EV Chargers Targeted: Why Repair Costs Skyrocket

EV Chargers Targeted: Why Repair Costs Skyrocket

Electric vehicle charging stations are becoming a tempting target for thieves, and a recent incident highlights a frustrating problem: repairing them can be incredibly expensive. For Lionus Media Group, a simple act of vandalism turned into a costly lesson about EV charger design and repair policies. When thieves cut the charging cables from their free employee EV chargers, the cost of replacement was eye-watering, forcing a rethink of their entire charging setup.

The damage occurred about a week before the video was filmed. While police offered moral support, the financial burden of the repairs fell squarely on Lionus Media Group. The initial thought was to simply replace the damaged cables, a task that seems straightforward given the basic design of many Level 2 chargers. A typical charger connects to a 240-volt power source, sending electricity through internal electronics that communicate with the EV. This communication activates a switch, called a contactor, which then allows power to flow to the car.

The thieves were able to cut the copper cables without being electrocuted because the power flow is only active when an EV is plugged in and communicating. Logically, replacing a damaged cable and charging gun should be a simple DIY job for many tech enthusiasts. However, when Lionus contacted Grizzl-E, the manufacturer of their chargers, they were met with a steep price tag and inconvenient process. The company quoted $200 Canadian for a replacement cable and charging gun, plus the cost of labor. To get this part, the entire hardwired charger would need to be detached and sent in at the owner’s expense.

This repair policy is a stark contrast to how some other manufacturers operate. While Grizzl-E used to offer user-installable replacement parts, they no longer do. Other companies and third-party sellers still offer standard replacement charging guns, like the J1772 connector, which are necessary to qualify for certain government rebate programs. However, these parts alone still cost around $200. This means that even if an end-user could perform the repair themselves, the savings would only be on labor and shipping, assuming their time is valued at zero.

Sourcing the specific four-core EV charging cable needed for these units also proved difficult. Local electrician supply stores were unable to help, directing Lionus back to the charger manufacturer. This lack of readily available parts and the manufacturer’s repair policy made fixing the damaged chargers nearly half the cost of buying new ones, especially when considering government rebates that often make new equipment more affordable. Ultimately, the decision was made to replace all the damaged chargers.

A New Charger, A New Network

Fortunately, there was a silver lining. Lionus Media Group had initially considered Ubiquiti’s UniFi EV Station Light chargers but they weren’t eligible for the local rebate program at the time. Now, they are. These Ubiquiti chargers cost about $700, a bit more than the previous Grizzl-E units. However, Ubiquiti provided all the necessary replacement parts, even covering the cost, and they integrate seamlessly into Lionus’s existing UniFi network infrastructure. This integration offers a significant advantage for managing access to the chargers.

The previous Grizzl-E chargers had a clunky scheduling system that relied on the Charge Lab app. To prevent unauthorized use on weekends, the only option was to set a very short, random charging window in the early morning, as the system couldn’t be turned off completely. The new Ubiquiti chargers, however, allow users to simply tap their access card to initiate charging. This method keeps the chargers accessible to employees while preventing neighbors or others from using them without authorization.

Beyond the improved access control, the Ubiquiti chargers offer a higher stock power output, 10 amps more than the Grizzl-E models. This translates to potentially 20% faster charging speeds, assuming the electrical breakers can support the higher amperage. While the installation itself is relatively simple, Lionus brought in professional contractors for the wiring and setup.

Upgrading More Than Just Charging Stations

In total, Ubiquiti sent seven UniFi EV Station Light chargers, allowing Lionus to replace all six of their damaged Grizzl-E units. Even the two chargers that weren’t damaged by thieves were swapped out to standardize the charging infrastructure. They also decided to keep an existing Tesla charger that came with the building, leaving them with one extra Ubiquiti charger. This upgrade also addressed a bottleneck at the studio building, where an older Siemens charger was causing charging delays.

The installation of the new Ubiquiti chargers went smoothly, a testament to their user-friendly design. Despite the initial setback caused by the copper thieves, the incident ultimately led to a more integrated, efficient, and secure EV charging solution for Lionus Media Group.

Specs & Key Features

• Ubiquiti UniFi EV Station Light:
• Price: ~$700
• Integration: Seamless with UniFi network
• Access Control: RFID tap-to-charge
• Power Output: Higher amperage than previous Grizzl-E models (potential for 20% faster charging)
• Rebate Eligibility: Covered under BC’s rebate program
• Grizzl-E Chargers (Previous):
• Replacement Cost (Cable + Gun): ~$200 CAD + labor
• Repair Process: Requires sending entire unit back to manufacturer
• Scheduling System: Clunky, relied on Charge Lab app

Who should care? EV owners, building managers, and anyone interested in the practicalities of EV infrastructure. This story is a wake-up call for the repairability and security of public and private EV charging stations. The high cost of repairs and the manufacturer’s policies can make vandalism a financially crippling event.

Availability: The Ubiquiti UniFi EV Station Light is available now. Pricing and availability of replacement parts for other brands may vary.

Source: Copper Thieves Stole Our EV Charging Cables (YouTube)