Hardwired EV Charger Installation

December 24, 2024

24 Views 0

A hardwired EV charger installation allows for higher amperage Level 2 EV charging, with the maximum amperage for a Level 2 hardwired EV charger reaching up to 80 amps.

Hardwired EV charger installation provides faster charging speeds compared to plug-in EV chargers, which are typically limited to 40 amps on a 50-amp circuit breaker. The increased amperage capacity of a hardwired EV charger ensures quicker recharging, making it especially useful when you return from a trip and need to charge quickly before heading out again.

For a hardwired EV charger installation, you’ll need a licensed electrician to ensure everything is done correctly and safely. They will:

Determine the appropriate dedicated EV charger circuit breaker amperage for your EV charger.
Select the appropriate wire sizes for the hot and ground conductors, rated for 75°C with copper wiring, while considering the distance to the point of use to minimize voltage drop.
Choose the right conduit size to protect the feeder wires from the electrical panel to the junction box.

Install and connect the wiring from the electrical panel to the junction box.

Connecting the hardwired EV charger to the junction box requires specific precautions and a solid understanding of electrical hazards, so professional installation is essential.

This guide simplifies the hardwired EV charger installation process. We provide detailed hardwired EV charger wiring diagrams for 12 Amp to 80 Amp Level 2 chargers available on the market today, tailored to various amperage levels. Our diagrams illustrate:

Wiring the circuit breaker in a single-phase 120/240V electrical panel (common in most U.S. homes).
Proper wire sizing for hot and ground conductors, rated for 75°C with copper wiring.
Conduit sizing for feeder wires between the electrical panel and the junction box.

Thinking about purchasing a plug-in or portable EV charger instead of a hardwired one? Check out our guide on installing NEMA outlets for plug-in EV chargers. Use these guides to compare installation processes between hardwired EV charger installation and Plug-In EV charger installation (NEMA Outlets installation) to help you decide which option is best based on your home’s existing electrical setup.

Table of Contents

Best Hardwired EV Chargers
Hardwired EV Charger Installation: Conductors, Breaker, and Conduit Guide
Why Install a Hardwired EV Charger Over a Plug-in EV Charger?
When to Choose a Plug-in EV Charger Instead

Check Price on Amazon

Add to compare

It’s worth noting that all the chargers listed above are fully compatible with the installation instructions provided in this guide. These chargers were tested using the same circuits outlined in our amperage-specific wiring diagrams, ensuring seamless integration, code compliance, and optimal performance for your hardwired EV charger setup.

Whether you’re looking for reliability, smart features, or future-proofing your permanent home EV charger installation, these chargers offer excellent value for your investment.

Hardwired EV Charger Installation: Conductors, Breaker, and Conduit Guide

The table below summarizes and provides essential guidelines for selecting the correct wire gauge, breaker size, and conduit for a hardwired EV charger installation. It takes into account the 80/20 rule for breaker sizing, proper wire gauge for continuous loads, grounding conductor requirements, and recommended conduit sizes based on the number of conductors and wire size used.

Hardwired EV Charger Rating (Continuous Loads)	EV Charger Dedicated Breaker Size (20/80 Rule)	Hot Wire Gauge (AWG)	Grounding Conductor Gauge (Copper)	Conduit Size
12 Amp	15 Amp	14	14 AWG	1/2 Inch Schedule 40
16 Amp	20 Amp	12	12 AWG	1/2 Inch Schedule 40
20 Amp	25 Amp	10	10 AWG	3/4 Inch Schedule 40
24 Amp	30 Amp	10	10 AWG	3/4 Inch Schedule 40
28 Amp	35 Amp	8	10 AWG	3/4 Inch Schedule 40
32 Amp	40 Amp	8	10 AWG	3/4 Inch Schedule 40
36 Amp	45 Amp	6	10 AWG	1 Inch schedule 40
40 Amp	50 Amp	6	10 AWG	1 Inch Schedule 40
48 Amp	60 Amp	4	10 AWG	1 Inch Schedule 40
56 Amp	70 Amp	4	8 AWG	1 Inch schedule 40
64 Amp	80 Amp	3	8 AWG	1 Inch Schedule 40
72 Amp	90 Amp	2	8 AWG	1 Inch Schedule 40
80 Amp	100 Amp	2	8 AWG	1 Inch Schedule 40

Expert Electric Vehicle Charger Hardwire Installation Notes:

EV Charger Dedicated Breaker Size (80/20 Rule): The breaker size is determined using the 80/20 rule, which means the breaker should be rated at 125% of the charger’s maximum amperage to account for continuous loads.

