How to Charge a Freightliner eCascadia Semi Truck

The Freightliner eCascadia, a battery-electric Class 8 truck, is a key player in the transition to zero-emission freight transportation. Designed for short-haul routes like last-mile logistics, local distribution, and warehouse-to-warehouse operations, this truck combines cutting-edge technology with Freightliner’s proven Cascadia platform. Here’s a detailed guide on how to charge the Freightliner eCascadia semi truck effectively. Many customers, including those operating in drayage at ports, rely on the eCascadia for efficient, sustainable operations.

Understanding the eCascadia’s Battery and Charging Options

Battery Options and Charging Times

The Freightliner eCascadia is available with three battery options:

• 194 kWh: Charges from 0% to 80% in approximately 62 minutes (at 150 kW). Full charge takes 150 minutes.
• 291 kWh: Charges from 0% to 80% in approximately 93 minutes (at 150 kW). Full charge takes 200 minutes.
• 438 kWh: Charges from 0% to 80% in approximately 138 minutes (at 150 kW). Full charge takes 300 minutes.

Connector Type

The Freightliner eCascadia uses the CCS1 (Combined Charging System Type 1) connector, a standard for DC fast charging in North America. This connector is compatible with most DC fast chargers and supports both AC Level 2 and DC charging, ensuring flexibility and convenience for semi truck operators.

Charging Power

• The eCascadia supports DC fast charging up to 250 kW, making it ideal for chargers in the 150-250 kW range. While higher-power chargers (e.g., 360 kW) can be used, the charging rate will be limited by the truck’s onboard system.
• Dual-port charging enables up to 270 kW, whereas single-port charging is typically capped at 180 kW, though practical observations often range between 120-150 kW.

Charging Profile: Understanding the CC and CV Phases

How to Start Charging the Freightliner eCascadia

To begin charging your Freightliner eCascadia, follow these steps:

1. Park the vehicle near the charging dispenser.
2. Turn the ignition key to the OFF position.
3. Set the parking brake.
4. Follow the instructions on the charge dispenser screen for payment or identity verification.
5. Remove the coupler from the charge dispenser.
6. Plug the coupler into the charge port inlet.
7. Listen for a loud click to confirm the coupler is fully engaged.

Troubleshooting Common Issues

1. The vehicle doesn't react, and the charger faults:
   • If the vehicle was idle for several minutes, it might have entered "sleep" mode. Try:
     • Opening the door.
     • Pressing the brakes.
     • Turning the vehicle ON and OFF briefly.
   • This should wake the vehicle and enable charging.
2. Charging starts and then stops:
   • This could indicate a problem with the charging station. Contact the 24/7 call center for assistance.
3. Charging doesn’t start at all:
   • Verify you have properly authenticated as a driver.
   • Ensure the vehicle is registered at the charging site.
   • If this is your first charge or the vehicle is new, you may need to:
     • Register the vehicle.
     • Request an access card for charging.

When charging the Freightliner eCascadia semi truck, the process involves two key phases: the Constant Current (CC) phase and the Constant Voltage (CV) phase. Understanding these ensures efficient and safe charging.

With Ampcontrol we monitored hundreds of charging sessions for the Freightliner eCascadia using our charging management software (CMS).

1. Constant Current (CC) Phase

• Overview: In this phase, the charger delivers a consistent current to the battery.
• Characteristics:
  • Charging power remains high and is limited by the charger and the truck’s onboard system.
  • This phase typically charges the battery from 0% to 80%.
• Efficiency: The CC phase is the fastest, making it crucial for quick turnarounds.

2. Constant Voltage (CV) Phase

• Overview: Once the battery reaches approximately 80% SOC, the charger maintains a constant voltage.
• Characteristics:
  • Current decreases as the battery fills, protecting the cells from overcharging.
  • Charging slows significantly during this phase.
• Efficiency: This phase ensures the battery safely reaches 100% capacity.

By understanding these phases, operators can optimize charging schedules, focusing on 80% charges for quick turnarounds and reserving full charges for extended downtime.

Charging Time Overview

The table below provides a breakdown of charging times for different battery sizes and charger power levels. The leftmost column lists battery capacities, while the other columns show estimated charging times for 80% and 100% charge levels at various power outputs. This helps fleet operators plan charging schedules efficiently. Exact values can be measured with Ampcontrol's energy management system.

‍Understanding Charging Costs and Savings

Charging Costs as example in California

For commercial charging, electricity rates average $0.15 per kWh in California.

Example Costs:

• For a 438 kWh battery, charging from 0% to 100% costs:
  • 438 kWh × $0.15 = $65.70.

Cost Per Mile

The Freightliner eCascadia semi truck is highly efficient, consuming approximately 2 kWh per mile:

• 438 kWh battery (230-mile range):
  • Cost per mile: $0.15 per kWh × 2 kWh/mile = $0.3 per mile.

Savings vs. Diesel Trucks

For comparison, diesel semi trucks typically achieve 6 miles per gallon (mpg):

• Diesel cost per mile: $5.00 per gallon ÷ 6 mpg = $0.83 per mile.

Example Savings:

• Electric truck: $0.30 per mile.
• Diesel truck: $0.83 per mile.
• Savings: $0.75 per mile.

Over 100,000 miles:

• Diesel truck fuel cost: $83,000.
• Electric truck charging cost: $30,000.
• Total savings: $53,000.

Additional Considerations

1. Maintenance Savings: With fewer moving parts, the eCascadia reduces maintenance costs by up to 50% compared to diesel trucks.
2. Incentives: California offers grants and incentives to encourage the adoption of electric trucks, further lowering costs.
3. Smart Charging: With intelligent load management, fleets avoid expensive electricity prices

By switching to the Freightliner eCascadia, fleet operators can cut operating costs and contribute to sustainable freight transportation. Using Ampcontrol's energy management fleets can further reduce the monthly charging costs.

Conclusion

The Freightliner eCascadia is revolutionizing the transportation industry by providing an eco-friendly, cost-effective solution for freight operations. This guide highlights the truck's impressive charging capabilities, operational savings, and environmental benefits. Whether you're focused on optimizing charging schedules or reducing your fleet's carbon footprint, the eCascadia delivers exceptional performance. Transitioning to this battery-electric semi truck not only ensures compliance with evolving regulations but also positions your business as a leader in sustainable logistics.

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