Electrify America Tackles EV Charger Downtime
As electric vehicle (EV) adoption grows, so does the reliance on charging infrastructure to power the future of mobility. But with this evolution comes a real and pressing challenge: charging anxiety. While range anxiety—the fear of running out of charge before reaching a destination—has been well-documented, another anxiety looms large: arriving at a charging station only to find it non-functional. It’s a frustrating issue that has snowballed over the years as older hardware in existing networks starts to show signs of wear. Electrify America, one of the largest EV charging networks in the U.S., is actively addressing these challenges with an extensive overhaul of its charging infrastructure.
The Problem: Aging Hardware and Increased Demand
Charging infrastructure installed years ago was sufficient for the fewer number of EVs on the road at the time. However, the surge in electric vehicle adoption has significantly increased demand, pushing the limits of these older chargers. Electrify America noted in a report to the California Air Resources Board (CARB) that their legacy hardware is now being used to charge the same number of vehicles in one week as it once did in an entire year. This increased usage has led to more frequent breakdowns, requiring more maintenance dispatches. As a result, Electrify America has acknowledged the growing need to replace aging hardware and improve reliability across the board.
To address this, Electrify America made the decision to pause the rollout of new stations in certain regions, such as California, during the second quarter of 2024. Instead, they’ve focused on upgrading existing stations with next-generation chargers. This decision highlights their recognition that maintaining and improving the current infrastructure is as critical as expanding it.
Next-Generation Chargers: A Step Toward Greater Reliability
The new generation of Electrify America chargers is designed to solve many of the issues plaguing older models. These chargers feature a more compact design and have an 80% reduction in the need for on-site maintenance, a crucial improvement for ensuring uptime and minimizing user frustration. With up to 350 kW of charging power, these chargers can quickly fill an EV’s battery, reducing wait times at stations.
The new chargers also come with significant usability upgrades. For instance, a liquid-cooled connector cable with a cable management system ensures that the charger can reach any part of an EV, regardless of how it’s parked. Additionally, a brighter 15-inch display is less susceptible to glare, making it easier for users to interact with the station even in direct sunlight.
Expanding Plug&Charge Technology
Another key development in Electrify America’s network is the increasing adoption of Plug&Charge technology. In California alone, over 20% of charging sessions in 2024 were initiated via this feature, which allows EVs to automatically start charging when plugged in, without the need for a card or app-based activation. The simplicity and convenience of Plug&Charge make it an ideal solution for streamlining the charging experience. However, this technology is still playing catch-up across the industry, and more widespread adoption is needed to make it the norm.
While card reader usage is dwindling (only 9.09% of charging sessions in California were initiated using a card), the push toward Plug&Charge indicates a future where charging sessions are as seamless as pumping gas, if not more so.
The Tesla NACS and the Future of Charging Standards
In a major move for the industry, Electrify America has announced plans to introduce Tesla’s North American Charging Standard (NACS) to its network. With the NACS J3400 connector expected to be available by 2025, this development will allow more EVs, especially those from Tesla, to access Electrify America’s growing network. This is a significant step toward creating a more unified charging ecosystem, as Tesla’s charging infrastructure has long been praised for its reliability and ease of use.
Innovative Solutions for Challenging Locations
Building new charging stations isn’t always a straightforward process, especially in states like California where Electrify America reports that the cost of building a station is 26% higher than in other regions. Permitting delays and utility site energization are two of the main culprits, leading to slower station rollout.
To overcome these challenges, Electrify America has introduced off-grid solar-powered chargers. Developed by Beam Global, these Level 2 chargers are powered by 4.28-kW solar arrays and feature a small battery energy storage system (BESS) that holds 32 kWh of power. Located primarily in California’s Central Valley, these chargers are independent of the electrical grid, offering a reliable alternative in areas where grid-based chargers may face issues. While slower than traditional fast chargers, these solar-powered stations offer an eco-friendly solution to areas underserved by the grid.
Future Expansion and New Charging Hubs
In addition to upgrading older chargers and introducing off-grid solutions, Electrify America is also focusing on building larger charging hubs. Earlier in 2024, the company opened its first indoor charging hub in San Francisco. This state-of-the-art facility features 20 hyper-fast 350-kW chargers in a climate-controlled environment, providing a reliable and comfortable charging experience for EV owners. The hub is staffed, which ensures that any technical issues are addressed promptly, further improving the reliability of the station. While this is currently the only station of its kind, it serves as a model for future charging hubs in cities where space is at a premium and weather conditions may impact outdoor charging stations.
Electrify America is also in the process of adding new stations across California. While the high costs and delays mean that station growth is slower than anticipated, the focus remains on increasing the number of chargers at existing stations to accommodate the growing volume of EVs.
Lessons for the Future
The evolution of Electrify America’s charging network highlights an important lesson for the EV industry: building a reliable and future-proof charging infrastructure requires ongoing investment and innovation. Charging stations, much like any other piece of technology, can’t be expected to operate flawlessly for decades without upgrades. By recognizing this reality and taking steps to upgrade legacy hardware, improve charging reliability, and introduce new technologies like Plug&Charge and NACS, Electrify America is positioning itself to meet the needs of an expanding EV market.
As EV adoption continues to rise, the importance of reliable charging infrastructure cannot be overstated. Electrify America’s commitment to addressing the challenges of aging hardware and improving the charging experience is a crucial step toward building a more sustainable and user-friendly EV ecosystem.