Hot Wire Gauge (AWG): For hot conductors (L1, L2), solid copper wire, rated for 75°C, is recommended. The appropriate gauge is determined by the amperage rating of the circuit and the load requirements of the EV charger.
Grounding Conductor Gauge (Copper): The grounding conductor size must comply with NEC standards and is typically determined based on the size of the circuit breaker. In most cases, the grounding conductor is smaller than the hot wire, but it must still be sufficient to ensure safe operation and protect the circuit against faults.
Conduit Size: The conduit size is determined based on the number of conductors (three: L1, L2, and Ground) and the wire gauge used. This ensures sufficient space for safe wire installation, accounting for heat dissipation and ease of pulling the wires.

We recommend selecting wire sizes based on the maximum amperage rating of the EV charger, especially if the charger’s amperage can be remotely adjusted via a smartphone app. However, if the charger features a physical DIP switch for adjusting its amperage, wire sizes can be chosen according to the adjusted amperage setting. It’s important to note that some inspectors may require this approach to ensure compliance with electrical codes and to pass the inspection for hardwired EV charger installations.

12 Amp Hardwired EV Charger Installation

A 12 Amp hardwired Level 2 EV charger typically provides a charging rate of up to 2.88 kW, making it suitable for users with moderate charging needs.

12 Amp Hardwired EV Charger Circuit Wiring Diagram

Diagram illustrating the installation of a 12 Amp hardwired Level 2 EV charger. It shows a 15A double-pole dedicated breaker in a panel, connected to the charger via a junction box. The diagram uses 14 AWG wires for the two hot (L1 and L2) conductors and the 14 AWG copper grounding wire. The neutral wire is connected to the neutral bus bar. A 1/2-inch Schedule 40 conduit is recommended to accommodate the wires comfortably.

12 Amp hardwired EV charger installation requires a 15 Amp dedicated breaker, as per the 80/20 rule, ensuring safe operation for continuous loads. The wiring includes 14 AWG wires for the hot conductors (L1 and L2) and a 14 AWG copper grounding conductor. For conduit, a 1/2-inch Schedule 40 conduit is recommended to accommodate the wires comfortably.

16 Amp Hardwired EV Charger Installation

A 16 Amp hardwired Level 2 EV charger offers a charging rate of up to 3.84 kW, making it ideal for users who need a moderate charging speed.

16 Amp Hardwired EV Charger Circuit Wiring Diagram

Diagram illustrating the installation of a 16 Amp hardwired Level 2 EV charger. It depicts a 20A double-pole dedicated breaker in an electrical panel, which connects to the charger via a junction box. The diagram specifies the use of 12 AWG wire for both hot conductors (L1 and L2) and the 12 AWG copper grounding conductor. A 1/2-inch Schedule 40 conduit is recommended for this installation to safely manage wires and ensure proper heat dissipation.

16 Amp hardwired EV charger installation requires a 20 Amp dedicated breaker, following the 80/20 rule for safe operation with continuous loads. The installation uses 12 AWG wire for the hot conductors (L1 and L2) and a 12 AWG copper grounding conductor. For conduit, a 1/2-inch Schedule 40 conduit is recommended to ensure proper wire placement and heat dissipation.

20 Amp Hardwired EV Charger Installation

A 20 Amp hardwired Level 2 EV charger typically provides 4.8 kW of charging power.

20 Amp Hardwired EV Charger Circuit Wiring Diagram

Diagram depicting the installation of a 20 Amp hardwired Level 2 EV charger. It illustrates a 25A double-pole dedicated breaker in an electrical panel, wired to the charger through a junction box. The diagram specifies the use of 10 AWG wire for both the hot conductors (L1 and L2) and the 10 AWG copper grounding conductor. A 3/4-inch Schedule 40 conduit is recommended for this setup, and the neutral wire is connected to the neutral busbar.

The diagram illustrates the installation of a 20 Amp hardwired Level 2 EV charger, showcasing a 25A double-pole dedicated breaker within the electrical panel, connected to the charger via a junction box. It specifies the use of 10 AWG wire for both the hot conductors (L1 and L2) and a 10 AWG copper grounding conductor.

