the installation work at your house will check to be sure your current electrical panel and service can handle the amount of power the F-150 Lightning would both pull from and push into your home’s wiring. They will let you know if any upgrades need to be made, and if so, how much they will cost.

Can the F-150 Lightning really supply my home with electricity for up to 10 days?

Yes. Ford recently announced the F-150 Lightning extended range battery will have a capacity of 131 kilowatt hours. For comparison, a typical Tesla home battery used for home backup power holds about 13.5 kWh. However, remember any energy your home uses out of the truck’s battery will decrease the number of miles the truck will be able to drive before getting re-charged.

If your home has solar, you may be able to modify your electric service so the solar array could send charge into the F-150 Lightning’s battery during a power outage, along with powering your other household electric needs. Your solar array would need to be sized to provide enough power to cover both your home’s needs and have power to spare to supply the truck with extra energy to allow you to drive it around during the blackout, if needed.

When Will I Get My F-150 Lightning?

Ford received more than 200,000 reservations for the Lightning, which were made at a cost of $100 each. Starting in January 2022, they will begin sending invitations to the reservation holders to order at staggered times. If the system works as it did for the Mustang Mach e, it will cost $1,000 to place an order. Once the order is placed, it will likely take 6 months to a year before you actually get the truck. According to communication sent recently by Ford to reservation holders:

Now, this kind of demand means many of you won’t get a 2022 F‑150 Lightning™ truck, but rest assured we will hold your reservation so you’ll have a chance to order a future model year.

Ford communication to F-150 Lightning reservation holders

Stay tuned for Part 2 of this post. I plan to get it published in a week or two.

Part 2 will discuss other things you can do with a big electric truck’s battery, to both help your community and save some money for yourself. It’s called Vehicle to Grid and it could be coming to your neighborhood sooner than you think.

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Rural Electric Co-op Will School Colorado On How To Make The Most Of An Electric School Bus

Rural Electric Co-op Will School Colorado On How To Make The Most Of An Electric School Bus

Durango, Colorado’s 9-R school district will soon be the owner of a brand-new, all-electric Bluebird bus. Thanks to a grant from the Regional Air Quality Council’s ALT Fuels Colorado program and southwest Colorado’s La Plata Electric Association (LPEA), the school district is getting the bus entirely for free. This was made possible by the state grant funding, which covered much of the $210,000 difference between the cost of a diesel vs electric bus, but also by LPEA’s initiative in penciling out how both they and the school district could benefit from nascent vehicle-to-grid (V2G) technology.

It will be the first use of V2G technology with a school bus in the state of Colorado. LPEA aims to demonstrate how electric school buses can provide benefits and savings to everyone in their service area. I spoke with Dominic May, LPEA’s Energy Resource Program Architect, to learn more about the bus, V2G and the benefits.

V2G gives LPEA a return on their investment

LPEA contributed about $150,000 to cover the remainder of the cost of the bus and to install a 60 kW bidirectional charger at the school district’s bus barn. Bidirectional chargers are at the heart of V2G technology. They take the AC power provided by LPEA’s electrical grid and turn it into DC power which fills the bus battery. They can also go the other way and change the DC power in the bus battery into AC power, which can then be sent back into LPEA’s electric grid.

The bus and the bidirectional charger are now owned by the school district, but they have an operational agreement with LPEA which allows LPEA control of the battery for the coop’s benefit.

V2G is the big reason I got interested, in addition to finding a project that could be entirely free for the school.

Dominic May, Energy Resource Program Architect
FROM: https://www.cleantech.com/ev-charging-software-and-grid-services/

How can the school district and LPEA both use the same bus?

We have an operational agreement that we will run the battery to perform energy arbitrage in the background. The school district will never notice we’re doing it but will always charge at our cheapest off peak rate.

Dominic May, LPEA Energy Resource Program Architect

The bus battery holds about 175 kWh of energy. It will charge overnight and during mid-day when the bus is back at the bus barn. On the commercial time-of-use rate LPEA provides, these are the cheapest times of day to use electricity.

After it returns from its morning route at about 9 AM, the bus will need about 3 hours to refill the battery. It arrives back from its afternoon route at 4:30 or 5:00 PM. LPEA’s evening peaks usually occur at about 6:30 or 7:00 PM. They will recharge the battery up until the evening energy use peak starts ramping up. As the peak 15-minute period approaches, LPEA will signal the bus battery to push 60 kW onto the grid. (60 kW is the maximum rate the bidirectional charger can discharge at.) When the peak is passed and peak rate time is over, the bus will continue recharging into the night.

What’s in it for LPEA?

