As an electrician, at some point, you will have to learn about the ins and outs of EV chargers. Most people have only dealt with gas-powered cars all their life and so understanding electric vehicles and what an EV charger is can be considered new territory. 

Since EVs are not that widespread, it may take a little extra training before you can start tinkering around with electric vehicles, EV chargers, and other related devices. Here are a couple of things you need to know about how EV chargers work. 

What is an EV charger?

What is an EV charger? An EV charger or Electrical Vehicle charger is a piece of equipment that supplies electrical power for charging plug-in electric vehicles.

Whether dealing with a battery electric vehicle or a plug-in hybrid electric vehicle, you will need a suitable EV charger to keep the battery alive. It works the same way as any other chargeable electronic device; this time, it’s just for the car. 

Just like there are various kinds of petrol options for fossil fuel cars, there are different types of EV charging cables for electric vehicles. Keep in mind that despite being more environmentally friendly and cost-effective, EV charging takes significantly more time than a pit stop at a gas station would.

What is a tethered EV charger?

So, what is a tethered EV charger? A tethered EV charger is referred to as the device having a charging cable permanently attached to the wall unit. 

There is no difference in the charger's performance, but there is the advantage for the user not needing to get the charger cable from their garage or beet every time they need to charge their electric car. On the other hand, the downside is that the whole unit will need to change if the cable type changes.  

What is an untethered EV charger?

What is an untethered EV charger? An untethered EV charger is a device that has no cable permanently attached to it. Since there is just the socket, they are also called “socket-only” EV chargers. 

An untethered charge point allows for more flexibility because it can charge any EV with the universal socket. There are no restrictions by the EV charger manufacturer regarding cable length either. The downside is that untethered chargers may be less secure because the charging cable is easier to access.  

EV chargers: everything you need to know

The more you know, the easier it’ll be. And the same goes for EV chargers. As the world increasingly gravitates toward electric vehicles, more and more questions are being brought up, and knowing the insides and outs of EV chargers will benefit you as an electrician in the long run. 

A part of it is knowing the various EV charger types and EV connectors and why they are important. Other details about what is inside an EV charger often depend on the type of device being discussed, like whether it is an EV home charger or a commercial one. So let’s get into it. 

EV charging types

EV charging comes in three types – rapid, fast, and slow. What these represent are the power outputs and charging speeds that are available to charge the electric vehicle. The power is measured in kilowatts (kW). 

Each type of charger comes with connectors designed for low or high-power use and AC or DC charging. 

• Rapid chargers

The fastest way to charge an EV is by using rapid chargers. These supply AC or DC to recharge a car in the shortest time possible, as quick as 20 minutes. 

Most rapid devices have charging cables tethered to the unit, and they can only be used on EVs that have rapid-charging capability. Rapid DC chargers can provide around 50 kW (125A) of power and use CHAdeMO or CC charging standards. These have been the most common and standard type of rapid EV charge points for a while now.  

On the other hand, Ultra-Rapid DC chargers can provide power up to 100 kW or more. Generally, you will find them to be 100 kW, 150 kW, or 350 kW. They can keep recharging times down despite increased battery capacities. 

• Fast chargers

The majority of fast chargers typically provide AC charging. They are rated at either 7 kW or 22 kW. Charging times depend on unit speed and the vehicle type, but you can expect a 7 kW charger to charge an EV with a 40 kWh battery in around 4-6 hours. 

Fast chargers are usually untethered, but some home and workplace units have cables attached. Another thing to note is that charging rates will vary depending on the EV’s onboard charger because not all models can manage 7 kW or more. 

• Slow chargers

You will find slow charging units rated up to 3 kW, though slow charging is usually between 2.3 kW and 6 kW. The charging times vary depending on the charging unit and which electric vehicle type is charged. Most slow charging units come untethered, so you need a cable to connect the EV to the charge point. 

Slow charging is a common method, and many EV owners tend to use them when charging their vehicles at home overnight. They are also found at public points and workplaces, though less commonly due to their long charge times. 

Types of EV connectors

There are four types of EV connectors that you should know about. Depending on the manufacturer, particular connector compatibility will be involved with the vehicle. You have to know which connector outlet will work for the EV you are dealing with. 