The conductors from the electrical panel to the junction box are housed in a 3/4-inch Schedule 40 conduit, providing protection and ease of installation. Additionally, the neutral wire is properly connected to the neutral busbar, ensuring correct circuit configuration and safety.

24 Amp Hardwired EV Charger Installation

A 24 Amp hardwired Level 2 EV charger delivers a charging rate of up to 5.76 kW, making it suitable for users who need faster charging times.

24 Amp Hardwired EV Charger Circuit Wiring Diagram

Diagram depicting the installation of a 24 Amp hardwired Level 2 EV charger. It shows a 30A double-pole dedicated breaker in an electrical panel, which is connected to the charger via a junction box. The diagram specifies the use of 10 AWG wire for the two hot conductors (L1 and L2), and also a 10 AWG copper grounding conductor. A 3/4-inch Schedule 40 conduit is recommended for this setup to ensure safe and proper wire management.

24 Amp hardwired EV charger installation requires a 30 Amp dedicated breaker, following the 80/20 rule for handling continuous loads safely. The installation uses 10 AWG wire for both the hot conductors (L1 and L2) and a 10 AWG copper grounding conductor. For conduit, a 3/4-inch Schedule 40 conduit is recommended to accommodate the wires and ensure proper ventilation.

28 Amp Hardwired EV Charger Installation

A 28 Amp hardwired Level 2 EV charger provides up to 6.72 kW of charging power, perfect for users looking for a balance between speed and efficiency.

28 Amp Hardwired EV Charger Circuit Wiring Diagram

Diagram illustrating the installation of a 28 Amp hardwired Level 2 EV charger. It depicts a 35A double-pole dedicated breaker in an electrical panel, connected to the charger through a junction box. The diagram shows 8 AWG wire for the two hot conductors (L1 and L2) and a 10 AWG copper grounding conductor. A 3/4-inch Schedule 40 conduit is recommended to ensure proper wire placement and heat dissipation.

28 Amp hardwired EV charger installation requires a 35 Amp dedicated breaker, adhering to the 80/20 rule for safety. The installation uses 8 AWG wire for both the hot conductors (L1 and L2) and a 10 AWG copper grounding conductor. A 3/4-inch Schedule 40 conduit is recommended to safely house the wires and maintain proper heat dissipation.

32 Amp Hardwired EV Charger Installation

A 32 Amp hardwired Level 2 EV charger offers up to 7.68 kW of charging power, making it ideal for faster home charging.

32 Amp Hardwired EV Charger Circuit Wiring Diagram

Diagram illustrating the installation of a 32 Amp hardwired Level 2 EV charger. It depicts a 40A double-pole dedicated breaker within an electrical panel, wired to the charger through a junction box. The diagram specifies the use of 8 AWG wire for both hot conductors (L1 and L2) and a 10 AWG copper grounding conductor. A 3/4-inch Schedule 40 conduit is recommended to ensure correct wire placement and heat dissipation.

32 Amp hardwired EV charger installation requires a 40 Amp dedicated breaker, according to the 80/20 rule, to accommodate continuous loads. The system uses 8 AWG wire for both hot conductors (L1 and L2), with a 10 AWG copper grounding conductor. A 3/4-inch Schedule 40 conduit is recommended for proper wire fit and heat management.

36 Amp Hardwired EV Charger Installation

A 36 Amp hardwired Level 2 EV charger provides up to 8.64 kW of charging power, suitable for users who require a quicker charge for their electric vehicles.

36 Amp Hardwired EV Charger Circuit Wiring Diagram

Diagram illustrating the installation of a 36 Amp hardwired Level 2 EV charger. It shows a 45A double-pole dedicated breaker within an electrical panel, connected to the charger via a junction box. The diagram specifies the use of 6 AWG wire for the two hot conductors (L1 and L2) and a 10 AWG copper grounding conductor. A 1-inch Schedule 40 conduit is recommended for this setup to allow sufficient space for wiring and ensure adequate ventilation.

36 Amp hardwired EV charger installation requires a 45 Amp dedicated breaker, following the 80/20 rule for handling continuous loads safely. The installation uses 6 AWG wires for the hot conductors (L1 and L2) and a 10 AWG copper grounding conductor. A 1-inch Schedule 40 conduit is recommended to allow ample space for the wires and ensure proper ventilation.

40 Amp Hardwired EV Charger Installation

A 40 Amp hardwired Level 2 EV charger offers up to 9.6 kW of charging capacity, making it an excellent choice for users seeking fast charging at home.