LPEA’s supplier, Tri-State Generation and Transmission Association, charges LPEA a monthly demand charge based on their peak monthly usage. For every kilowatt LPEA uses during their peak 15 minutes in each month, Tri-State charges $20/kW. By reducing their peak with the bus battery, LPEA realizes 60 kW x $20/kW = $1,200 savings a month. Says May, 60 kW of demand “that’s like a dozen houses or more coming off the grid during the peak hour.”

Just selling that off-peak energy, we don’t make much more than $0.02 per kWh and it would’ve been close to a 400 year payback period, but doing demand managing with the V2G system turns it into about a five to eight year payback period.

Dominic May, LPEA Energy Resource Program Architect

After that, the savings will accrue to LPEA’s membership.

The bus is free to the school district, but is it cheap?

The electric fuel for the bus will be one sixth the cost of diesel. The electric motor and drive train require much less maintenance than gas or diesel buses. No oil or coolant changes, no air filters, no tune-ups. LPEA’s use of the battery doesn’t require any changes to the regular schedule the bus would run. They only use it when it would be sitting at the bus barn anyway.

A diesel bus will have to be sacrificed as a condition of the state grant dollars. The school district’s oldest bus must have its axles broken or its engine cored to ensure it is permanently disabled. The intent of the state grant is to reduce air pollution by taking old diesels, which have very dirty exhaust, off the road.

What else can you do with a school bus full of cheap energy and V2G technology?

Provide mobile electricity sources during blackouts.

Any school or other buildings designated as emergency shelters would need to be outfitted with a bidirectional charger, and the electrical infrastructure to support it, to be able to receive the energy in the event of a blackout. Once installed, these chargers could also be used as fast chargers for any electric vehicle in non-emergency circumstances.

They definitely can serve as an emergency generator. One of the cooler things they could do is come up and power something like a FEMA shelter. However, the caveat is the places have to be wired up to receive this and infrastructure will need to be built to support it.

Dominic May, LPEA Energy Resource Program Architect

Demand Management

Demand management is getting bigger and bigger, especially as renewables come on the grid. You have this extremely cheap and clean energy, but it’s intermittent. So, anything you can do for storage is really what this is all about. That’s the dream of V2G – that we would multi-purpose this giant fleet of batteries that are out there to make the grid cheaper, cleaner, and more resilient.

Dominic May, LPEA Energy Resource Program Architect

Does the electric school bus help decrease greenhouse gas emissions?

On some grids, the power used at peak times is dirtier than at other times. For example, on a grid which has solar generation, and uses natural gas “peaker” plants to provide energy during the peak evening hours just as solar is waning, energy used at peak times will have higher carbon dioxide emissions per kilowatt. By decreasing the amount of kW used at peak times, those higher emissions are avoided.

 https://www.canarymedia.com/articles/ev-charging/time-shift-how-to-make-ev-charging-as-clean-as-possible

On our current fuel mix, the school bus will reduce carbon emissions by about 2 ½ times its weight in carbon dioxide every year.”

Dominic May, LPEA Energy Resource Program Architect

When greenhouse gas emissions are decreased, the other pollutants associated with burning petroleum are also decreased. Diesel engines emit particulate matter, nitrogen oxides, carbon monoxide and numerous toxic volatile organic compounds.

The bus is expected to arrive in Durango by the end of October 2021. It’s now at its final stop, getting outfitted by a company on the front range to the school district’s specifications.

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SW Colorado: LPEA EV Webinar Coming Up

Join southwest Colorado’s La Plata Electric Association on Tuesday, July 27th at 6 p.m. for the second webinar in LPEA’s Beneficial Electrification series focused on electric vehicles (EVs).

Topics include:

  • EV models
  • Financial incentives for EVs
  • EVs vs. standard vehicles
  • Batteries, batteries, batteries
  • Charging options
  • Local EV infrastructure
  • A “day in the life” of an EV driver
  • EV road-tripping
  • Q & A

Advanced registration is required: https://us02web.zoom.us/webinar/register/WN_YAx0dfXfTj2JXR4Rr_4ZmA

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There’s a New EV in Town: It’s 1971 VW Fastback

Mick Longley’s 1971 VW Fastback now driven by a Nissan Leaf powertrain

No joke. The 1971 VW Fastback pictured above is powered by a 2015 Nissan Leaf powertrain.

The powertrain of any vehicle includes the mechanisms which transmit engine power to a vehicle’s axles, and the axles spin the wheels. In petroleum-powered car, it includes the engine, transmission and axles. In an EV, power flows from the battery directly to an electric motor on the axle which spins the wheels.

Definition of powertrain

Many of us have loved and lusted after certain classic vehicles from years gone by. For Mick Longley of Durango’s Busaru, those vehicles have been Volkswagens.

