Retrofit Cable Management System for DC Fast Charging Stations
EV Chargers Without Cable Management System
Operational Problem
In high-power DC fast charging stations, charging cables are among the most frequently replaced components in the field.
This results in:
- High replacement cost per charging point
- Frequent field maintenance visits (truck-roll costs)
- Charger downtime and lost revenue
- Connector strain and mechanical fatigue
- Inconsistent and improper user handling
These issues scale directly with the size of the charging stations.
A Retrofit Cable Management System for Existing Chargers
Our cable management system provides external mechanical support for heavy DC charging cables, reducing stress on connectors and enabling controlled cable movement during daily operation.
Key features:
- Retrofit installation on existing charging stations
- Reduction of mechanical load on cable and connector interface
- Designed for continuous outdoor operation
- Compatible with pedestal and wall-mounted chargers
Operational Impact for Charge Point Operators
Implementing a BESSUN Cable Management System directly optimizes the Total Cost of Ownership (TCO) of your charging infrastructure through:
- Reduced cable wear and replacement frequency
- Lower maintenance requirements and fewer service visits
- Improved charging station uptime and availability
- More consistent and controlled user handling
- Reduced long-term OPEX per charging point
Additional benefits:
- Reduces the physical effort required to handle heavy charging cables
- Keeps cables off the ground, minimizing dirt accumulation and wear
- Maintains a cleaner and more professional station appearance
By reducing mechanical stress on charging cables, operators can improve maintenance efficiency and reduce service frequency, leading to lower total cost of ownership (TCO) over time.
Evaluating Your Charging Station Needs
Before implementing a cable management system, consider the following key factors to ensure optimal performance and return on investment:
1. Cable Specifications
Evaluate cable length, diameter, and total weight to ensure the system can support the required mechanical load.
2. Operating Environment
Determine whether the installation is indoor or outdoor. Outdoor environments require higher resistance to UV exposure, corrosion, and weather conditions.
3. User Profile
Identify the primary user group. Fleet operations prioritize durability and efficiency, while public charging environments require ease of use and accessibility.
4. Compliance Requirements
Ensure the system meets relevant safety and accessibility standards in your target market.
Retrofiting cable management system Projects
Explore how our cable management systems are applied in real-world DC fast charging stations.
These examples demonstrate how retrofit solutions improve cable handling, reduce mechanical stress, and enhance station usability.
Warranty-Friendly Installation
We understand that protecting your equipment’s warranty is a top priority. Our Cable Management Systems are engineered to be compatible with existing infrastructure:
Non-Invasive Integration: Most installations do not change the product’s technical data or internal circuitry.
Alternative Mounting Options: If direct attachment to the EV charger is not permitted, we provide versatile mounting kits—including pedestal, wall, or ceiling mounts—to ensure a seamless setup without modifying the charger.
By choosing a non-invasive retrofit CMS, operators can meet accessibility standards (like PAS 1899) without the need for expensive, warranty-voiding structural changes to the charger cabinet.
Retrofitting EV Chargers with Swivel Arms
Retrofitting EV Chargers with Swivel Arms with retractor
Retrofitting EV Chargers with cable retractor with housing
Retrofitting EV Charger with cable retractor with housing
Retrofitting EV Chargers with standalone Swivel Arms
Retrofitting EV Chargers with overhead retractor
Regulatory Compliance & Global Standards
Our CMS solutions are engineered to align with the latest international mandates and accessibility guidelines.
Europe (AFIR): Compliant with (EU) 2023/1804 requirements for existing station upgrades.
United Kingdom (PAS 1899): Meets accessibility standards for cable weight and ground clearance.
North America (ADA/NEVI): Designed to support “operable parts” reach and force requirements.
FAQ
Can I retrofit a Cable Management System (CMS) on any brand of EV charger?
Yes. Our retrofit solutions are designed for broad compatibility. Whether you have pedestal or wall-mounted chargers, we offer customized connecting plates and mounting kits that fit most major DC fast charging brands without internal modifications.
Will installing this system void my EVcharger's manufacturer warranty?
Generally, no. Our CMS is a non-invasive mechanical addition. Since it is installed externally and does not alter the EV charger’s electrical circuitry, technical data, or IP rating, it typically does not impact the original equipment warranty.
What are the main benefits of a swivel arm for existing charging stations?
The primary benefits are reduced maintenance costs and improved user experience. The swivel arm supports the weight of heavy DC cables, prevents them from dragging on the ground (reducing wear), and minimizes mechanical stress on the connectors and cable glands.
Is the cabel mangegment system suitable for extreme outdoor environments?
Absolutely. Our systems are engineered for continuous outdoor operation. We use materials resistant to UV exposure, corrosion, and extreme temperatures to ensure long-term durability in diverse climates.
Does the retrofit CMS help with accessibility compliance?
Yes. Our designs align with international standards like UK PAS 1899 and US ADA by reducing the physical force required to manage heavy cables, making charging easier for all users, including those with limited mobility.
What are the advantages of the Rotational Spring Balancer compared to other systems?
The Rotational Spring Balancer is a standalone solution that offers maximum flexibility for site operators. Its primary advantages include:
Ease of Installation: It can be quickly integrated into existing stations without complex structural changes or specialized tools.
Independent Operation: As a standalone mechanical unit, it doesn’t require power from the charger, ensuring reliability and zero interference with the charger’s electrical systems.
Space Efficiency: Its compact design provides a sleek, professional look while significantly reducing cable tension and ground contact.
Does the retrofit solution require regular professional maintenance?
One of the main advantages of our cable management system design is that it is maintenance-free. Beyond occasional visual inspections and cleaning, the cable management system is built for high-cycle durability in outdoor environments, significantly reducing the need for “truck-roll” service visits.
Can the CMS be moved or re-installed if the charger is replaced?
Absolutely. Because the system is bolted externally (on a pedestal or via a connecting plate), it can be easily uninstalled and moved to a new unit or a different site. This makes it a future-proof investment for fleet operators and site owners.
How does the retrofit CMS improve the "Total Cost of Ownership" (TCO)?
By extending the lifespan of expensive DC charging cables and connectors, the cable management system reduces CAPEX (replacement parts) and OPEX (labor and downtime). Most operators see a return on investment (ROI) within the first year by avoiding just one or two cable replacement cycles.