TRAINING & WEBINARS
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EV Charging Systems: Powering Your Shop
What Technicians Need to Know About Charging Levels, Connectors, Onboard Chargers and Shop Setup
EVs aren’t rare anymore — they’re in everyday bays.
And when charging concerns become customer complaints, warning lights or drivability issues, technicians need more than surface-level knowledge.
Recently, Aaron Jones, Tesla Support Technician & Trainer at Opus IVS, hosted a live webinar covering the fundamentals of EV charging systems. This post recaps the key takeaways from that session and includes a downloadable EV Charging Systems Guide for technicians who want a deeper reference.
WATCH THE WEBINAR RECORDING HERE
KEY TAKEAWAYS
Why Charging Matters in Your Shop
Aaron emphasized that charging is now a vital system and a vital diagnostic tool.
Shops need charging capability to:
- Duplicate charging-related complaints using known-good equipment
- Properly diagnose communication and charging faults
- Improve customer experience (customers see charging activity in their apps)
- Signal that the shop understands modern EV systems
Charging Levels Explained
Technicians only need to understand three real-world categories:
Level 1 (120V)
Cheap and portable. Very slow. Useful for testing, not for daily shop operations.
Level 2 (240V)
The practical choice for most professional shops. Faster, affordable, durable, and compatible with modern connectors.
DC Fast Charging
Very fast but requires significant infrastructure and cost. Not realistic for most independent shops.
Connectors & Charge Ports
Aaron reviewed the most common connector types techs will encounter:
- J1772 – Standard AC connector for Level 1 & 2 charging
- CCS1 – Adds two DC pins for fast charging
- NACS (SAE J3400) – One connector supports both AC and DC
- CHAdeMO – Legacy DC connector found on some older EVs
Understanding connector types matters because AC charging and DC fast charging use different internal system paths.
What Changes During DC Fast Charging
During DC fast charging:
- The onboard charger is bypassed
- DC power flows directly to the battery
- Contactors and communication modules control safety and power flow
That’s why some vehicles may charge normally on Level 2 but fail only on DC fast — the systems involved are not the same.
How to Recognize Onboard Chargers
Aaron shared a simple, practical rule for identifying onboard chargers:
Look for:
- High-voltage power in
- High-voltage power out
- Often coolant lines in and out
If you see HV in, HV out and cooling lines, you’re almost certainly looking at the onboard charger — regardless of OEM.
Choosing the Right Charger for Your Shop
Aaron compared real-world pros and cons:
- Level 1 – Cheap, mobile, slow, easily damaged
- DC Fast – Powerful but unrealistic for most shops
- Level 2 – Best balance of speed, cost, durability, and practicality
How IVS 360 Supports EV & Charging Diagnostics
As EV systems become more common and more complex, technicians don’t have to troubleshoot alone. Opus IVS 360 Support can be used when charging behavior, communication faults or system responses don’t clearly point to an answer. Through IVS 360, technicians can collaborate live with Master Technicians, review scan data together, walk through test results and validate repairs before the vehicle leaves the shop.