A closer look at DC fast charging stations for business

 

DC Fast Charger: A Rapidly Evolving Business Opportunity 

Refueling a car used to be an activity exclusive to gas stations. With EVs, drivers can now (theoretically) charge their cars wherever they park, creating new and innovative opportunities for businesses to tap into.   

With rising EV sales, range anxiety has become a major obstacle to widespread adoption. This fear of being stranded with a depleted battery has discouraged many potential EV owners. However, strategically placed public fast chargers can address this issue directly.

As the electric vehicle (EV) industry continues to grow, businesses are presented with a unique chance to enter the fast EV charging market, and many are considering investing in DC charging solutions. Let’s explore the technical side of DC charging and gain a better understanding of this 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. These chargers 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, depending on the vehicle’s specifications.  

DC charging provides significantly faster charging times compared to slower AC charging. To put it into perspective: 

• Using a DC fast-charging station, the average time to charge a medium-sized electric car is between 17 and 52 minutes.  
• Using an AC charging station, the average time to charge a medium-sized electric car ranges from 1 hour and 45 minutes to 6 hours. 

From this comparison, you can see why DC charging would likely appeal more to your customers. But how does such a significant difference happen?   

Why is DC Charging Faster than AC?

Without getting too technical, EV batteries—like any other battery—can only store DC (Direct Current), while the grid delivers AC (Alternating Current). Therefore, AC must be converted into DC for the battery to store energy. The reason DC charging is so much faster lies in where this conversion happens. AC charging relies on onboard converters in the vehicle, while DC fast charging stations convert AC to DC within the unit itself before delivering power to 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 are in a different league and require a significant investment. The exact upfront cost depends on several factors, including the maximum power output you want, your site’s location, and the complexity of installation.  

However, to give you a ballpark figure, a DC charging station typically costs around €50,000 per station, not including installation, which usually accounts for 30–50% of the total upfront cost. 

DC Charging Station Architecture 

When it comes to DC charging stations, you’ll want to know the size of your new station’s footprint. In reality, it may 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 includes all necessary electronics, converters, and user interface in a single unit. It operates independently once installed, offering everything needed for fast charging. These stations are capable of delivering high-power outputs, typically ranging from 50 kW to 400 kW, depending on the model. Standalone units are ideal for those who want a fully integrated system in a small footprint. 

Split DC Charging Stations

Split chargers consist of two components: the user unit and the power unit. The user unit is the point of interaction for the customer, while the power unit is installed separately, often inside a nearby building. This setup allows for greater flexibility in installing or repositioning charging points. Split stations can deliver up to 600 kW but have a larger footprint. 

Standalone vs. Split DC Charging Stations

Now that you understand the two types of DC charging architecture, 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 type. 

Standalone DC Charging Station Use Case

Standalone DC charging stations can deliver high power per connector and are commonly found at locations like fuel retail sites or highway charging network hubs. 

Generally, standalone DC charging requires less cabling and has a simpler installation. It also optimizes maintenance needs since each station is connected separately. 

Split Architecture DC Charging Station Use Case

Split architecture DC charging stations are more common in commercial, parking, or hospitality locations where multiple connectors are needed and flexibility in relocation is important. 

However, this added power and flexibility come with downsides, including a larger footprint. Split architecture DC charging solutions typically require more cabling, have a more complex installation process, and generally involve higher maintenance needs. If maintenance is required, the entire site may need to be shut down, unlike a standalone station that can be serviced individually. 

DC Charging Cable 

DC stations always come with integrated charging cables for a good reason. While it's a common misconception that thicker cables are purely for safety, this isn't the case (other parts of the station ensure safety). The thicker cables are designed to avoid derating, allowing the maximum amount of power to be delivered efficiently under any conditions. Some cables even have active cooling to handle the high power flow effectively. 

 

Maximum Power Output Is Not Always What’s Delivered 

This is often overlooked. Even if a DC charging station has a maximum power output of 300 kW, the vehicle will only receive the amount it can safely accept. Nearly all modern EVs are compatible with DC charging, but the power they can handle varies based on their battery capabilities. Some batteries can handle up to 350 kW, while others are limited to 50 kW. Vehicles like the Smart EQ Fortwo, with smaller or older batteries, may not be suitable for DC charging. 

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

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 two Tesla Model 3s at the same time, both cars will only receive 120 kW each. 

DC Connector 

DC fast charging connectors allow electric vehicles (EVs) to charge rapidly. These connectors vary globally but are all designed to support rapid charging rates.  

Compatible charging infrastructure, including 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 by region to accommodate different electrical grids and common EV models. 

EU and North America

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

Tesla Connector

Tesla uses its own Supercharger connector, specifically designed for high-speed charging of Tesla vehicles. Recently, Tesla has opened up its charging connector design, inviting charging network operators and vehicle manufacturers in the US to adopt the Tesla charging connector, now called the North American Charging Standard (NACS). 

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.