40 Amp Hardwired EV Charger Circuit Wiring Diagram

Diagram illustrating the installation of a 40 Amp hardwired Level 2 EV charger. It depicts a 50A double-pole dedicated breaker within an electrical panel, connected to the charger through a junction box. The diagram specifies the use of 6 AWG wire for both hot conductors (L1 and L2) and a 10 AWG copper grounding conductor. A 1-inch Schedule 40 conduit is recommended for safe and organized wiring.

40 Amp hardwired EV charger installation requires a 50 Amp dedicated breaker, adhering to the 80/20 rule for continuous load safety. The system uses 6 AWG wires for the hot conductors (L1 and L2) and a 10 AWG copper grounding conductor. For conduit, a 1-inch Schedule 40 size is ideal to ensure a safe, organized installation.

48 Amp Hardwired EV Charger Installation

A 48 Amp hardwired Level 2 EV charger delivers up to 11.52 kW of charging power, providing one of the faster home charging options.

48 Amp Hardwired EV Charger Circuit Wiring Diagram

Diagram illustrating the installation of a 48 Amp hardwired Level 2 EV charger. It depicts a 60A double-pole dedicated breaker within an electrical panel, connected to the charger through a junction box. The diagram specifies the use of 4 AWG wire for the two hot conductors (L1 and L2) and a 10 AWG copper grounding conductor. A 1-inch Schedule 40 conduit is recommended for proper wire routing and ventilation.

48 Amp hardwired EV charger installation requires a 60 Amp dedicated breaker, following the 80/20 rule for optimal safety with continuous loads. The installation uses 4 AWG wires for the hot conductors (L1 and L2), paired with a 10 AWG copper grounding conductor. A 1-inch Schedule 40 conduit is recommended for proper wire routing and ventilation.

56 Amp Hardwired EV Charger Installation

A 56 Amp hardwired Level 2 EV charger provides up to 13.44 kW of power, suitable for those who need fast, efficient home charging.

56 Amp Hardwired EV Charger Circuit Wiring Diagram

Diagram illustrating the installation of a 56 Amp hardwired Level 2 EV charger. It depicts a 70A double-pole dedicated breaker within an electrical panel, connected to the charger through a junction box. The diagram specifies the use of 4 AWG wire for the two hot conductors (L1 and L2) and an 8 AWG copper grounding conductor. A 1-inch Schedule 40 conduit is recommended to ensure proper spacing and heat management.

56 Amp hardwired EV charger installation requires a 70 Amp dedicated breaker, following the 80/20 rule to safely accommodate continuous loads. The installation uses 4 AWG wires for the hot conductors (L1 and L2), with an 8 AWG copper grounding conductor. A 1-inch Schedule 40 conduit is recommended to ensure proper spacing and heat management.

64 Amp Hardwired EV Charger Installation

A 64 Amp hardwired Level 2 EV charger delivers up to 15.36 kW of charging power, ideal for users who need rapid charging for multiple electric vehicles or larger battery capacities.

64 Amp Hardwired EV Charger Circuit Wiring Diagram

Diagram illustrating the installation of a 64 Amp hardwired Level 2 EV charger. It depicts an 80A double-pole dedicated breaker within an electrical panel, connected to the charger through a junction box. The diagram specifies the use of 3 AWG wire for the two hot conductors (L1 and L2) and an 8 AWG copper grounding conductor. A 1-inch Schedule 40 conduit is recommended to accommodate the larger wires and ensure proper ventilation.

64 Amp hardwired EV charger installation requires an 80 Amp dedicated breaker, following the 80/20 rule for safety. The installation uses 3 AWG wires for the hot conductors (L1 and L2), paired with an 8 AWG copper grounding conductor. A 1-inch Schedule 40 conduit is recommended to accommodate the larger wires and ensure proper ventilation.

72 Amp Hardwired EV Charger Installation

A 72 Amp hardwired Level 2 EV charger offers up to 17.28 kW of charging power, making it one of the fastest options for home installations.

72 Amp Hardwired EV Charger Circuit Wiring Diagram

Diagram illustrating the installation of a 72 Amp hardwired Level 2 EV charger. It depicts a 90A double-pole dedicated breaker within an electrical panel, connected to the charger through a junction box. The diagram specifies the use of 2 AWG wire for the two hot conductors (L1 and L2) and an 8 AWG copper grounding conductor. A 1-inch Schedule 40 conduit is recommended to ensure proper wire placement and avoid overheating.

