EV Charging Hardware
Selecting the right Product for the right Application
Guide to selecting EV Charging Hardware
We suggest three guiding rules when selecting EV Charging Hardware:
Getting the balance right between speed of charge (kW), location, electrical capacity constraints, and budget. By selecting the best long term product/solution.
Don't assume that all EV Charging Stations available on the market are 'fit for purpose'. Dependent on your particular application, there will be a Station that may suit you more ideally. E.g., Quality, Billing and Load Management capability, handling environmental conditions, ease of use etc.
Don't overlook the importance of the interconnected associated Infrastructure. Integration with the electrical infrastructure, access to good internet, having the ability to upgrade/scale over time, ease and safety of the Driver and their vehicle - all need to be considered.
How long do you have, or would you like your guests to plug in for? E.g., Providing a 20 min charge will require a larger budget and electrical connection, than a 4 hour charge.
Finding the right location for your installation is crucial. Close enough to access to enough electrical capacity (including renewable energy integration - if required), strong and secure internet connection, as well as being safe and convenient for the User to leave their vehicle for a period of time.
Most vehicles could charge within 2 to 4 hours on an AC 3 phase, 22kW, 32 Amp connection. Versus a 3-phase, DC 150kW, 250 Amp connection, that would be required for a 20 min charge.
Single or multiple EV Charging represents a relatively large electrical load. Most of the time the Hardware will be installed into existing buildings/ networks. When installed within limited infrastructure, or at scale, they will need to be load managed - i.e., have their output automatically ramped down during high use peak periods.
A 22kW AC Station will cost between AUD$2.5 to 4.5k, installed. Versus approx. AUD$90k+ for a 150kW DC Station. However, the DC Station is likely to receive higher utilisation and provide a better ROI.
The key vehicle requirements from Charging Infrastructure, include particular AC and DC charging top end limits, the required plug type connection (mostly Type 2 for AC and CCS2 for DC), and ease of reaching the charging port location on the vehicle. For assistance, covering the various vehicle OEMS, see this AEVA link.
EV Charging Hardware Applications
AC - Residential
For an overnight charging (idol time of vehicle) window of approx. 8 to 10 hours, then (in most scenarios) an AC, single phase - 240V, 32A, 7.4kW station is quite satisfactory. User friendly added features include Solar integration, simple load management, longer cable options, and a Station App for visibility and scheduling management. Consider the Evnex stations.
DC 40kW - Movable
The Kempower Movable T Series Charger is a transportable DC fast charger suitable for charging all types of electric vehicles, cars, trucks, buses, boats and off-highway vehicles. You can easily charge EVs at events, car dealerships, bus and truck depots, boat harbours, building and mine sites. It can also be bolted down into a fixed position. Plugs in via a standard 32A or 63A socket. 500VDC and 800VDC output options.
AC - Apartment
Apartment/ Strata and Commercial applications, rely on fitting in and integrating with the existing infrastructure, together with a simple billing solution. The Stations need options in single and three phase, tethered cable or socket, wall or pedestal mount, OCPP for load management, security RFID authentication and billing. As well as Wi-Fi, 3/4G, Ethernet internet connection options. Consider the Schneider EVlink Pro AC with LMS
DC - Less than 80kW
The rule of thumb for a 50kW DC Station, is that it will charge most EV in approx. 45 mins. They cost approx. AUD$45k and require 85 Amps. Plug Type options include CCS2, CHAdeMO and AC Type 2. Supplied as standalone, all-in-one unit. A 'Modular' power module design will offer simultaneous (multiple vehicle) charging, at the same time. Our preferred options (dependent on application) includes the Kempower C Station.
AC - Public Access
AC Stations, used for open Public engagement, need to be solid and robust, weatherproof (rain and UV), and easy to use. Ideally mounted on a stainless steel combi pole (to raise the Station off the ground), Type 2 socket/s, RFID reader, User-friendly LED indication, third party OCPP supported, 4G built-in modem with free (no ongoing cost) data connection. For this application, the EVBox BusinessLine is perfect.
DC - 80kW to 600kW
DC Charging Stations above 80kW capacity, get more complex. They are supplied as either standalone combined units, such as the EVBox Troniq Modular or Kempower C Station. Alternatively, the Kempower C&S Series, CPU Control Units (up to 600 kW), connected to separate (remote) Satellite Stations, that can accommodate up to 8 x connectors - all dynamically sharing available capacity.
EV Charging Hardware Selection FAQs
Q - How can I find out what my vehicle's AC & DC charging limitations are? So that I can select the right size Station for my application.
A - Either check with your vehicle Dealer, or via EV Fact Sheets on this link found on the AEVA (Australian EV Association) webpage.
Q - We have solar, however I am not sure if I will also require the built-in load management feature of the Station. Can you advise?
A - Unless you are connecting a Station to a new building, that has the allowed electrical capacity required, then there is good chance that you will require load management. Even as a precaution for future. For most EV Stations, load management capability is not easily retrofittable.
Q - What is OCPP and do I need to connect the Station to the internet and software?
A - OCPP stands for Open Charge Protocol. It is the syntax language that is used to communicate with EV Charging Stations. If you require a 'Smart' Station, i.e. one that communicates with your vehicle, load management, App management, billing, reporting, then both third party OCPP capability and a good internet connection will be required. At a minimum, a Station should have an internet connection (Wi-Fi) for OEM support diagnostics and firmware updates etc.
Q - What electrical protections are required, for an installation?
A - To start with, EV Stations must be correctly third party tested and certified, for the country that they are sold in. For the installation, check that the Station has built-in 6mA DC protection. If so, then each socket must have a dedicated connection from the switchboard, protected by a RCD Type A. If the Station does not have 6mA DC protection built-in, then a more expensive RCD Type B is required. As per AS/NZS 3000 (Electrical Wiring Rules), Isolation switches are not mandatory, but make logical sense.
Please contact us through the below form, if you have any further questions.