From www.busaru.com

Recognizing the huge impact burning fossil fuels has on our planet’s climate, some of us regret we can no longer drive those cars or trucks. Or we’ve driven an electric vehicle and experienced how vastly superior they are and don’t want to go back to the cost and inconvenience of petrol power. For Mick Longley, this was a problem he could solve.

Mick’s love for classic VW’s started in the mid 2000’s when he picked up a VW Westfalia camper to travel around in. He moved out to Durango, Colorado in that van and started BUSARU, the VW to Subaru engine swap business. He had been holding onto the 1971 VW Fastback for a few years – awaiting a project.

I was initially going to put a Subaru engine into it but got re-inspired by the EV conversion scene. I had converted a 70’s Kawasaki motorcycle and a slough of classic bicycles back in the day, even had a small business doing that in CA called zombiEVintage.

Mick Longley

Short summary:

  • The most difficult part was mounting the battery and motor in the old VW, but he was able to find a solution which allowed keeping the LEAF battery completely intact, including all its safety mechanisms.
  • Removing the internal combustion engine (ICE) equipment is actually a ton of fun!
  • LOTS of experience with electronics packages for the do-it-yourself (DIY) Subaru-VW community helped with navigating the electronics and wiring diagrams for the LEAF-based conversion.
  • Will he convert your classic car into an EV?
    • He’s definitely interested in taking on projects once he gets more experience converting his own vehicles.
    • He’d love to hear about other people’s EV projects. Let him know what dreams you’re cooking up.
    • He plans for Regen EV’s to offer kits for DIY tinkerers to more easily retrofit their VW Bus and Vanagons (and possibly other vehicles) to electric power.

For a deeper dive into Mick’s work on the Fastback, check out his YouTube channel video below and continue reading below the video!

As Mick expected, the mounting of the battery and motor were the most challenging parts. Most VW conversions rely on using the VW transaxle and adapter plate to mount an aftermarket motor, and batteries mounted in the cargo areas.

Since I wanted to use a mass-produced donor vehicle to keep costs low and reliability high, it brought up some unforeseen challenges. In a way, the VW chassis made the battery location decision for me. The floor pan was rotten with rust, which needed to be replaced anyway, so I just cut all of it out and built a frame out of rectangular tubing. This allowed me to keep the LEAF battery completely intact, including all of its safety mechanisms, as well as providing a structural component for the car – the many benefits of keeping the center of gravity low in the chassis! Once the battery was mounted it took a few days of playing with different drive unit mounting schemes. In short, once the battery was figured out, everything else came together pretty easily.

Mick Longley

What was the biggest challenge in starting this project? It was believing it could be done!

Parsing the overall project into smaller projects really helps. Removing the internal combustion engine (ICE) equipment is actually a ton of fun. You get to see how cars are put together without the pressure or fear of breaking something you’ll need. In the case of the Fastback project, I knew I wasn’t going to be using any of the VW ICE equipment, including the transmission, so it was pure fun removing the old rusty grease-caked parts to make way for a clean EV drive unit.

Mick Longley
Mick’s Leaf-Hearted VW Fastback

In a Subaru engine conversion, the most intimidating part of the project for do-it-yourself DIY folks is the electronics. I have completed nearly 1000 electronics packages for the DIY Subaru-VW community and that experience really helped me navigate the electronics and wiring diagrams for the LEAF-based conversion. With the electronics mystery figured out, the conversion became more and more fun to work on, and a great learning experience. The next conversion will benefit greatly from what I learned on this one.”

MIck

Does Mick plan to do more EV retrofits?

I want to get a couple more personal EV conversions finished before taking on customer work. These include a 1973 VW Bus (LEAF conversion) a 1965 GMC pickup (Tesla conversion), and a 70’s vintage Ford Bronco project that I’m converting for a friend.

Mick
Could it be an EV?!?
By Andrew Duthie from Nashville, TN, USA – Ford BroncoUploaded by oxyman, CC BY-SA 2.0, https://commons.wikimedia.org/w/index.php?curid=12853385

I am definitely interested in taking on projects once I get a little more experience converting my own vehicles. I like to experiment on my own vehicles first! I love to hear about other people’s EV projects though, so let me know what dreams you’re cooking up.

Mick

Does he have plans to make EV retrofits of classic cars part of his regular business?

Yes, like with BUSARU, I plan for Regen EV’s to offer kits for DIY tinkerers to more easily retrofit their VW Bus and Vanagons (and possibly other vehicles) to electric power. I’ll keep supporting the VW community (especially the camper van VW’s) because they really represent the spirit of adventure and travel, and there’s nothing like cruising to an adventure destination on battery power!

Mick
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