EV Infrastructure

EV Charging Station
Power Infrastructure

Complete electrical systems for AC and DC fast-charging networks — from MV transformer to charger distribution, engineered for high-utilization, harmonic-rich loads.

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EV Charging Solutions

Scalable power infrastructure for Level 2 AC chargers through ultra-fast 350 kW DC stations.

Dry-Type Transformers

Low-noise cast-resin transformers with K-factor harmonic derating, ideal for urban and indoor charging installations. Available 500–2,500 kVA in SCB13/SCB14 efficiency grades.

500–2,500 kVAK-4 to K-13<55 dB(A)Class H Insulation

LV Switchgear

Main distribution boards with MCCB feeders for charger circuits, surge protection, and energy metering. Modular design for easy expansion as charging demand grows.

Up to 4000A BusMCCB FeedersSurge ProtectionModular Design

Harmonic Filters

Active and passive harmonic filters to mitigate THD from power electronics in EV chargers. Ensures compliance with IEEE 519 power quality standards at the point of common coupling.

THD <5%Active & PassiveIEEE 519Modular Racks

PFC Capacitor Banks

Automatic power factor correction systems to maintain PF >0.95, reducing utility penalties and freeing up transformer capacity for additional chargers.

PF >0.95Automatic ControlDetuned ReactorsVentilated Enclosure

Compact Substations

Complete EV charging substation in a single weatherproof enclosure: transformer, LV switchgear, harmonic filter, PFC, and metering. Pre-tested and ready for rapid on-site deployment.

Turnkey PackageSound AttenuatedWeatherproofType Tested

Battery Storage Integration

Optional BESS integration for peak shaving and grid buffering. Reduces demand charges and enables off-grid or weak-grid charging station deployment.

Peak ShavingDemand ReductionOff-Grid ReadyContainerized

Station Types We Power

From highway corridor ultra-fast hubs to urban destination charging, each station type has unique electrical requirements.

Highway Fast-Charging Hubs

Chargers4–20× DC Fast Chargers
Site Load1–5 MW Site Load

1,500–2,500 kVA oil-immersed transformer + LV switchgear + harmonic filtering. Compact substation with future expansion bays.

Urban Destination Charging

Chargers10–50× AC Level 2 + 2–4× DC
Site Load500 kW–1.5 MW Site Load

Low-noise (<50 dB) dry-type transformer for indoor/parking garage installation. Modular LV boards for phased deployment.

Fleet Charging Depots

Chargers20–100× Mixed AC/DC
Site Load2–10 MW Site Load

Multiple transformers with load-sharing, BESS integration for peak shaving, and advanced energy management for overnight fleet charging schedules.

Shopping Mall & Retail

Chargers6–20× AC + 2–4× DC
Site Load500 kW–1 MW

Compact dry-type transformer + LV distribution with load management. Sound-attenuated enclosure for customer comfort.

Workplace & Office Parks

Chargers10–30× AC Level 2
Site Load200–500 kW

Modular LV-fed distribution with smart load balancing. Future-proofed for DC fast charger addition.

Truck & Bus Depots

Chargers4–20× High-Power DC
Site Load2–8 MW

Dedicated MV supply + multiple transformers + BESS for demand charge management. Rugged outdoor design for industrial environments.

EV Transformer Design Factors

Key engineering considerations when specifying transformers for electric vehicle charging applications.

Harmonic Mitigation

EV chargers (especially older DC fast chargers) inject harmonics into the supply. K-rated transformers (K-4, K-7, K-13) are designed to handle these harmonic currents without overheating. K-factor selection depends on charger type and quantity.

Diversity Factor

Not all chargers operate at full load simultaneously. A realistic diversity factor (0.5–0.8) reduces transformer kVA requirements significantly versus simple sum-of-chargers sizing. Fleet data shows typical 30–50% coincident load.

Load Cycling

Charging stations see rapid load changes as vehicles connect/disconnect. Transformer mechanical design must withstand thermal cycling and electrodynamic forces from frequent inrush events without insulation degradation.

Noise Constraints

Urban and residential charging sites require low-noise transformers. Dry-type cast-resin designs achieve <50 dB(A), making them suitable for parking garages, shopping malls, and mixed-use developments.

Future-Proofing

Charger power ratings are increasing (150 kW → 350 kW → 1 MW MCS). Specifying transformers with spare capacity and LV boards with empty breaker slots enables economical future expansion without rework.

Energy Metering

Sub-metering at charger circuit level enables billing, usage analytics, and demand response participation. Smart LV switchgear with integrated metering and Modbus/OCPP communication simplifies energy management.

Frequently Asked Questions

What is the difference between K-4 and K-13 transformers for EV charging?+
K-4 transformers handle moderate harmonics (typical with modern IGBT-based chargers), while K-13 handles higher harmonic content from older SCR-based chargers or mixed charger types. Most modern DC fast-charging stations with active front-end chargers are adequately served by K-4 rated transformers.
Do I need a separate transformer for EV chargers?+
For commercial charging stations, a dedicated transformer is strongly recommended. EV charging loads are non-linear and can cause power quality issues for other building loads. A dedicated transformer isolates harmonics and allows proper K-factor specification for the charging load profile.
How long does installation of an EV charging substation take?+
With Ziyao compact substations, site preparation takes 2–4 weeks (foundation slab, MV cable trenching), and the substation itself can be installed and commissioned in 3–5 days. Traditional stick-built installations typically require 8–12 weeks on site.
Can you integrate battery storage with the charging substation?+
Yes. We offer containerized BESS options (200 kWh–2 MWh) integrated with the substation LV switchgear for peak shaving, demand charge reduction, and grid buffering. This is particularly valuable for sites with limited grid capacity or high demand charges.

Power Your EV Charging Network

Tell us about your charging station plans — number of chargers, power levels, and site location — and receive a complete electrical infrastructure proposal.

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