72 Amp hardwired EV charger installation requires a 90 Amp dedicated breaker, according to the 80/20 rule, for safe continuous load handling. The installation uses 2 AWG wires for the hot conductors (L1 and L2), with an 8 AWG copper grounding conductor. A 1-inch Schedule 40 conduit is recommended for proper wire placement and to avoid overheating.

80 Amp Hardwired EV Charger Installation

An 80 Amp Level 2 hardwired EV charger delivers up to 19.2 kW of power, providing one of the fastest charging rates for residential applications.

80 Amp Hardwired EV Charger Circuit Wiring Diagram

Diagram illustrating the installation of an 80 Amp hardwired Level 2 EV charger. It depicts a 100A double-pole dedicated breaker within an electrical panel, connected to the charger through a junction box. The diagram specifies the use of 2 AWG wire for the two hot conductors (L1 and L2) and an 8 AWG copper grounding conductor. A 1-inch Schedule 40 conduit is recommended to accommodate the larger wires and ensure proper ventilation.

80 Amp hardwired EV charger installation requires a 100 Amp dedicated breaker, following the 80/20 rule for optimal safety. The system uses 2 AWG wires for the hot conductors (L1 and L2), with an 8 AWG copper grounding conductor. A 1-inch Schedule 40 conduit is recommended to accommodate the larger wires and ensure proper ventilation.

Why Install a Hardwired EV Charger Over a Plug-in EV Charger?

A hardwired EV charger offers several key advantages over a plug-in EV charger, making it the preferred choice for many EV owners, particularly in residential and commercial settings where reliability and safety are top priorities.

1. Enhanced Safety

Eliminates Plug Connections: Hardwired chargers connect directly to your electrical panel, eliminating the risks associated with loose or worn plug connections that can lead to overheating or electrical faults.
Weatherproof Installation: A hardwired installation is typically sealed and better protected against environmental factors like rain, dust, and debris, making it more suitable for outdoor use.

2. Greater Power Capacity

Higher Amperage Support: Many hardwired chargers can handle higher amperage, enabling faster charging speeds compared to some plug-in models that are limited by outlet capacity.
Reduced Risk of Circuit Overload: A direct connection to the electrical system ensures that the charger is adequately supported by the home’s wiring and circuit breakers.

3. Permanent, Code-Compliant Setup

Meets Electrical Codes: Hardwired installations are often required to meet local building codes and safety standards, ensuring compliance and long-term operational integrity.

Professional Installation: Hardwiring typically involves licensed electricians, which ensures a properly configured and optimized setup for your specific needs.

4. Clean and Professional Aesthetic

No Visible Cords or Outlets: Hardwired chargers have a cleaner appearance as there is no need for bulky outlets or visible cords. This is particularly appealing for residential garages or commercial spaces.
Less Wear and Tear: With no need to repeatedly plug and unplug the charger, hardwired setups minimize wear and tear on both the charger and the outlet.

5. Reduced Risk of Accidental Disconnection

Permanent Connection: A hardwired charger cannot be unplugged accidentally, ensuring uninterrupted charging, which is especially important for high-demand or fleet environments.

6. Scalability and Future-Proofing

Supports Future Upgrades: A hardwired installation can often support more powerful chargers or additional units in the future without requiring significant modifications.
Ideal for Permanent Locations: If the EV charger is intended to remain in the same location long-term, hardwiring provides a robust and reliable solution.

When to Choose a Plug-in EV Charger Instead

While hardwired chargers offer significant advantages, plug-in chargers may still be suitable for renters, those who need portability, or in cases where local electrical codes or infrastructure constraints make hardwiring impractical.

About the Author: James Ndungu

James Ndungu, founder and editor-in-chief of Electric Vehicle Geek, brings over five years of hands-on experience in Electric Vehicle Supply Equipment (EVSE) selection, permitting, and installation. He specializes in assisting businesses and homeowners in the United States with a seamless transition to electric vehicles.

As a certified EV charger installer and holder of advanced certifications, including the EVITP (Electric Vehicle Infrastructure Training Program), Diploma in Electric Vehicle Technology, and Diploma in Engineering Fundamentals of Electric Vehicles, I provide expert guidance and in-depth reviews on the latest EV charging equipment.

Read more…