EV Charger Installation Guide (2026) | PES Supply

EV Charger Installation Guide (2026)

Complete guide to Level 2 EV charger installation, sizing, and wiring

EV Charger Levels Explained

Level Voltage Amperage Charging Speed Range/Hour
Level 1 (120V) 120V 12-16A 1.4-1.9 kW 3-5 miles
Level 2 (240V) 240V 16-80A 3.8-19.2 kW 12-60 miles
Level 3 (DC Fast) 480V 100A+ 50-350 kW 100-300+ miles

Level 2 Charger Sizing

Most homes have a 200A service. To determine what amperage EV charger you can support:

Available capacity = Service amps - Existing load - 25% safety margin

Example: 200A - 120A (existing) = 80A available. At 80%: 64A charger max.

Charger Amps Power Wire Size Breaker
16A Level 2 16A 3.8 kW 12 AWG 20A
32A Level 2 32A 7.7 kW 8 AWG 40A
40A Level 2 40A 9.6 kW 8 AWG 50A
48A Level 2 48A 11.5 kW 6 AWG 60A
80A Level 2 80A 19.2 kW 4 AWG 100A

Installation Steps

  1. Calculate available capacity — Perform load calculation (NEC 220)
  2. Choose charger location — Near parking, within 25 ft of panel
  3. Install dedicated circuit — 240V, correct wire size, GFCI breaker
  4. Mount charger — Wall or pedestal mount, weatherproof if outdoor
  5. Connect to WiFi — For smart charging features and monitoring
  6. Set charging schedule — Charge during off-peak hours for savings
  7. Permit and inspect — Required by most jurisdictions

Solar + EV Charging

Pairing solar with an EV charger can make driving essentially free:

EV Model Battery Range Solar Panels Needed Charge Time (32A)
Tesla Model 3 75 kWh 358 mi 12 × 450W (5.4kW) 5.5 hrs
Tesla Model Y 82 kWh 330 mi 14 × 450W (6.3kW) 6.0 hrs
Ford F-150 Lightning 131 kWh 320 mi 22 × 450W (9.9kW) 9.5 hrs
Chevy Bolt 65 kWh 259 mi 10 × 450W (4.5kW) 4.5 hrs
Rivian R1T 135 kWh 314 mi 23 × 450W (10.4kW) 9.8 hrs