What Are the Electrical Requirements for Level 2 and DC Fast Charging Stations?

Understanding the electrical requirements is crucial for installing efficient Level 2 and DC Fast Charging Stations. Level 2 chargers provide faster, reliable charging, ideal for home and commercial use, operating on a 240-volt power supply. Proper installation, adhering to National Electrical Code (NEC) standards, ensures safety and performance. They offer convenient charging speeds, balancing cost and efficiency. Comprehensive planning in installation supports seamless integration with existing electrical systems.

Who does NEC 625 apply to?

The NEC, like the International Building Code (IBC), is established by the industry rather than the federal government. State and local governments adopt these codes to ensure that residential and commercial buildings are safe for occupation and use.

EV charging has been added to NEC Chapter 6, which deals with “Non-Typical or Specialized Areas of Work.” More specifically, Article 625 now covers EV charging for passenger automobiles, buses, trucks, vans, electric motorcycles, and other types of EVs that are primarily powered by an electric motor that draws current from a rechargeable battery or fuel cell.

It also covers direct current (DC) system voltages of up to 1,000.

Regardless of the published standards, it is crucial to always review the recommendations from the charging station manufacturer. If you're unsure about the appropriate electrical configuration for a charging station, make sure to check the manufacturer's guide and installation manuals. Each station is designed to work with a specific electrical setup.

What are the essential electrical requirements for Level 2 charging?

Level 2 charging is a faster way to power electric vehicles using a 240-volt outlet, similar to what's used for ovens or dryers. It is commonly found in homes, workplaces, and public stations. Level 2 charging typically adds 20 to 25 miles of range per hour, offering a much faster alternative to standard Level 1 charging.

Most residential Level 2 (L2) charging stations, such as the Blink HQ 200, require a dedicated dual-pole circuit and a line voltage of 208 or 240 volts to operate in North America. This power input is similar to that required by larger appliances like ovens and dryers.

To comply with NEC Article 625, cables and the circuit breaker must be rated for at least 125% of the output of a continuously operated device. The latest 50-amp home chargers require a dedicated 70-amp circuit. The HQ 200 features flexible amperage up to 50 amps and can be hardwired into an electrical system or plugged into a NEMA 14-50 plug.

In commercial settings, the power input for L2 charging stations, like the Blink Series 7, is typically 208V, although they can be wired into a 240V system.

L2 chargers generally provide ~6.2 - 19.2 kilowatts (kW) of power, filling a battery in a few hours, depending on the amperage and vehicle.

Blink’s residential and commercial EV solutions

The residential HQ 200 has a variable current output of 12 - 50 Amps (A) and a voltage input requirement of a single phase 180 - 264 VAC (volts alternating current). It has selectable input/output power of 2.9kW, 3.8kW, 7.7kW, 9.6kW, or 11.9kW.

The dual-port, commercial Series 7 and Series 8 chargers, which both come equipped with two charging ports, are configurable up to a maximum of 80A of output current per charging port.

When connected to a 100A circuit, the system can deliver a maximum power output of 19.2 kW with 240VAC or 16.64 kW with 208VAC.

What are the essential electrical requirements for DC fast charging?

Due to their increased input requirements and higher output capabilities, DC fast chargers demand a 3-phase AC input. Operators also must carefully plan for the dc fast charging voltage range that the charger will support, since mismatches can degrade performance or require voltage conversion.

Typically, DCFCs can provide 150kW to 350kW of power output, although that can be lower, like with the Blink Series 9 DCFC, which has a maximum of 30kW of power output when connected to a 3-phase AC system with 480Y/277VAC. These low-power DCFC are an excellent solution or hosts that need a fast charger without incurring the upgrade costs of a higher-powered charger.  

The most powerful of these, the 360kW model, has an output dc fast charging voltage range of 150 – 1,000 VDC (volts direct current) and a maximum output current of up to 1,200A. To run the 360kW DCFC, installers must connect it to a 3-phase 480VAC system on a 600A or larger circuit. 

Upgrades may be required

Most American homes have single-phase electrical systems, perfect for residential Level 2 charging stations.

Commercial and industrial applications, however, may have a 3-phase electrical system to accommodate large electrical machinery. Note that even if a commercial site has 3-phase electrical power, it may require some electrical upgrades to accommodate EV charging, especially if a site host installs multiple DCFCs. Per NEC 625, each charging station must have a dedicated circuit.

Therefore, installing EV charging stations may require installing a new electrical panel or even a transformer on site to help with the additional electrical loads caused by the EV charging infrastructure.

Major industrial campuses may also consider installing a battery energy storage system (BESS), which acts as a giant battery that is capable of storing electrical power for later use. A BESS can be charged during off-peak hours when electricity is cheaper (generally evenings, nights, weekends, and holidays) and then used to power EV charging stations during peak hours when electricity rates are higher.

Conclusion

EV charging stations are designed to work with most electrical systems. Residential and commercial Level 2 charging stations are meant for single-phase systems, and commercial DC fast chargers are usually designed for 3-phase systems. During your EV charging site assessment, your electrician will ascertain whether or not you may require any upgrades. Ready to get started? To speak to one of our experts, please contact Blink Charging today.

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