DIY charging stations: the danger around the corner

I write this column as a representative of the international committees for standardization of which I am a member.

FYI – Christoph Erni, founder and CEO of Juice Technology AG, has been a member of the Swiss committee for IEC 61851 (stationary chargers) and IEC 62752 (portable chargers) since 2015. Since 2019 he has also been a member of the German associated committee and since 2017 of the international committee for the standardization of portable charging stations.

Recently, there has been a proliferation of reporting articles on the Internet instructions on how to build the charging stations yourself. These articles, as well as some technically inadequate finished products on the market, arouse some concern in us regulators. In countless hours of intense work sessions, specialists around the world strive to standardize the minimum requirements for making safe products. The charging infrastructure they should not endanger human lives: this is the top priority of the IEC 61851 (for fixed charging stations) and IEC 62752 (for mobile charging stations) committees. And it is even sadder to have to note that there are both kits and entire charging stations that do not care about the standards, simply do not meet the minimum requirements and, nevertheless, deceptively (not to say fraudulently) affix the CE mark.

Electric mobility is a great thing, but it involves one large amount of high power electricity. In order to ensure that the use of these devices is safe, there are many safety aspects to consider. It is no coincidence that the regulatory booklets for charging stations are over a centimeter thick. Products that fully meet all applicable standards and tests are authorized to affix the CE mark to devices under their own responsibility.

First of all, in the last point: unfortunately, even in the case of really complex products such as charging stations, the self-declaration is sufficient. Good manufacturers have their products tested and validated by neutral external institutes such as TÜV or VDE. But there are also charlatans that, for example, are limited to carrying out a test of the utility model, which does not guarantee compliance with the legislation, but only says that the product can be used for the designated purpose. There are even offers that deliberately refer to outdated standards or stations, the components of which are not even approved for wall charging stations.

There are also stations that are not dangerous, but they cheat on the price. Some of them do not include the mandatory parts and must be retrofitted, at great cost, by the electrician who installs them in the building’s distribution system. In addition, the cable is missing at many charging points. For the user, this means 300 euros more than the price of the charging station. It is a pity that even the automobile associations fall into these traps and then choose the wrong station as the winner. (And my judgment is neutral, as none of our stations were included in this test).

Finally, unfortunately there is no effective market surveillance. Both incomplete and dangerous kits as well as unauthorized charging stations are neither criticized nor withdrawn from the market. It is clear that our sector is still too young and that the authorities do not have sufficient knowledge. For the customer, this means finding dangerous (often cheap) products in-store right next to safe and elaborately developed stations. What will he choose, if he thinks everything is identical?

It is urgent to clarify. As representative of the standardization committeesI appeal to the media to explain to electric vehicle drivers where the cheap ends and where the dangerous begins.

For comparison, we have all heard of young people being electrocuted while playing in the bathtub with their cell phones charged. One of my colleagues on the standardization committee has shown that the standard dictates exactly how far the creepage distance must be in the charging parts and that, therefore, original equipment manufacturers produce safe devices. But low-cost producers, obviously with the CE mark, do not respect it and put young lives at risk.

It is unbearable to see that dangerous products can be sold here in Europe with impunity. Electric mobility is really taking off. We must have the courage to call the black sheep by name and to impose the withdrawal of products. Manufacturers who endanger their customers must be held accountable for their actions.

Last but not least: no, do not trust the 250 euro kits. You can’t get the components for a serious and future-proof charging station at that price.

This column is edited by Christoph Erni, founder and CEO of Juice Technology AG, a Swiss manufacturer of charging stations and solutions. He has always had a practical inclination, so much so that he left school shortly before his baccalaureate to take a business administration course at university, and then moved on to the IT sector soon after. But this was not enough for Christoph Erni: he wanted more! About 20 years ago he founded his own business consulting firm, Erni Associates AG.

In 2014, noticing the lack of suitable charging solutions, he decided to enter the manufacturing sector and founded Juice Technology AG. In its first year of operation, the company secured pole position in this segment with the 22 kW Juice Booster 1 portable charging station, and has remained there ever since.

Christoph Ernifounder and CEO of Juice Technology