• CHAdeMO

CHAdeMO stands for “Charge de Move” and was designed by a collection of carmakers industry groups, mainly in Japan. Nissan, Toyota, and Mitsubishi are some manufacturers that use it as a standard. 

• CCS

The Combined Charging System (CCS) is commonly used globally and is primarily associated with North American and European automakers. It is designed to be an “open industry standard.” Except for Tesla, all newly manufactured EVs use CCS connectors. 

• Tesla 

Tesla was one of the first EVs to come to the market with fast charging, so they had to design their connector. Tesla vehicles also generally come with an adaptor for AC Levels 1 and 2 (J1772) and offer a CHAdeMO to Tesla Adaptor for DC charging. 

• L2 - J1772

This connector is for Level 1 and Level 2 AC charging. Although much slower than DC Fast Charging, this connector is for those clients who don’t mind charging their vehicles over a few hours at work or home.  All-electric vehicles can use this connector for AC charging, except for Tesla. 

Types of EV chargers

Before you start searching for charging cables, you have to know everything about the various types of vehicles and EV charger types you are working with. For example, most cars in Europe work with Type 2 EV chargers, but vehicles from Asian manufacturers still use Type 1. 

You also have to consider the performance of the EV charger and what type you are buying because if the client’s vehicle ends up taking too long to charge or causes other issues, it’ll become nothing but a waste of time and money. 

Type 1 EV charger

What you get with EV charger types that are Type 1 is a 5-pin design that can transmit power load and an earthing mechanism for safety purposes. The resistors present in the Type 1 cable can detect whether the cable is plugged in or not and will automatically turn off when the lever is pressed to unlatch the plug. 

Type 1 EV chargers are single-phase and can give you fast charging at an output anywhere between 3.7kW and 7.4kW AC which provides around 12.5-25 miles range per charging hour. 

The one disadvantage you will have to deal with is that even though the latch provides a security measure to stop the cable from falling out by accident, anyone can manually remove the EV charger cable from the car. 

Some electric vehicles that use EV charger types that are Type 1 include Citroen C-Zero, Ford Focus Electric, Mitsubishi Outlander PHEV, Kia Soul EV, Nissan Leaf 2012-2017, Toyota Prius, Vauxhall, and more. 

Type 2 EV charger

When it comes to Type 2 charging cables, they are particularly ideal for high-capacity EVs, so it would be a smart choice to go for a longer charging cable that has charging sockets on one side of the body. That way, it will be more convenient to reach the charging point without hassle. 

Compared to Type 1, Type 2 EV chargers come with a 7-pin design and can fit in with both single and three-phase mains power. 

You will get around 30 to 90 miles of range per charging hour and a charging speed of up to 22kW (domestic charge stations) and 43kW (public charge stations). Considering most public charging stations are compatible with Type 2 EV chargers, you’ll be in luck.

Some cars that use Type 2 charging cables include Audi Etron, BMW i3, Hyundai, Jaguar, KIA, Range Rover, Renault, Mercedes Benz EQC, Mini Countryman, Nissan Leaf 2018, Porsche, Tesla, Toyota, and more. 

How to install EV chargers

Here’s a quick guide on what to do when tasked with an EV home charger installation. As a professional, keep in mind all the necessary technical and safety regulations that you are expected to comply with. 

Step 1: Choose between Level 1 and Level 2 chargers

The two common chargers used in residential areas are Level 1 and Level 2 chargers. A Level 1 charger uses a regular 3-prong household outlet available in most homes. EVs are usually sold with Level 1 chargers. 

An electric vehicle trickle-charges at 2-5 miles per hour when using Level 1 charging. For plug-in hybrid EVs, this setup fits the best. Level 1 chargers need fewer electrical upgrades as well in the long run. 

On the other hand, Level 2 chargers can charge EVs faster than 8-24mph. They will require a 240V outlet – basically what large appliances like electric stoves and dryers use. 

Step 2: Choose the right charging equipment 

Since different EV models charge at different speeds depending on the capacity of the EV’s onboard charger, you need a charging unit that delivers the adequate amount of power that the EV can run on. 

