A closer look at DC fast charging stations for business

 

DC Fast Charger: A Growing Business Opportunity  

Refueling a car used to be an activity done only at gas stations. With electric vehicles (EVs), drivers can now charge their cars wherever they park, opening up new and innovative opportunities for businesses.   

With rising EV sales, range anxiety has become a significant barrier to widespread adoption. However, strategically placed public fast chargers can help address this issue head-on.

As the electric vehicle industry continues to grow, businesses have a unique chance to tap into the fast EV charging market. Many are exploring investing in fast charging (DC) solutions. Let’s take a closer look at DC charging technology.  

What is DC Fast Charging?  

DC fast charging, also known as Level 3 charging, is the fastest and most powerful option available for EV charging. It can deliver between 50 kW and 400 kW, adding between 173 miles (278 km) and 298 miles (480 km) of range in just one hour.  

DC charging delivers significantly faster charging times compared to AC charging. To put it in perspective: 

• When using a DC fast-charging station, the average time it takes to charge a medium-sized electric car lies somewhere between 17 and 52 min.  
• When using an AC charging station, the average time it takes to charge a medium-sized electric car lies somewhere between 1 hour and 45 min and 6 hours. 

From that quick comparison alone, you can see which method will probably be more appealing to your customers. But how can this difference be so significant?   

Why is DC Charging Faster Than AC?

Without getting too technical, EV batteries—like any battery—can only store DC (Direct Current) and the grid only delivers AC (Alternating Current). Therefore, in any case, AC needs to be converted into DC for a battery to store energy. The reason DC charging is faster is because the conversion from AC to DC happens within the station itself, rather than in the vehicle. 

You can read more about the differences between AC and DC here. 

How Much Does a DC Charging Station Cost?  

Compared to commercial AC charging stations, DC fast chargers require a significant investment. The upfront costs depend on factors such as the maximum power output you want, your site's location, and the complexity of installation.  

However, to give you a ballpark number, on average, a DC charging station will cost approximately €50,000 per station, not including installation, which is usually between 30-50% of the total upfront costs. 

DC Charging Station Architecture 

When it comes to DC charging stations, understanding the footprint is key. In reality, it may actually have two feet. 

Broadly speaking, there are two types of DC charging station architecture: standalone and split.

Understanding the distinctions between these two architectures is key for business owners to identify the most appropriate system for their site.  

Standalone DC Charging Stations 

A DC standalone charging station comprises a single unit incorporating the necessary electronics, converters, and user interface for fast charging. In essence, it operates independently as a self-contained unit with everything required to DC charge a vehicle once installed. 

These stations can deliver high power outputs, typically ranging from 50 kW to 400 kW, depending on the model and technology. Standalone units are ideal for those who want a fully integrated system in a small footprint.  

Split DC Charging Stations

Split chargers are an alternative type of rapid DC charging stations. They consist of two main components: the user unit and the power unit.  

The User Unit

The user unit is the charging point that the customer interacts with. It often looks like a typical EV charging station, where most customers won't realize it's part of a larger system.  

The Power Unit

The power source for the charging unit is often located inside a nearby building. It performs electrical mediation away from the consumer, allowing for greater flexibility when installing or repositioning the charging points. However, split charging stations have a bigger footprint, but the power output can go up to 600 kW.  

Standalone vs. Split DC Charging Stations

Now that you understand what each architecture type is, you might wonder which suits your business best. The answer depends on various factors and your specific needs. Here's a brief overview of typical use cases for each DC charging architecture.  

Standalone DC Charging Station Use Case

Standalone DC charging stations can deliver high power outputs per connector and are typically seen at on-the-go locations such as fuel retail locations or highway charging network operator hubs. 

Generally, standalone DC charging architecture requires less cabling and installation is simpler. Additionally, it optimizes maintenance needs, as each station is connected separately.  

