Chennai-based Plugzmart Receives ARAI Certification for 60kW DC Fast Charger, Enhancing EV Infrastructure with Advanced Safety, Compatibility, and Fast Charging Technology
Plugzmart, a Chennai-based OEM of EV chargers, secured certification for its 60kW DC fast EV charger from the Automotive Research Association of India (ARAI) last month. ARAI, under the Union Ministry of Heavy Industries, sets standards for vehicles and components.
This marks a significant step towards developing an indigenous EV infrastructure in India, especially as the country struggles to keep pace with the growing fleet of domestic electric vehicles. Moreover, the local manufacturing of key components for EV charging infrastructure is still in its early stages.
The ARAI certification for Plugzmarts 60kW DC fast charger and its proprietary controller card signifies that the charger meets Indias strict operational safety standards and efficiency norms. This certification ensures the products reliability and compliance with industry regulations, marking a significant milestone for the Chennai-based startup.
Co-founder Ragavendra Ravichandran stated, “A majority of EV chargers in India today are imported and often of low quality, primarily from China”. While Chinese chargers are priced low, they come with the challenge of lack of support after installation, which is a significant issue.
He added, “We miss the technical support of imported products and face difficulties resolving issues without adequate service backup. As EV adoption grows among consumers and in the commercial sector, the demand for chargers from 2, 3, and 4-wheeler manufacturers and charge point operators will scale rapidly. The ARAI certification for their fast DC charger, which can provide 75% charge in 30 minutes, is another step toward addressing this challenge”.
Meanwhile, Vivek Samynathan, founder and CEO of Plugzmart, commented on the milestone of achieving the ARAI certification for their DC fast charger, saying, “Securing the ARAI certification for our 60kW DC fast charger, especially with our controller card”, is a significant achievement for us. As part of our broader vision, we are committed to building a comprehensive ecosystem of hardware and software solutions in the energy domain.
He added, “Our goal is to provide end-to-end solutions that not only address the current needs of the electric vehicle sector but also pave the way for future innovations in sustainable energy. By integrating smart technologies, advanced control systems, and IoT-enabled platforms, we aim to create a seamless, efficient, and scalable energy infrastructure that supports the global transition to greener and more sustainable transportation options.”
Plugzmart Develops Advanced 60kW DC Fast Charger to Support Indias EV Infrastructure Growth
Over the past two years, the team faced several challenges in the development process. The primary challenge was designing a proprietary controller card that could seamlessly handle high-speed charging while maintaining a compact size, he adds.
What does a controller card do?
Ragavendra explains, “The controller card manages power distribution, communication, and safety protocols during charging. It monitors critical parameters, such as voltage, current, and temperature, to prevent overheating and overcharging, ensuring safe operation. The controller also enables intelligent load management, balancing power across multiple charging points, allowing simultaneous charging of multiple EVs”.
He adds, “Achieving efficient heat dissipation at such high power levels, minimizing energy losses, and preventing component damage were critical challenges too. We also focused on ensuring compatibility with multiple vehicle models and integrating advanced load management features”. One of the key issues with many common charging stations in India is their inability to cater to different vehicle models and their battery specifications.
How the 60kW DC Fast Charger Operates:
As Vivek explains, “The 60kW DC Fast Charger converts AC power from the grid into DC power using an internal rectifier (AC/DC converter)”. It delivers high-power DC output directly to the battery, bypassing the vehicles onboard charger for quicker energy transfer. The charger communicates with the vehicles Battery Management System (BMS) to determine the required charge level and adjusts the power output dynamically.
Going further, Vivek also explains some of its key specifications:
Major Components of the DC Fast Charger include:
The major materials used in the manufacturing of this EV charger include: high-grade metals for the rectifier and controller card, advanced cooling materials for the thermal management system, durable plastics for the outer casing, and specialized power filters to ensure clean and stable power output.
But can we install it at home?
The 60kW charger is designed for four-wheelers and can charge a vehicle (with a larger battery pack) from 0 to 80% in 60 to 90 minutes. For vehicles with smaller battery packs, it can go from 0 to 75% charge in 30 minutes.
While this charger is primarily designed for public or commercial use, it can be installed in residential homes with sufficient grid capacity (340V+ AC supply). However, most homeowners may opt for smaller chargers (7-22 kW) due to space and electrical limitations. For those who can meet the requirements, setting up this fast charger requires a robust electrical infrastructure and space for cooling and ventilation, explains Ragavendra.
Plugzmart Develops In-House Controller Card, PLC Module, and Load Management Software for Enhanced EV Charging Efficiency
What is the PLC Module?
According to Vivek, The PLC (Power Line Communication) module transmits data over the same power lines used for charging. This reduces installation complexity and allows real-time communication between the charger and the vehicles onboard systems.
The PLC module enables the charger to negotiate with the vehicle on how much power it needs, ensuring the vehicle receives the optimal charge rate. It ensures compatibility with various vehicle types and allows the charger to comply with international charging standards, making it versatile for different environments, he adds. In some systems, PLC modules are also involved in enabling Vehicle-to-Grid (V2G) communication, where the vehicle can return power to the grid, thus helping with grid stabilization.
While some components are developed in-house, others, like semiconductors, rectifiers, and cooling systems, are sourced from trusted suppliers in India and abroad, particularly from China and Taiwan, known for their expertise in high-power electronics, explains Vivek.
The Key Factors that differentiate Plugzmarts from current technologies include
Cost and Customer Base
A single unit of the 60kW DC Fast Charger, complete with its proprietary controller card and PLC module, costs around Rs 8 to Rs 9 lakh, depending on customization and quantity.
Speaking on the customer base for their fast charger, Vivek says, “We have attracted interest from fleet operators, EV manufacturers, and charging network operators.”
Several companies, particularly in public transportation and fleet management, have shown interest. We have received preliminary commitments and purchase orders from fleet operators and EV charging infrastructure developers, including local government initiatives for public charging, he adds.
Edited by Gayathri
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