Some things to consider when it comes to EV chargers feature include: 

• Amperage – this determines the rate of charge. Depending on the EV model, it will accept a different amperage level, so installing charging equipment with anything that’s higher will be useless. Always match the amperage of the equipment with the EV. 
• Smart EVSE & Basic EVSE – While Basic EVSE can only be used when the EV is charging, Smart EVSE is WiFi-enabled, provide advanced connectivity with other smart devices, and monitor energy consumption, charging rate, and other data. They also allow advanced scheduling that can be done through a smartphone. 
• Cord length – The cord must be long enough to reach the vehicle; extension cords should generally be avoided as they are dangerous to use with EVs. 
• Safety – charging device must be certified by an established testing organization in your region. 

Step 3: Electrical upgrades

As an electrician, it is important to notify your client of whatever electrical upgrades they might require, and if they have installed a Level 2 charging capacity, there are two typical upgrades they may need. The first is adding capacity to the unit or house panel, and the second is upgrading electric service capacity to the MUD from the utility. 

To add capacity to the unit or house panel, you can upgrade it to a new panel and reconfigure the current panel to provide sufficient breaker space. In addition, you can add a subpanel for the EVSE unit or add a separate panel from the existing service. 

Step 4: Get electrical permits 

As a licensed electrician, it's your job to obtain all necessary required permits, and they have to file before the installation process begins. 

You will have to submit a load calculation for the installation and the standard electrical permit application. Once the necessary documents are submitted, and the fee is paid, the permit will be approved. 

Step 5: Install the EVSE

Level 1 chargers are generally easier to install and only need the EVSE plugged into an outlet after the necessary electrical upgrades. 

With Level 2 charger installation, there may be permitting and inspection fees your client will have to pay before you can get started. You will most likely have to run wires from the electrical panel to the installation location for the EVSE connection. 

The ideal situation is if the panel is close to the EVSE location, but if the distance increases, you can charge additional costs for the materials and labor that will go into it. If the EVSE site is located in a more complicated location, such as an underground parking garage, there are probably some engineering tests like X-raying concrete that have to be done. 

What is an EV smart charger?

EV smart chargers have changed the game in recent times; also known as intelligent charging, it is a system where an EV and its charging device share a data connection. The charging device also shares a data connection with the charging operator. 

Compared to the usual EV charger types, EV smart chargers allow the charging station owner to monitor, manage, and restrict the use of their devices remotely. EV smart chargers are a cloud-based solution that enables optimized energy consumption. 

Features of smart EV charging

Here are a couple of features of smart EV charging that make them as convenient as they are. 

• Admin panel

When operating multiple charging points across multiple locations, things become a lot easier when there’s an admin panel you can work with. Prices for public charging can be set through it, and management can be done remotely. Viewing and downloading usage statistics also becomes much easier. 

The admin panel provides tools that allow the user to obtain all the relevant station statistics, station details, and prices based on key metrics. Making changes in the features according to what you need is also possible. 

The admin panel provides charging network operators information about customers, registrations, and RFID tag shipments. Admin panels are the key to efficient and smooth station management. 

• Automatic payments and billing 

Manually charging customers is a thing of the past with the automatic payments and billing system with smart EV charging. The platform itself takes care of this, and customers can choose how they want to pay. RFID tags, mobile apps, and one-time payments using a card are available options. 

• Mobile and web apps

This benefit exists more for the end-users than anybody else, and it helps elevate customer experience to another level. EV drivers can find and reserve available charging points, add their preferred stations, view their charging history, etc. 

With the mobile app, real-time data regarding the charging station is available and just a click away. 

• Roaming

Thanks to roaming, charging station owners can attract more users and gain a higher income. Roaming overall improves the user experience since it works the same way as mobile data roaming. The devices just have to be connected to the roaming networks. 

• Dynamic load management (DLM)

Dynamic load management refers to a smart EV charging platform's ability to automatically distribute the available power between the building and the EVs that are being charged simultaneously. 

This protects the local grid from peak loads, so there won’t be the need to upgrade the building’s energy infrastructure. 