Split Architecture DC Charging Station Use Case

Split architecture DC charging stations are more often seen at commercial, parking, or hospitality locations where there is a need for multiple connectors on a single location and flexibility in relocating the charging stations. 

But all that additional power and increased flexibility comes at a downside, and not just a bigger footprint. Split architecture DC charging solutions typically require more cabling, have a more complex installation process, and generally come with a higher need for and less ideal (preventive) maintenance. In the case of installation—or (preventive) maintenance—it is required to shut down the whole site as opposed to just a single station that needs servicing. 

DC Charging Cable 

DC stations always come equipped with their own integrated charging cables, and for a good reason. However, it's a common misconception that the thicker cables are purely for safety reasons. While other parts in the station ensure safety, the thicker cables are designed to avoid derating (when a system or component is operating below its normal limit). This ensures that the maximum amount of power can be delivered efficiently under any conditions. Some cables even have active cooling to handle the high power flowing through them. 

 

Maximum Power Output Is Not Always What’s Delivered 

This is an often-overlooked fact. If a DC charging station has a maximum power output of 300 kW, this doesn’t mean the car will receive 300 kW. An EV will only take the maximum amount of power it can safely receive, no matter how much your charging station can offer. 

Nearly all modern electric vehicles (EVs) are compatible with DC charging, but the power capacity they can handle varies based on their battery capabilities. While some batteries can handle up to 350 kW, others are limited to accepting only 50 kW. There are a few vehicles, like the Smart EQ Fortwo, equipped with smaller or older batteries that are not suitable for DC charging. 

For example, a Tesla Model 3 has a maximum DC charging capacity of 250 kW, so when charging at a 300 kW charging station, it will only be able to receive 250 kW. 

Simultaneous Charging Affects the Maximum Output 

Another often-overlooked fact. The maximum power output refers to the entire station, not individual charging points. So, if we take a 240 kW DC charger and plug in not one but two Tesla Model 3s at the same time, both cars will only be able to receive 120 kW at the same time. 

DC Connector 

EV DC fast charging connectors allow electric vehicles (EVs) to charge rapidly. These connectors come in various types globally but are all designed to handle rapid charging rates.  

Compatible charging infrastructure, including charging stations with the right connectors, is essential for DC fast charging. These connections are vital for enhancing the usability and convenience of EVs, enabling long-distance travel, and minimizing charging time for drivers. 

Common Standards in Various Regions

DC fast charging connectors vary to accommodate different regions' electrical grids and common EV models. 

EU and North America

In Europe and North America, the widely adopted Combined Charging System (CCS) connector combines AC and DC charging in one, allowing for flexible slow and fast charging. CCS connectors have two additional DC pins beneath the AC pins.
Europe uses the CCS2 variant while the US uses the CCS1 variant. 

Tesla Connector

Tesla employs its own Supercharger connector, specifically designed for high-speed charging of Tesla vehicles. Adopting their unique design has meant that Tesla owners had to ensure they were familiar with all necessary connection adapters if they wanted to charge at a non-Tesla charging station. Recently, Tesla has opened up its charging connector design and invited charging network operators and vehicle manufacturers in the US to adopt the Tesla charging connector and charge port, now called the North American Charging Standard (NACS), on their equipment and vehicles. 

China

China's national standard for DC fast charging is the GB/T connector, resembling the Type 2 AC connector but with additional DC pins for high-power charging. 

It's worth noting that some charging stations accommodate multiple connector types, providing flexibility for EV owners with different models and contributing to the global adoption of electric vehicles. 

Japan

CHAdeMO, originating in Japan, features a distinctive "T" shape and works well with Japanese automakers like Nissan, Mitsubishi, and Subaru. 

More detailed information about different charging cables and plugs can be found here. 

Discover Our DC Fast Charging Stations 

We provide a range of DC charging stations as part of our end-to-end electric vehicle charging solutions for businesses around the world. For a complete list of tech specs and use cases, as well as more information, take a look at our portfolio of DC charging stations designed for every business looking to electrify its operation.