The results
By refurbishing existing DC chargers, extending the life of current assets.
The Challenge:
Outdated EV charging infrastructure
Our customer’s outdated charging system struggled to keep pace with the demands of their growing EV fleet. The charger set up presented several key challenges:
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Unmanaged chargers & phase imbalance:
Operating in "dumb mode", the chargers lacked central control, causing uneven power distribution (phase imbalance) and inefficiency. -
Limited power & manual control:
Despite a substantial 600A building supply, the EV charging was restricted to 200A, managed by a manual switch system, limiting the number of simultaneous charging sessions. -
Overnight tripping & delivery delays:
Frequent overnight power trips resulted in uncharged vehicles, causing delivery delays and impacting customer satisfaction.
This outdated system created a significant bottleneck, hindering their ability to efficiently manage their EV fleet and maximise their return on investment.
The Tap Electric & Charge-M8 solution:
Smart, integrated, and efficient
Tap Electric provided the intelligent software, and Charge-M8 delivered the robust hardware and expert installation, going beyond just supplying equipment to optimise the entire charging infrastructure.
Charge-M8 overhauled their EV charging infrastructure:
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Upgraded chargers:
Refurbished existing DC chargers and installed new, smart AC chargers, ensuring a modern, efficient, and reliable charging setup. -
Intelligent power management:
Installed a Libra dynamic load balancing device, enabling optimisation between charging demand and building load. The device is integrated out of the box with the Tap platform for simple onboarding. -
Expanded charging capacity
Added a third EV charging circuit and upgraded the electrical infrastructure to double the charging capacity, accommodating future growth.
Technical deep dive with Charge-M8: The installation and hardware changes
For installers and technical professionals, here’s a closer look at the key hardware and installation changes:
Dynamic Load Balancing with Libra DLB:
- Installation of the Charge-M8 Libra DLB unit to manage the 600A parallel incomer.
- Implementation of 110mm Rogowski coils and integrators for precise load measurement.
- Dynamic load management across a mix of AC and DC chargers from different brands.
Zoned charging and circuit upgrades:
- Addition of a third EV charging circuit, creating three distinct charging zones.
- Installation of dedicated distribution boards for each zone.
- Management of each zone at 100A, 125A, and 160A by Tap Electric DLM, effectively doubling the previous static load management capacity.
Charger upgrades and connectivity:
- Firmware updates and 3G communication enablement for existing Delta Electronics DC Wallbox 25kW chargers.
- Replacement of 11 outdated single-phase AC chargers with 8 Charge-M8 Delta 22kW AC units, equipped with 4G communication for remote management and monitoring.
- Configuration of all chargers to online PnC mode for user simplicity.
Tap Electric provided advanced, reliable energy management software:
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Prevented overloads:
Provided dynamic load balancing and zoned charging to ensure the system operates safely and reliably, preventing costly downtime. -
Maximised uptime:
Optimised energy distribution to keep chargers running smoothly, minimising disruptions and maximising productivity. -
Simplified operations:
User-friendly platform for charger management and monitoring. -
Data-driven insights:
Provided tools for tracking energy usage and generating reports, enabling informed decision-making and cost optimisation.
The results:
Enhanced efficiency and streamlined operations
The impact of the Tap Electric and Charge-M8 solution was immediate and significant:
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Eliminated downtime:
Overnight tripping was completely eradicated, ensuring vehicles are always charged and ready for delivery. -
Improved customer satisfaction:
On-time deliveries, powered by reliable charging, enhanced customer satisfaction and brand reputation. -
Reduced costs:
Significant savings were achieved through reduced energy consumption, lower platform fees, and the elimination of penalty charges.
Ready to power up your EV charging?
Why choose the Tap x Charge-M8 Libra device solution?
Integration
Seamlessly integrates with existing and new charging infrastructure, out of the box.
Robust yet simple
Manage complex balancing requirements with a few clicks and full automation.
Cost-effective
Significant cost savings and long-term value.
Customer support
High quality local technical support for both the hardware and software.
Ready to power up your EV charging?
