This is how one cable can redefine the future of EV charging infrastructure

One significant obstacle is the lack of harmonisation and standardisation between different countries and markets. This forces EV charger manufacturers’ engineers to spend time on market-specific product adjustments that don’t improve the customer experience instead of focusing on what truly matters – enhancing all aspects of the EV ecosystem. In many instances, these inconsistencies are unnecessary and simply a result of outdated legacy practices.

Despite these challenges, we’ve observed that single cable installations are pivotal in creating flexible and future-ready EV charging solutions.

Traditionally, EV chargers have been installed using individual cable installations, where each charging point requires a dedicated cable running directly from the distribution board. This method was once necessary because older chargers lacked integrated circuit breakers and a reliable communication system – that is until Zaptec Pro revolutionised the market. While the multi-cable approach has been necessary, it poses several challenges as the demand for EV charging grows:

• Cost: Running individual cables for each charger significantly increases material use and labour costs, making large-scale installations incredibly time-consuming and difficult to price accurately.

• Complexity: Managing multiple cable runs for every charger introduces layers of complexity to both installation and future maintenance. Greater complexity also increases the likelihood of potential faults over time.

• Scalability: Expanding charging points using traditional methods often requires significant rewiring, which makes adapting to growing EV demand costly and complicated.

As EV infrastructure grows in size and complexity, it's clear that this traditional approach is no longer the optimal solution. A streamlined and flexible approach is essential to meet the rising demand for EV charging.

This is where single cable installations come in. Instead of running a dedicated cable for every charger, a single cable – whether round or flat – connects multiple charging points along one main power line. This method significantly reduces the amount of material required and simplifies the installation process.

Furthermore, Zaptec Pro chargers, which include built-in circuit breakers and multiple reliable communication options (such as 4G, WiFi, and PLC), make this an exceptionally reliable way to plan and execute complex charging projects.

Round cables are perfect for installations with predetermined layouts. Multiple charging points are connected along a single round cable, reducing the amount of wiring needed compared to individual cables. However, all connection points must be installed upfront, which can make the project more complex if EV adoption among users doesn’t meet the expected growth.

For maximum flexibility, flat cable installations are the ideal solution. Flat cables allow installers to tap into the cable at any point along its length, meaning chargers can be placed wherever they’re needed. This approach works particularly well for large or irregularly shaped parking areas and projects anticipating future expansion.

Historically, the cost of flat cables and their connection modules has been higher than that of round cables. However, the price difference has decreased as the technology has advanced.

The switch to single cable installations offers several clear advantages over traditional individual cable runs. Since we are still in the early stages of this technological shift, costs are likely to decrease as the market matures. The decision comes down to whether labour costs in your region are relatively higher than material costs. However, this dynamic will continue to evolve in the coming years.

• Cost savings: Using a single cable for multiple charging points can reduce cabling costs by up to 70% and labour costs by up to 60%, especially in large-scale installations (these figures are based on a UK case study where single round cables were used compared to the traditional method).

• Simplified installation: Fewer cables mean a faster, simpler installation process, reducing disruption to existing infrastructure and making installations quicker to complete.

• Enhanced scalability: Adding new charging points is much easier with a single cable installation. In particular, flat cable installations offer maximum flexibility, making future expansions both less labour-intensive and simpler.

We’ve designed Zaptec Pro to fully optimise the potential of single cable installations, offering several key features that set it apart from other chargers on the market:

• Built-in circuit breaker and type B RCD: One feature that makes Zaptec Pro extremely flexible is its built-in circuit breaker and type B RCD. This eliminates the need for external fuse boxes, which are typically required in other charging systems. By integrating this into the charger itself, we simplify the installation process, reduce costs, and make the entire system safer and more reliable.

• Integrated communication: Zaptec Pro’s built-in communication system manages all communication between chargers via 4G, WiFi, or PLC. This feature eliminates the need for additional communication cables, further streamlining the installation process and ensuring the system remains clean, efficient, and easy to manage.

Single cable installations, combined with Zaptec Pro, provide real-world benefits across a variety of scenarios:

• Apartment complexes: In shared residential parking areas, a single power circuit can support multiple chargers, efficiently managing charging for residents with varying arrival times and needs while keeping costs down.

• Workplaces: As more employers provide charging infrastructure for employees, single cable installations allow for easy scalability. This ensures that as EV adoption increases, additional charging points can be added without significant rewiring or disruptions.

• Destination charging: In cases where the number of future chargers is uncertain, single cable installations provide a flexible solution. Offering EV charging as an incentive to attract more visitors, such as at shopping centres or hotels, is made easier with a scalable single cable system.

As the EV revolution continues, building scalable, flexible, and cost-effective charging infrastructure will be essential to meet the growing demand. Single cable installations offer the best of both worlds: efficiency today and flexibility tomorrow.

At Zaptec, we’re proud to lead this change.