Charging & Fueling | ZEV TruckStop
Charging and fueling is an important part of adding zero-emission vehicles to a fleet. Choosing the right approach can help keep vehicles operating reliably while managing costs.
There is no one-size-fits-all solution. The best option depends on fleet size, how vehicles are used each day, budget, available power, space, future growth plans, and available charging or hydrogen fueling options near the facility.
Many fleets install charging or fueling equipment at their facility, while others rely on public stations, shared charging locations, mobile equipment, or subscription services. Many fleets use a combination of these options.
Know the Basics
Battery-Electric Vehicle Charging
Battery-electric vehicles (BEVs or EVs) are powered by electricity and are charged by plugging into electric charging equipment. Fleets can choose from several charging options based on how vehicles are used, how quickly they need to recharge, and their budget. The main types of charging are:
- Level 1 Charging(120 volts) uses a standard household outlet. It is the slowest charging option and is generally best for light-duty vehicles with low daily mileage or overnight charging.
- Level 2 Charging(208/240 volts) is the most common charging option for fleets. It works well for vehicles that return to a depot or workplace and can charge over several hours or overnight. For many fleets with predictable daily routes, Level 2 charging is all that's needed.
- DC Fast Charging (DCFC) provides much higher power than Level 2 and charges vehicles much more quickly. It is best for fleets that need to recharge during the workday, operate multiple shifts, or travel longer distances with limited downtime. DC Fast Charging typically costs more to install than Level 2 charging.
- Megawatt Charging System (MCS) is a new, high-power charging standard designed for heavy-duty trucks and other large commercial vehicles with very high energy needs. As MCS becomes more widely available, it will support much faster charging for vehicles with large battery packs.
Hydrogen Fuel Cell Electric Vehicle Fueling
Hydrogen fuel cell electric vehicles (FCEVs) use hydrogen to generate electricity that powers an electric motor. Instead of plugging in to charge, they are fueled with hydrogen gas in about the same amount of time it takes to fill a gasoline or diesel vehicle. Many medium- and heavy-duty FCEVs can also travel long distances between fueling stops.
Fleets have several options for fueling hydrogen vehicles. They can use public hydrogen fueling stations, install private fueling equipment at their facility, or, in some cases, use mobile hydrogen fueling services. The best option depends on factors such as fleet size, vehicle routes, fueling frequency, and the availability of hydrogen infrastructure in the area.
Find Public Hydrogen Stations Near You
Hydrogen Fuel Cell Partnership Station Map
Explore Incentives
Financial assistance may be available to help pay for charging or fueling equipment, installation, vehicles, and other project costs.
Charging and Fueling Options
Every fleet is different. Some fleets install charging or fueling equipment at their home base, while others use public stations, shared charging sites, mobile equipment, or subscription services. Many fleets combine several options to meet their operational needs. Below are options to consider.
Home-Base/Depot Charging
Home-base or depot charging is the most common option for fleets that return to a central base. This type of charging allows for scheduled overnight charging and can work with fleet and energy management systems to help reduce costs and improve efficiency. It works best for fleets with predictable routes and schedules.
- Tips to Control Costs: Consider Managed Charging
Electricity costs can vary based on the time-of-day vehicles are charged and the highest amount of electricity the facility is using at one time, known as peak demand. Managed charging can help reduce these costs. These tools are often software-based and may be offered by utilities, charging providers, or third-party companies.- Managed charging helps fleets reduce electricity costs by controlling when and how vehicles are charged. Managed charging works best for fleets with predictable or flexible schedules and is commonly used with depot charging.
- Smart charging is a type of managed charging that schedules vehicle charging during lower-cost, off-peak hours.
- Automated load management is another type of managed charging that limits how much electricity is used at one time to reduce peak demand charges.
Public DC Fast Charging
This type of charging can support longer routes alongside depot charging. On its own, public DC Fast Charging works well for decentralized fleets or those needing flexibility on the road. The number of public stations is growing but is still limited for heavy-duty trucks. Fleets should make sure that public stations can accommodate their trucks when planning routes. Below are links to find public charging stations.
Mobile Refuelers / Off-Grid Charging
Mobile refuelers and off-grid charging are portable systems that can be set up quickly at temporary sites or where the grid isn’t available. This can be a solution while permanent charging or hydrogen stations are being built. These systems are useful for pilot projects or when grid upgrades are delayed. Capacity and power vary, so fleets should check that the mobile charger meets their vehicles’ needs.
Truck-as-a-Service
Truck-as-a-Service is a broad term for new business models to help fleets get into zero-emission vehicles. One common approach is a subscription that bundles electric trucks, charging, maintenance, and telematics into one monthly fee. This model removes upfront costs and allows fleets to try out the technology. Truck-as-a-service is still new and is best suited for fleets looking for a low-risk option or if they have limited in-house expertise.
Charging-as-a-Service
Charging-as-a-Service is an option that has no upfront infrastructure costs. Providers handle equipment, installation, and daily charging. This is ideal for fleets that want a simple solution that can grow over time. It is also good for fleets without access to depot chargers. Charging-as-a-service may also include energy management, monitoring, and maintenance bundled into one service.
Shared Charging Sites
Shared charging sites are charging stations that can be used by multiple fleets and are run by third party companies. This reduces capital costs and provides faster access to high-power charging. Fleets may need agreements or schedules to access these sites. Availability varies by location.
Hydrogen Fueling Options
Hydrogen offers fast fueling for drayage and regional haul heavy-duty fuel cell trucks. Option for hydrogen fueling includes on-site depot fueling, mobile fuelers, and public hydrogen stations. Hydrogen fuel offers diesel-like convenience with zero emissions. Hydrogen infrastructure is expanding, especially in California and pilot regions.
Find Public Charging & Fueling Stations
There are tens of thousands of electric charging stations throughout California. Hydrogen stations are in most metropolitan areas, with more planned statewide.
California: Medium/Heavy Duty Zero-emission Station Development
Nationwide: Medium/Heavy Duty Zero Emission Infrastructure Map
Installing Infrastructure: Getting Started
For fleets preparing to install charging infrastructure, a wide range of resources are available to make getting started as simple as possible.
Electric Utility Resources
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GO-Biz The Governor’s Office of Business and Economic Development (GO-Biz) has developed a set of permitting guidebooks to assist cities and counties with the permitting process. |  |
California Energy Commission
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CALSTART
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Still have questions about Charging & Fueling?
Cal Fleet Advisor is a free service to help determine your infrastructure options and to help you find funding and answer your questions.