Que: Can you tell us about Plugzmart key portfolio and how does Plugzmart differentiate itself from other EV charger manufacturers in India?

Ans: At Plugzmart, our product range includes AC chargers from 3.3kW to 22kW and DC chargers from 30kW to 360kW. What truly differentiates us from other EV charger manufacturers in India is our focus on indigenous technology. We design and develop all the critical components in-house—from charger controller systems to PLC modules and charging stack protocols. This ensures not only quality and reliability but also reduces dependence on foreign imports. Our chargers are CPRI (NABL) and ARAI-certified, reinforcing their credibility and performance in real-world conditions.

Que: What are the technical challenges you faced while developing the proprietary controller card for the DC Fast Charger?

Ans: Building a proprietary controller card for our DC Fast Chargers came with its own set of challenges:
• Optimizing Power Electronics: Managing high power levels efficiently while keeping heat dissipation low requires extensive testing and fine-tuning.
• Communication & Interoperability: We ensured seamless integration with different EV models by implementing OCPP 1.6/2.0, CAN, and Modbus protocols for smooth interaction with vehicles and grid systems.
• Safety Mechanisms: Developing robust protection algorithms for overvoltage, overcurrent, and overheating was crucial for long-term reliability.
• Firmware & Real-Time Processing: Achieving low-latency control for dynamic load adjustments and compatibility with various battery chemistries was a key challenge.
• Regulatory Compliance: Meeting BIS, ARAI, and IEC standards required rigorous testing, especially for electromagnetic interference (EMI) shielding and harmonic distortion limits.

Que: How does Plugzmart ensure interoperability of its chargers with different EV models and manufacturers and what communication protocols are used in Plugzmart's smart chargers for connectivity and data exchange?

Ans: EV charging interoperability is standardized, every EV follows ISO 15118 and DIN protocols, and all CCS2 chargers comply with these standards. This ensures that any EV with CCS2 can connect to our chargers without compatibility issues. That said, we go a step further and actively test every new EV model as soon as it launches to guarantee seamless operation.

Our chargers also support OCPP 1.6 and OCPP 2.0.1, enabling smooth integration with different Charging Management Systems (CMS). This allows users to charge their EVs through multiple service providers (EMSPs), making our chargers widely accessible.

Que: What are the considerations for integrating solar power into Plugzmart's charging solutions and what methods are used in Plugzmart’s chargers to detect grid instability and prevent failures?

Ans: We’ve designed Plugzmart chargers to work effortlessly with solar power. By incorporating MPPT-based DC-to-DC conversion, we ensure maximum utilization of solar energy, reducing reliance on the grid and lowering costs for EV owners.

To maintain grid stability, our Energy Management System (EMS) continuously monitors voltage, frequency, and power quality. In case of fluctuations, the charger automatically adjusts power levels or switches to an alternative energy source.

For added reliability, we use AI-driven predictive maintenance to detect potential faults early. If the grid becomes unstable, our automatic islanding protection safely disconnects the charger, preventing failures and ensuring uninterrupted operation. With this technology-first approach, Plugzmart chargers offer a future-ready and sustainable EV charging solution.