Charging Station Extension Cord

Published 3/3/2018

L2 Charging Station Extension Cord

This weekend my wife took the Bolt to visit her mom’s house in Idaho. This journey is 142 miles each way. Even going 80mph the whole way, the Bolt has plenty of battery capacity to make it there but not enough to go round trip on a single charge. Even driving conservatively to where I can regularly get 280 miles to a charge, the Bolt is still about 44 miles short of making a round trip. Plugging in overnight on a 120 volt outlet provides sufficient charge to make the round trip but sometimes, depending on what projects her brother is working on, the garage outlet is not accessible. It’s also too slow for just a day visit. Adding a 240V outlet was the logical solution. That would work but still it would depend on the driveway being clear of any “projects” in work and accessible. This was not always the case. 

Most extension cords are only meant for temporary and intermittent use. If you are going to be charging on an L1 circuit like this for several hours at a time, you need a much more robust cord. Even then you are still limited to only charging at 960 to 1440 watts. This only adds back 3-5 miles of range per hour. This is just too slow. Add in the resistive losses of an extension cord and it will be slower still.
240V extension cord
A level 2 charger on the Bolt can deliver up to 7200 watts, six times faster than level 1 charging. 
With conservative driving, the L2 charge restores about 30 miles per hour. A 2-hour visit while charging will restore 60 miles, more than enough margin to make it back home again. 
With 80 mph fast driving, the L2 charge will restore about 20 miles of range per hour. A 5-hour visit would be necessary to restore enough range to make it back home again. 

I wanted Cheryl to have to option of charging up at her mom’s house in only a couple hours. With her mom’s permission, I installed a 240 VAC outlet on the back of the garage. It is installed in a spot that hopefully will never be blocked by automotive projects that always seem to be going on in the driveway. 
Unfortunately the back of the garage is 50 feet away from the street where visitors can park. To solve this problem, I made an 8AWG NEMA 14-50 extension cord. This cord can plug in to the 240 stove plug, (NEMA 14-50 outlet) and the Juicebox charger can plug into the end of the extension cord. In this manner an EV can charge up at Grandma’s house on an L2. 
How much power is lost through this long extension cord?

Back at home, I took some measurements with and without the Bolt charging up on a level 2 charger in the garage.  

Vehicle charging: Chevy Bolt 7200 watt internal charger, 31.9 Amps (7500 watts) from wall.
House wiring is comprised of 6 AWG cable and runs from the breaker box to a 14-50 outlet in the garage. 
The extension cord is made from 8-3 SOOW SO and is 50 feet long.
Here are the voltage measurements and power measurements from TED. 
No Extension
226 VAC
227 VAC
Extension
222 VAC
224 VAC
Power measurement TED
7532, 7542 watts
7546 watts
Using these voltage measurements, and the 31.9 amp current draw, the calculated resistive power losses are as follows. 
Wire Element
Extension cord and house wiring
Just the extension cord
Just the house wiring
Voltage drop
4 volts
3 volts
2 volts
Resistive power Loss
127.6 watts
95.7 watts
63.8 watts
I can live with that.
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