EV Charger Installation Requirements for Electricians

EV chargers must be located so their output cables can easily reach the vehicle’s charging ports. This guideline ensures that the charging process is convenient and safe without unnecessary strain on the cables. Most charge cables are between 18’ and 25’, suggesting the station should be positioned within that distance from the typical parking spot. Ideally, the charger should be installed in a central location relative to the vehicle’s parked position, ensuring the cable can comfortably reach the port without excessive stretching or needing to reposition the vehicle.

When installing an EV charger, it’s crucial to get the mounting height right for both safety and accessibility. The NEC (National Electrical Code) mandates that chargers must be mounted at least 18 inches (450 mm) off the ground for indoor installations and 24 inches (600 mm) for outdoor setups to avoid potential damage from flooding or debris. The maximum reach height for any charger should not exceed 48 inches, as per ADA (Americans with Disabilities Act) guidelines, to ensure accessibility for all users.

So, how high should you mount your EV charger? The ideal height for most installations is between 24 and 48 inches from the ground to the charging port, depending on whether the unit is being mounted on a wall, pole, or pedestal. This height range ensures the charger is easy to reach and compliant with safety regulations without putting undue strain on the charging cable.

For charging cables longer than 25 feet, the NEC requires that they be enclosed within a dedicated cable management system, such as a reel or enclosed retractable system, to keep them organized and safely elevated. Simple retractors aren’t sufficient; the cables must be fully contained to prevent tripping hazards and ensure long-term durability. These systems should be mounted at the same heights as the chargers—18 inches indoors and 24 inches outdoors—allowing for easy accessibility while maintaining compliance with safety standards.

The charging cables must carry the appropriate NEC trade name designation, such as EV, EVJ, EVE, EVJE, EVJT, or EVJT, depending on the specific use case. NEC Table 400.4 provides further details on the categories of EV charging cables suited for various applications, highlighting the nuances in cable selection based on the installation environment and requirements.

Proper ventilation is a critical consideration for indoor EV charger installations. While the NEC recommends consulting the equipment manufacturer for specific ventilation requirements, Table 625.52(B) offers guidance based on power ratings and the total number of EVs that can be charged simultaneously. It’s important to note that ventilation requirements do not apply to outdoor chargers.

For outdoor chargers or installations in wet locations, NEC Code 625.56 requires the use of a waterproof enclosure to protect the equipment from moisture and environmental damage, ensuring the charger’s longevity and safety. Look for chargers that are NEMA 4 rated or better for high confidence.

All chargers must be equipped with a personnel protection system to safeguard users from electrical shock. This system is designed to detect and prevent electric shock, adding an essential layer of safety during the charging process.

In addition to these NEC requirements, it’s important to consider state and local codes, which may impose additional regulations. 

• For those in the United States, UpCodes is a valuable resource for understanding local code requirements. 
• The Canadian Standards Association (CSA) catalogs commercial electrical codes and offers training. 

Canada also adheres to International Electrotechnical Commission (IEC) technical specifications. For EV chargers, these specifications are prefixed with “IEC TS 61851.”

Ensure that the charger is receiving the correct voltage from the electrical panel. Verify that the circuit breaker dedicated to the EV charger is in the “on” position and hasn’t tripped. If it has tripped, inspect for possible short circuits or overloads.

Examine the charging cable and connectors for any visible damage or wear. Ensure that the cable is securely connected to both the charger and the vehicle. Loose connections can result in intermittent charging or a complete failure to charge.

Test the charger with a different electric vehicle. If the second vehicle charges successfully, the issue may be with the original EV rather than the charger.

Ensure that the charger’s software is up to date. Outdated firmware can cause compatibility issues or prevent the charger from functioning correctly. Updating the software might resolve the problem.

Many smart chargers rely on a stable internet connection for functions like remote monitoring and software updates. Check the charger’s network connection (Wi-Fi, Ethernet, or cellular) to ensure it is functioning correctly.

Over time, electrical connections can degrade due to factors like improper torquing or thermal cycling. Inspect the charger’s installation, including wiring and junction boxes, to ensure all connections are secure and free from corrosion or damage.

Power surges or fluctuations can damage the charger or cause it to malfunction. Ensure that the electrical system is protected with surge protectors or voltage stabilizers, especially in areas prone to power instability.

Refer to the charger manufacturer’s troubleshooting guide for specific diagnostic procedures. This can provide additional steps or considerations that are unique to the particular charger model.