Partnering with a Clean Energy Innovator to Enable Rapid EV Charger Deployment
As momentum builds around electrification and decarbonization in the U.S., a leading company in the clean energy and electrified transportation space—focused on turnkey fleet electrification solutions—approached NJ Sullivan with a time-sensitive challenge. Their mission: to rapidly deploy electric vehicle (EV) charging infrastructure in support of large-scale electrified school bus and municipal vehicle programs across the country.
Challenge
Standard power distribution equipment available in the market could not meet their needs—long lead times, limited configurability, and lack of field-ready modularity stood in the way of their aggressive deployment schedule. The customer needed a custom-engineered distribution assembly that could be:
- Rapidly designed and manufactured
- Configurable for different site loads
- Reusable across multiple projects
- Scalable to accommodate future system expansion
- Affordable within project cost constraints
NJ Sullivan’s Solution
From the outset, NJ Sullivan worked as a collaborative design and manufacturing partner. We combined customer design input with the deep application and installation expertise of our engineering team to co-develop a power distribution solution tailored to the realities of EV charger deployment.
Key design elements included:
- Multiple branch circuits ranging from 100A to 400A, with a scalable design to support future expansion up to 800A
- A 2000A bus-rated auxiliary gutter to feed the branches, designed per National Electric Code (NEC) tap rules
- A 2000A bolted pressure switch as the main incoming disconnect, integrated with ground fault protection, arc flash mitigation, and robust surge protection
- Field-serviceable, transport-friendly construction, allowing the system to be broken down, shipped, and reassembled quickly onsite
Throughout the project, our team prioritized standardization of components where possible to support long-term reuse, while still allowing for flexibility in configuration across different sites.
Execution and Responsiveness
Understanding the critical nature of deployment timelines, NJ Sullivan delivered the system on schedule and within budget—overcoming one of the customer’s biggest concerns: long lead times from conventional suppliers. Our proactive communication, design agility, and manufacturing responsiveness were key to earning the customer’s trust.
So much so that midway through the original project, the customer turned to NJ Sullivan with an urgent request: a completely different custom housing needed on short notice to keep another critical infrastructure project on track. We delivered—again—ensuring their schedule didn’t slip and reinforcing NJ Sullivan as a trusted partner for future electrification initiatives.
Supporting the Future of Electrification
This project illustrates not only our ability to engineer and manufacture complex power distribution solutions, but also our alignment with customers advancing the energy transition. As more municipalities, transit agencies, and private fleets turn to electric vehicles, the demand for rapid, flexible, and scalable charging infrastructure will continue to grow.
At NJ Sullivan, we’re ready to meet that demand—one custom enclosure at a time.
