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Fast Charger Connectors for 3 different electric vehicles

DC Fast Charger Internet Connectivity | A Complete Guide

  • May 23, 2024

In a tangible way, electric vehicles are changing the face of transportation. With more EVs on the road, more EV chargers are proliferating – including DC fast charger stations that can power up vehicles quickly.

Here’s the challenge.

These IoT-enabled chargers need secure, unwavering Internet connectivity to function. But too often, project managers don’t have the bandwidth to source the right connectivity. When that happens, the path to deployment stops.

This guide will help you choose the right connectivity option for fast charger ports. And get your fast chargers deployed on time.

What are DC Fast Chargers?

Level-3 DC (Direct Current) EV chargers, also known as DC fast chargers or DCFCs, are high-powered charging stations built for speed.

How do fast chargers work? Put simply, direct current electricity flows to the EV battery, bypassing the onboard charger. This allows for faster charging rates compared to Level-1 and Level-2 AC chargers.

Key characteristics of Level-3 DC EV chargers include:

  1. High charging power – Level-3 DC chargers go from 50 kW to 350 kW or even higher, depending on the specific charger model and configuration. This range is attractive to EV drivers, who can power up to at least 80 percent in minutes. Level-1 or Level-2 chargers can’t compete.

  2. Rapid charging speeds – With its high-power output, a level-3 DC charger improves one’s travel range in a relatively short timeframe. Depending on the EV model and battery capacity, charging times can range from approximately 15 minutes to around an hour for a full charge.

  3. Compatibility with DC-capable EVs – Most modern electric vehicles, particularly those designed for long-range driving or rapid charging, come equipped with DC charging ports that connect directly to level-3 DC chargers.

  4. Increasing availability – DC fast chargers are not as ubiquitous as Level-1 or Level-2 chargers. That said, you can find new installations along major highways, at rest stops, and in urban areas. In the future, more fast chargers will support long-distance travel and provide quick recharging.

All compelling reasons why drivers are flocking to electric vehicles.

The Challenges of Fast Charger Connectivity

Today, most EV drivers charge their vehicles via AC chargers, either overnight at home or within city limits at a store or workplace. But as infrastructure expands according to demand, additional level-3 EV fast chargers will be needed for wider coverage and mileage.

By 2030, an estimated 182,000 fast charging ports will be needed at public/commercial charging stations, especially for EV drivers lacking consistent access to off-street parking, and for those driving long distances.

National Renewable Energy Laboratory Tweet

Connectivity Pathways for Every DC Fast Charger

What makes DC fast chargers so attractive to EV drivers also creates challenges for project developers. Fast chargers have unique infrastructure needs, which means they can only be installed in public or commercial areas. Reliable Internet connectivity is essential for efficient charging and dynamic pricing. But in such zones, that connection may be hard to come by.

Think of DCFC providers and operators who install stations in rural areas away from wired lines. If they manage a large portfolio of EV chargers, they will also need to monitor their fleet remotely. They will save money if they can diagnose and fix problems offsite, avoiding expensive truck rolls. Additionally, payment processing must be convenient and secure. Above all, fast-charger stations must stay online during periods of operation.

Given these practicalities, fast chargers need top-tier connectivity.

Electric vehicle charging spots on Japanese highways.

A Level-3 DCFC typically connects to the Internet using one of several methods:

  1. Embedded solution – Here, integrated modules support Ethernet, Wi-Fi, or cellular connectivity. An embedded module connects directly without need for additional external devices. Remote monitoring, management, and firmware updates are automatic.

  2. Ethernet or Wi-Fi – Some Level-3 chargers have Ethernet ports or Wi-Fi capabilities for connecting to a local network or Wi-Fi hotspot. This may be a good option for chargers installed in locations with existing network infrastructure. It can also work well for temporary deployments with limited cellular coverage. However, this option may be less secure, more expensive, and difficult to scale. But Wi-Fi-enabled devices are great as a backup when Ethernet is the primary mode of connection.

  1. Cellular Router or SIM Card – Fast chargers can easily connect via cellular routers or SIM card slots, for a wireless data connection using 4G LTE. Cellular is flexible, reliable, and easy to operate independently of local networks. It also ensures connectivity in remote or temporary locations. Here, though, the type of router or SIM matters. Some developers deploy dual-SIM or eSIM capability for extra protection during network outages.

