I considered putting this in the vroom forum but there's so many EV threads it could get lost in I thought it better here. Besides, it applies to all high load appliances not just EVs.
Chatting in the pub with a mate who is an electrician we somehow got onto cable sizes for showers & car chargers. Possible I mentioned how annoyingly difficult it would be to upgrade the cable to my shower (10mm²) leaving me stuck with 8.5kW, aka pissy landlord spec. As we chewed the fat on that he mentioned there'd been an article in the trade rag he gets about the cost of the electrical losses in cables where the installer fits the minimum size cable fit for the job, that can be as little as 4mm² for an EV. He'd been surprised how fast the payback on bigger cables was. Losses in cables (and the cost of) have always been known about wrt showers & immersions of course but now that we have high load car chargers running for hours and hours and electricity prices at record levels it is even more pertinent. Said rag was still on his van so he lent it to me.
The upshot of the article is if we have
- 32A car charger (7.3kW)
- running 4.5 hours a day 5 days a week
- 10m installed cable length
- 35p per kWh electricity cost
Then for these cable sizes the cost per year in energy lost in the cable is:
- 4mm² - £37.18
- 6mm² - £24.84
- 10mm² - £14.76
So by asking your fitter to use 6mm² cable instead of 4mm you save £12.34 per year. The article then compares the cost of those cables and the payback time is just under a year. I knew there would be a break even time but I did not expect it to be that fast. If you request 10mm² instead of 4 you save £22.42 per year and the installation payback is 1.64 years.
What the article doesn't do is put that weekly charge duration into any real world context, how far would you be driving per week for that surprisingly fast payback rate to apply? In the example above we are putting 32A * 230V * 4.5h * 5d / 1000 = 165.6kWh per week into the car. Charging losses in the car
can be as much as 13% so we get 144kWh of usable power in the car's battery. Use your own miles per kWh to calculate how far you'd have to drive.
The loss costs above do work out pro rata on meters cable length so if you'd need a 12 meter cable just multiply the loss costs by 1.2. The payback time will not change .
The article is online here
https://professional-electrician.com/magazines/november-2023/ - page 55.
For my Leaf which seems to be averaging out around 4.5 miles per kWh year round (~4.1-4.2 now, was ~4.8-4.9 in the summer) 144kWh used is 648 miles. I don't do that a month in my EV but that's partly because I have a dino burner for the long distance stuff and tip runs. My payback would be closer to a decade. However, I would ask for 10mm² or even 16mm² ignoring the up front cost. Why? Not because my usage pattern could increase in future shortening the payback rate. It's more because 7.2kW is state of the art in home chargers today but what if 10kW home charging becomes available tomorrow? Or 15kW? That's not an outrageous possibility, showers have increased in capacity over time and now max out at 10.3kW. If better home chargers become available in the future getting the cable changed will cost one hell of a lot more than the cost differential of the cable today.