Want to Install an EV Charging Station? Why Material Quality Matters

The Basics of EV Charger Installation

All EV charging solutions share a few basic components. The most important one is the charging unit, a device that regulates the power drawn to charge your vehicle. These charging units, also known as electric vehicle supply equipment or EVSE, come with a user interface and built-in safety features designed to protect your EV battery during charging.

Additionally, any EV charger installation project will require wiring that runs from the charging unit to your home’s electrical panel to provide power for the charger. While some charging units are hardwired into the panel, others plug into a dedicated 240V outlet rated for EV charging.

The Crucial Role of Wiring in EV Charger Installation

EV charging requires a continuous load, so there is a risk of overheating. The best way to mitigate this risk is to install wiring rated for the charging unit you’re using.

Residential EV charging has lower power requirements compared to a commercial EV charging station, but can draw up to 80 amps depending on the charger you purchase and whether you choose to hardwire or use a NEMA 14-50 outlet for a plug-in connection.

What is the best wire for EV charging?

Copper wire is best. The high, continual amperage makes copper wiring the preferred choice due to its better thermal conductivity. In fact, most EV chargers aren’t rated for aluminum wiring since it’s generally an unsafe choice for any device that continually uses high powers of energy such as electric vehicles charging overnight, every night.

Can aluminum wire be used for EV chargers?

Yes, but it should be avoided. Aluminum wire can contract and expand over time as a result of heating and cooling from use as electricity passes through the wire, which leads to loosened connections and can result in melted components, electrical fires, and other safety hazards. While using aluminum wiring may save you on your upfront installation fees, the cost of using lower-quality and improperly graded wires can be catastrophic and even deadly.

To safely install an EV charging station at home, you’ll also have to install wiring with the right gauge or thickness. In most cases, six-gauge wires are ideal since they match the terminals of the charger while being rated for 60 amps or more but depending on your home, intended use, and existing electrical infrastructure, your licensed electrician may suggest alternate options that will better suit your needs while still providing a safe and efficient charging experience.

Outlet Grades and Their Implications

If you want to install an EV charging station that plugs into an outlet, you’ll have to pick the right product based on its National Electrical Manufacturers Association (NEMA) rating. An outlet’s NEMA rating indicates under which circumstances the product is safe to use.

If you are installing an outlet to plug your EV charging station in instead of hardwiring the EV charger, a NEMA 14-50 and GFCI with EV charging should be used for at-home charging. Under the National Electrical Code, you’ll need a Ground Fault Circuit Interrupter (GFCI) to prevent shocks at the outlet level.

This outlet can handle up to 50 amps, however, not all NEMA 14-50 outlets are designed for the continuous load that a Level 2 EV charger will require, which can result in melted components and electrical fires, and creates a dangerous risk over time. While this is the same outlet type commonly used for residential clothes dryers, you do not typically use your dryer continuously for 4-10 hours every day.

Hardwiring the charging equipment directly into your electrical panel allows you to bypass these requirements, while potentially enhancing reliability and performance. If your EV charger is designed to handle more than 50 amps, it can also help you unlock the full capabilities of your at-home EV charging experience.

When you install an EV charging station and hardwire it directly to the electrical panel, it not only helps eliminate some of the additional installation requirements and allows for you to enjoy a higher powered EV charging experience, but by eliminating the outlet and a stress point, it also creates a safer and more efficient charging experience for years to come.

A qualified electrician can help you compare both options and determine which one makes the most sense for your home, charging needs, and current electrical infrastructure.