EV Pro, a solar-fed 80 amp home electric vehicle charger

Off the roof

The array feeds the charger directly.

Panels make DC. Batteries take DC. A normal setup converts to AC at the inverter, sends it to the wall, then converts it back inside the car. EV Pro skips that round trip and wires the array to the charger on the DC side.

Round trip loss avoided
14%
Array input
12 kW

Current

80 amps continuous, on the same wall.

Most home units stop at 48 amps because their contactors cook above it. The switching here is solid state and liquid cooled, so it holds 80 all night without derating. A 75 kWh pack goes from 10 to 80 percent in about two and a half hours.

Output
19.2 kW
Continuous
80 A

Safety

It cuts power before you would notice.

Three thermal probes watch the connector head, the busbar and the contactor. If any of them climbs faster than the model expects, or if leakage current crosses 6 mA, the unit opens the circuit in 18 milliseconds and tells you which sensor tripped.

Trip time
18 ms
Leakage threshold
6 mA DC

Inside the housing

Sixty four parts, four of them ours.

Scroll to pull the unit apart. Four of the pieces inside are what make 80 amps survivable: the cold plate, the solid state contactor, the sensor spine, and the DC input busbar.

The EV Pro charger shown disassembled, with the glass fascia, fin stack, copper busbar, contactor, sensor board and liquid cold plate laid out in a row.

Loading the teardown…

Smoked glass fascia Chemically strengthened and bonded straight to the shell, so there is no gasket to perish.
Fin stack Where the heat finally goes. Sized for 80 amps in still air, with no fan to fail.
DC input busbar Solid copper. Takes the array feed straight in, so the inverter never sees this power.
Solid state contactor No moving armature, so there is nothing to weld shut. It opens in 18 milliseconds.
Sensor spine The busbar and contactor probes and the leakage detector share one board, polled at 1 kHz.
Liquid cold plate Bolted to the rear shell on three copper studs. This is why 80 amps never derates.
Specifications
Continuous output19.2 kW240 V at 80 A, single phase
Solar input12 kW DCDirect from the array, no inverter stage
Fault response18 msThermal runaway or 6 mA DC leakage
Cable7.6 m braidedRated to 80 A, cooled at the head
EnclosureIP66Anodised aluminium, no exposed fasteners

Charge on the sun you already own.

First units ship in spring. Leave an address and we will send the install survey a month before yours is built.

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See what is inside