  2. Gateway Devices or Controllers – Some DC fast chargers may connect via gateway devices or intermediary controllers. These consolidate communication from multiple chargers and manage data exchange with external systems. Such gateway devices also simplify load balancing, energy management, and network security.

  3. Vendor-Specific Solutions: Level-3 chargers can also benefit from cloud-based platforms that streamline connectivity and remote management. These solutions typically include dedicated hardware, software, or web-based interfaces. For example: OptConnect provides a full array of Tier-1 hardware, connectivity plans, and management services that fit any use case.

    Ultimately, the right connectivity solution will simplify deployment for EV station owners and operators. That means faster time to market, improved revenue, and customer satisfaction at every stop along the journey.

4G LTE Wireless Technology

When choosing a cellular connectivity solution for your DC fast charger:

  • Consider your desired location and usage goals. Talking with a solution engineer is the best first step.
  • Understand the pros and cons of embedded modules or eSIM technology before you ask for these solutions.
  • Ask your cellular solution provider about the ease of regular maintenance, firmware updates, and remote monitoring.
  • Find out what level of support is needed for your particular connectivity solution.

Get your EV chargers connected - fast.

No matter how many level-3 chargers you plan to deploy, OptConnect can help connect them at scale.
Learn More

Benefits of Reliable Connectivity

While each type of connectivity has its merits, a cellular solution can offer additional benefits – particularly if it includes full management and monitoring that enables proactive maintenance and significantly reduces downtime for DC fast chargers. 

Fully managed connectivity can simplify remote diagnostics, firmware updates, load balancing, and other tasks. Other benefits include all-in-one billing, seamless support, and robust warranties.

Improved Uptime via Real-Time Monitoring

Real-time monitoring is critical for several reasons, such as:

  1. Proactive Maintenance: If you have a fleet of chargers, you need to spot potential issues before they escalate. And resolve them without sending a technician to fix the problem on site. Remote monitoring lets you do it all.
  2. Operational Efficiency: You already have to monitor metrics like energy usage and charging patterns. Cellular monitoring helps you also check usage, signal strength, and other connectivity metrics.
  3. Security: The right cellular solution works proactively to safeguard chargers and customer payments. Built-in sensors can further protect valuable equipment. You also receive alerts when events occur.
  4. Regulatory Compliance: Use real-time data to inform decisions, reduce operational downtime, run reports, and stay compliant.

Enhanced Customer Satisfaction via Seamless Service

Of course, a reliable connection extends beyond operational efficiency.

When EV drivers experience issues with a DC fast charger port, they look for immediate resolution. At least in terms of connectivity, a robust cellular solution provides instant troubleshooting and real-time updates to owners and operators. This helps mitigate frustration and allows customers to stay informed of any ongoing issues or expected resolutions.

Moreover, such transparency can improve trust and loyalty. The more uptime at the EV station, the greater its reputation and likelihood that customers will return. This level of service can significantly differentiate your business in a competitive market.

Reduced Operational Costs via Remote Maintenance

Here are two seemingly unrelated realities: Network outages will happen. It’s not “if,” but “when.” Secondly, truck rolls are expensive.
 
When your fast chargers go down, it’s not always convenient – or cheap –  to roll a truck, especially if it’s possible to re-establish a connection offsite. The right cellular solution makes it easy to check connectivity, perform proactive maintenance, re-boot a router, view usage and signal strength, install firmware updates, and do it all autonomously. 
 
As part of a fully managed plan, owners of EV chargers should also have 24 x 7 support when issues arise. Before committing to a cellular provider, ask about their tech support and customer service. An outage is not a good time to fill out a support ticket and wait. Live support is invaluable, both in terms of time and money.

Conclusion

Maybe you need to connect an urban charging station via both Wi-Fi and Ethernet or a remote, highway charging station with cellular solution. Or, you want a mixed-use scenario with integrated communication modules and gateway devices. Not every type of connectivity looks the same, which is all the more reason to discuss your project with an expert before deployment.

Many DC fast charger owner/operators are unsure about the merits and logistics of connectivity, which is why it’s possible to make mistakes. Remember, it costs nothing to talk with a solution engineer. Your future customers will thank you.

Simplify Cellular Deployment with OptConnect

Have a complex deployment ahead? Our cellular IoT experts can help. Contact us today.
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