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How Many Electricians Does It Take To Install The New Ford Lighting Level 2 Charger?

This was one of the first Ford EV PRO charger installs and some of the team members at Traditional Electric wanted to see it in action. So how many electricians does it take to install the new ford lighting level 2 PRO charger? The answer is 4 plus marketing to take pictures.

Here at Traditional Electric, we had the opportunity to Install the Ford level 2 PRO charger for one of the first Ford Lighting’s delivered in Canada. This particular installation was not your standard EV install, as the job had specific requirements. Nothing our electricians at Traditional Electrical couldn’t handle.

At our initial site inspection due to the layout of the house, it was not possible to access the garage directly from the electrical room. This job required us to install conduit (at the homeowner’s request) on the exterior of the building to the mechanical room access point.

Exterior Conduit Run

The main electrical panel was full and already had 2 subpanels installed that were also full. Our team needed to install a 3rd subpanel and several circuits needed to be relocated to the newly installed subpanel. this made room for the 2 pole breaker for the Ford EV Pro charger on the main subpanel.

The next complication this house presented required the installation of the Black Box Power management system. The addition of the Ford Charging Station PRO exceeded the house’s load calculation, even though the house already had 200 amp service. Traditional Electrics solution was to provide and install the Black Box power management system for this specific job. The Black box system provides the ability to install up to an 11.5KW or 48A charge rate electric vehicle charger on an existing electrical service that would otherwise cause overloading issues. No need for a service upgrade, and passes local municipality inspections.

Black Box Power Management System

If you are looking to get a quote for your EV installation, or have any questions contact us at 1-877-353-0367 or email us at info@traditionalelectric.ca. We are more then happy to help.

What is the difference between Level 1, Level 2 and Level 3 Charger?

Level 1

chargers are typically included with the purchase of an EV.  It plugs into a standard 120 (v) AC outlet with a power output of 1.3kW to 2.4 k.W.  This power outlet is equivalent to 3-4 KM of EV range per hour in ideal situations. This is the slowest charging rate outlet available. A 10 hour over night charge will add 30KM to 40KM of distance. A full charger for an empty EV battery can take over 24 hours using a level 1 charger.  

Level 2

Level 2 Charger: A Level 2 charger will operate between 208Volt -240 Volt. It is either hard wired or plugged in. There are a variety of different scenarios depending on your circuit breaker, and whether you use a plug or wall box. As each wall box from each car manufacture varies on power output this is just an approximate calculation and will vary based on your wall box. The Power output has been reduced to take into account impedance (the opposition to electrical flow) and length of wire.

  • 20 amp circuit breaker plug: Power output is on average 3.5kW
  • 20 amp circuit breaker wall charger: Power output is on average 4kW
  • 40 amp circuit breaker plug: Power output is on average 7kW.
  • 40 amp circuit breaker wall charger: Power output is 8kW
  • 50 amp circuit breaker plug: Power output is on average 9kW
  • 50 amp circuit breaker wall charger: Power output is 10kW
  • 60 amp circuit breaker wall box (can only be on a wall charger): Power output is 11.5kW

Some wall connectors like the tesla are directly wired, some wall connectors like Hyundai can be directly wired or plugged into a Nema 14 (stove plug) or Nema 6 (similar to stove plug but different connection points) receptacle

If you are using a wall chargers box you may not need a Nema Plug, it can be hardwired directly into the wall charger.

 A Level 2 charger will operate between 208Volt -240 Volt. This requires a Nema

You cannot rate a stove plug at a stove value. It cannot use stove wiring as it is not de-rated like a stove is. De-rated means that the amperage value expected on the wire is less then the maximum allowed amount.

Level 3

Level 3 Charger: Is 347 volts – 900 volts and uses Direct Current (DC), this is only practical for commercial use. You will find these at dealerships or dc fast charging stations. This is NOT a residential application. A Level 3 charger is typically not possible because the amount of utility work and installation required for a residential location could cost upwards to a million dollars.

Why upgrade your Level 1 Electric Vehicle Charger

Currently most EV cars come with an adaptor that your can plug into a charging unit that plugs into any standard 120 volt outlet. However, if you look at the charging rate for a 120 Volt outlet it will charge your Electric Vehicle VERY slowly.

A Level 1 charger that plugs into a dedicated standard housing plug can deliver at most 12 amps. This means it will delivery approximately 30-40 km for a 10-hour charge. This may sound like a lot of Kilometers, but if you start factoring dropping the kids off at school, driving to work, running out to grab lunch, picking up the kids from school and driving them their various afterschool activities pretty soon that one charge a night on the level 1 charger is not going to cut it. This does not even take into consideration what a cold Canadian winter day does to driving distances. At a outside temperature of -15 degrees Celsius the range of your vehicle is reduced by 50%. A overnight 10 hour charge on the level 1 charger may not provide enough range for your day to day activities. If you live out of town and commute into work the level 1 charger may not even be a feasible option.

There was one dealership that sold an electric vehicle to a customer that lived out in a rural community and commuted 128 Kilometers to the city at least 3 times a week. Unfortunately the dealership did not know the details around the vehicle use and the standard level 1 overnight 10 hour charge did not meet this customers driving requirements.

In Canada it is highly recommended to upgrade to a level 2 charger. A Level 2 charger will give you between 220KM -660 KM for a 10 hour over night charge. this is a significant increase from the Level 1 charger with a 30-40KM Range for a 10 hour charge. A Level 2 charger allows you to drive further on less charge time. The variables in the charge rate is dependent on the amperage in your electric vehicle charger circuit as detailed in the above graph.