PowerON Energy Solutions, a leader in electrification infrastructure, was tasked with designing and deploying a bespoke charging system tailored to the fire hall’s unique requirements. This case study highlights the challenges, innovations, and outcomes of this project.
Challenges Encountered & Solutions
Upgrading Charging Capacity
The fire hall’s existing 20 kW DC wall box charger was insufficient for rapidly charging the fire truck’s 100 kWh battery. Given the critical nature of emergency response, fire trucks must maintain constant operational readiness with minimal downtime, ensuring immediate availability for deployment. A faster, higher-powered 50 kW charger was therefore essential. During installation, the distribution panel was relocated within line-of-sight, and redundant safety disconnects were eliminated — optimizing the electrical layout and reducing both installation time and overall project cost.
Custom European Vehicle Requirements
The fire truck was a custom European vehicle, requiring additional documentation of its specific charging behavior and requirements to ensure compatibility and reliability. The large vehicle size required longer charging cords to ensure flexible and easy connections without compromising operational efficiency and reducing trip hazards.
Performance and Safety Testing
A half-day commissioning process validated the system’s reliability under real-world conditions, ensuring the truck can complete 95 percent of its calls entirely in electric mode*:
- Edge Case Simulations: Testing included scenarios such as unintended parking brake disengagement during charging and abrupt charging termination from either the vehicle or charger.
- Safety Protocols: Automated shutdown mechanisms and fail-safes were implemented to prevent electrical hazards.
PowerON also conducted hands-on training for the fire hall’s electrical staff and operators, ensuring proficiency in charger maintenance and emergency protocols.
*https://www.victoria.ca/city-government/news/victorias-first-electric-fire-truck-arrives