• Energy management features

Energy management features are what connect the EVs to the grid. Smart charging stations allow EVs to be used in supporting the electricity system. 

This works by balancing the variations of energy production and demand, vehicle-to-grid (V2G) technology enables scaling up renewable energy. This allows EV users to be part of the change towards cleaner energy. 

Benefits for EV charging networks 

It is impossible for utility companies with their EV charging networks to function without a smart EV charging solution. Some of the benefits that come with it are as follows. 

• Stabilizing the grid

Controlling smart charging events using different signals becomes an option. For example, charging can be set to start automatically when electricity demand is low. This feature that allows for controlling charging based on various energy production and consumption signals allows for more business opportunities. 

• Be up-to-date with trends

Change is often happening rapidly in the mobility sector, and not everything about the future is as predictable as it seems. Smart EV charging, therefore, brings flexibility because of how it can be updated, changed, and developed whenever the need may arise. 

• Managing smart EV charging stations

For network operators, creating device groups and pricing models and packages for end-users becomes easier to manage. With smart EV charging management tools, testing various prices and managing station groups is hardly a hassle anymore. 

Benefits for businesses

EV smart charging brings many benefits to EV charging businesses because they can monitor EV charging events remotely thanks to the smart management system. They can monitor, control, and view usage statistics and report issues instantly when identified. 

And since all the stations are connected via the same charging platform, grouping and managing them in a stack becomes a breeze. A hassle-free billing system is no longer a pipe dream since EV users are billed automatically according to the set prices. 

Another advantage is solid control over electricity consumption. Businesses will be able to get controlled charging events, so the chances of exceeding the capacity of their local grid drop down significantly. This saves money because there is now a need to grow the electrical connection. 

Domestic vs. Commercial EV chargers

Knowing the difference between domestic EV chargers and commercial EV chargers is necessary because a pretty thin line separates the two. And one of the best ways to understand is to lay out the various challenges that domestic and commercial EV charging brings.

Domestic EV charger

• Property ownership – For clients living in a shared vicinity or apartments, charging their electric vehicles at home is a very big hassle and downright impossible. Getting an EV home charger means facing many regulatory issues, specifically for those who live near or with them. There is also the issue of infrastructural limitation because most residential properties do not have extra incremental load handling strategies.
• Charging is slower – Usually, domestic settings host Level-1 chargers, which charge EVs at a slower rate. Although Level-2 chargers are also available for domestic residential areas, the associated infrastructural cost stops most EV drivers from going for them and relying on the slower option instead.
• Ampere rating – The days when most EVs get charged on 32A EV chargers are slowly disappearing. The newer EVs being produced all require a 48A EV or 40A EV charging capability, and the numbers will likely go higher as time passes. 

This leads EV owners to think twice when choosing a charging port or infrastructure, especially if they have a domestic charging plan.

Commercial EV charger

• Demand charges – With commercial EV charging stations come demand charges as a resistive force. Commercial EV charging station owners have to pay a fixed amount per month because of their disposal's large energy. Customers also bear the weight of it with costly EV charging prices.
• Bureaucratic issues – An EV charging commercial setup means dealing with import duties and getting the necessary permissions and licenses. All this hassle increases the time it takes to establish a commercial EV charging station, causing a drop in morale for those working on it.
• Location – As of now, most if not all EV owners opt to charge at home rather than at commercial EV charging stations. Often, when users search “EV chargers near me,” nothing comes up, and it becomes inconvenient to get to them. Therefore, the demand for commercial charging stations is continuing to die down. 

Best Domestic and Commercial EV Chargers

• GARO Standard Domestic Wall Charger

GARO Electric is one of the most reliable domestic EV charger providers based in the UK and Ireland. They produce a stylish design for their wall chargers with smart functionality and a simple charging procedure. 

So what is inside an EV charger, specifically the GARO Standard Domestic Wall Charger? Well, it comes with a 7.4kW socket and is a Type 2 tethered lead. Its features include DC monitoring, installed DLM, a motorized interlock, and a LAN connection for control and billing ease. 

