XCharge’s Integrated DC Fast Charger Departs Fort Collins

End of an Era: Out of Spec Reviews Relocates and Replaces XCharge DC Fast Charger

The automotive world is constantly evolving, and sometimes that means saying goodbye to familiar technology as we embrace the new. In a significant transition for the Out of Spec Reviews team, their long-serving XCharge NetZero Series battery-integrated DC fast charger, a fixture at their Colorado office, is being relocated. This isn’t a story of failure, but rather one of progress and strategic movement as the team shifts its operations to the East Coast.

For an extended period, the XCharge unit served as a vital DC fast charging resource at The Powerhouse in Fort Collins. While it performed admirably, the Out of Spec Reviews team’s relocation to North Carolina necessitates the charger’s removal. However, the departure isn’t leaving a void. A new, more appropriate charging solution is being installed to ensure continued DC charging availability for the community.

The XCharge NetZero Series: A Closer Look

The XCharge NetZero Series unit was more than just a charger; it was an integrated system featuring a 230 kWh battery pack. This design allowed it to operate effectively even with a less robust grid connection. While the building’s 480-volt system provided approximately 30 kW of power to charge the internal battery, the unit could then output around 180 kW (with 400-450 amp cables in boost mode) for vehicle charging. This approach was ingenious, enabling high-speed DC charging where a direct high-power grid connection might have been prohibitively expensive or complex.

During its tenure, the XCharge unit dispensed an impressive 89,885 kWh of energy over 2,583 charging sessions. The average charging duration was approximately 37.23 minutes, delivering an average of 35 kWh per session. Interestingly, data revealed a strong preference for the CCS port, which accounted for 68.3% of all charging sessions and 74% of the total energy dispensed, compared to the NACS (Tesla) port.

A New Chapter with Autel

As the XCharge unit makes its journey east, The Powerhouse will welcome a new charging solution: the Autel MaxiCharger DC Mini. This 40 kW DC fast charger, affectionately nicknamed ‘Kevin,’ is considered a perfect fit for an office building environment where vehicles typically dwell for extended periods. While not as powerful as the XCharge, its 40 kW output is significantly more than a Level 2 charger and is ideal for topping up vehicles without requiring users to rush.

The transition also involves replacing the outgoing XCharge with a more suitable solution for the facility. The Autel MaxiCharger DC Mini, a 40 kW unit, has been chosen. This charger, known for its robustness and previously used by Out of Spec Reviews in mobile generator setups, will provide a reliable DC charging option for the community. The choice of a 40 kW unit is strategic, balancing charging speed with the typical dwell time at an office building, ensuring a full charge is achievable without the rush associated with higher-powered chargers.

Community Impact and Future Plans

The XCharge unit was not just a piece of equipment; it was a community resource. While its primary use was intended for the office, it often served local EV drivers. The new Autel charger, provided to CSU (Colorado State University), will continue this legacy. While initially planned for closed-access charging, CSU has expressed interest in making it available to the wider community once their systems are sorted.

The relocation of the XCharge unit is part of a larger strategy for Out of Spec Reviews. The team has ambitious plans for the charger on the East Coast, hinting at future projects and educational content that will further explore the capabilities of integrated battery storage and DC fast charging technology. Details remain under wraps, but the prospect of seeing this unit in new, exciting applications is a testament to its enduring capabilities.

The Transition Process

The dismantling process, handled by the expert team from Windmaran, showcased the robust engineering of the XCharge. Even after extensive use, the AC-to-DC and DC-to-DC power modules remained in excellent condition. The careful disconnection of capacitors and other components ensured a safe removal of the unit. The sheer scale of the 230 kWh battery pack, weighing significantly, required specialized equipment like a forklift for its transport, highlighting the logistical challenges of moving such substantial EV infrastructure.

The data gathered from the XCharge’s operation offers valuable insights into real-world charging habits and the current landscape of EV adoption. The strong preference for CCS over NACS, despite the growing adoption of the latter, underscores the current market dynamics. As the industry continues its rapid expansion, such data becomes increasingly crucial for network planning and infrastructure development.

The move signifies not just a change of scenery but a forward-looking step for Out of Spec Reviews, leveraging their experience with cutting-edge EV technology to create more engaging and informative content for their audience. The XCharge may be leaving Colorado, but its journey is far from over, promising more insights and adventures in the world of electric vehicles.

Source: Removing My XCharge Battery-Integrated DC Fast Charger! Data Analysis, Removal Process & What's Next (YouTube)