It is one of the best home EV chargers and delivers between 3.7kW and 22kW. Its DLM protects the main fuse in an installation by reducing the EV’s charging current when the total load is high and increasing it when the total load is low. 

The built-in DC leakage monitoring makes sure that the protective devices are operating under fault conditions and negates the need for a Type B RCD. And with the WiFi module, it is possible to configure and update both firmware and software remotely. This domestic EV charger isn’t limited to domestic spaces and can be installed at workplaces, car parks, and hotels. 

• GARO LS4 Electric Car Charging Station

GARO’s LS4 is a commercial EV charger that meets all the requirements for devices installed in public places. Manufactured from marine-grade aluminum, its construction allows it to be directly bolted to the concrete ground and can even be mounted on a pole-mounted assembly. 

At the top of the charger, you will find a 360◦ light indicator that shows the charge status of each station from a distance. This EV charging station comes with two illuminated type 2 sockets and is available in 16 A, 32 A versions, both single and 3-phase, with an optional MID certified electricity meter. 

In addition, the LS4 is equipped with smart controllers for each of the sockets enabling work with OCCPP 1.5 AND 1.6 protocols. This device can be installed in commercial spaces such as car parks, supermarkets, shopping centers, bus and rail stations, restaurants, etc. 

• GARO Standard Domestic Wall Charger (Fixed Lead Type)

The GARO Standard Domestic Wall Charger with a fixed cable comes with a Type 2 connector, 7-22kQ, and with or without an energy meter. Its main features include Mode 3 communication and can either be mounted on the wall or on a GHL stand. 

This EV home charger comes with various options such as a local load balance, an RFID reader for additional security, and WiFi communication. It has a DLM installed to protect the main fuse and a motorized interlock that prevents the cable from being removed while charging. 

In addition, there is back-office software available from third-party OCPP software providers. This is one of the best home EV chargers that also sports a PME fault detection which disconnects all phases and earth if a PME fault is detected. Read more about our Garo EV chargers in our recent blog. 

• GARO 2x22kW Outlets Metered & Ethernet 

The GARO 2x22kW Outlets Metered & Ethernet EV charging station is a product for commercial applications designed from aluminum, giving it the strength EVs need. This EV charging station sports a voltage rating of 30/400, has two sockets (Type 11) included, and can either be grounded or wall-mounted. 

It has an EV charging mode of 3, a 4G connection & RFID reader, and an external meter with load management. It is designed specifically for single and three-phase solutions and comes with a three-year warranty to boot. 

Are EV chargers waterproof?

A common question that people ask is, are EV chargers waterproof? And the answer to this is yes, EV chargers are indeed waterproof and are designed to protect both the car and the person dealing with them from electric shock. 

That means users can charge their EVs outside when it's raining, and electricians don’t have to worry too much about keeping EV chargers in a completely dry area when working. 

Both the EV chargers themselves and the cables that come with them are waterproof, and waterproofing outdoor electrical equipment is pretty much the standard regardless. EVs can be charged in just about any kind of weather condition – even against something like dust particles. 

An electric car or truck, like the Nissan Leaf, has an IP rating of 67. This number system is known as the Ingress Protection Rating, and the first number relates to any small foreign objects, like dust particles or dirt. The second relates to protection against water and other liquids. 

According to the rating scale that extends from 1-6 for dust/solid object protection, 6 is the best number you can get, while 1 is the worst. For liquids, the range is 1-5, so the higher the number, the better the protection you are getting. 

For EVs such as the Nissan Leaf, with a 67 IP rating, any vehicle component can be submerged in water at 1 meter for 30 minutes without retaining any damage. The battery and electric motors are built well enough to withstand this level of time and depth of exposure to liquids. 

So this rating confirms that plugging an EV into a charging station in the rain is hardly anything to worry about. There is no physical way for the electrician or the end-user to be in danger due to electric shock, even if the vital cables and cords are disconnected. 

In addition, most EVs are programmed to shut themselves down in case of an accident to ensure there is no electricity discharge. 

For any more information regarding the installation of EV chargers, please contact us via live chat or call us on 028 (048) 867 51515 to speak to an expert.