Retrofit Cable Management System for EV Charging Stations
A practical retrofit solution to manage heavy charging cables on existing chargers. Improve safety, keep the site tidy, and make charging easier for both drivers and operators.
Heavy charging cables can be difficult to manage on existing chargers
Long and heavy EV charging cables can be hard to handle, may touch the ground, and can create safety and operational challenges at busy charging stations.
BESSUN provides practical cable management solutions that can be retrofitted to existing EV chargers. Our systems help to support and guide the cable, keep the site tidy and safe, and make the charging process easier for drivers and operators.
BEFORE RETROFIT
Common Cable Management Problems
Many existing EV charging stations do not have a proper cable management system. Long and heavy EV charging cables are often left on the ground, which can lead to:
Safety Hazards
Cables on the ground can create tripping risks for drivers and pedestrians.
Damage and Wear
Cables may be dragged, stepped on or even run over by vehicles, leading to insulation damage and reduced service life.
Tangling and Poor Appearance
Long cables can easily become tangled, making the charging area look messy.
Difficult Handling
Heavy DC charging cables can be difficult for users to handle without support.
CABLE MANAGEMENT SOLUTIONS
Flexible Retrofit Options for Different Project Needs
Many EV chargers were installed without a cable management system. This often happens for 3 reasons:
Cable management was not considered in the original design.
Adding it later is difficult because of the charger’s appearance, size, or installation constraints.
The impact of long, heavy charging cables on daily operation, wear, and maintenance was underestimated.
That is where a retrofit cable management system becomes especially valuable.
Swing Arm
Supports and guides the charging cable while providing an extended working range around the charging station. Different configurations are available to suit the charger structure and installation conditions.
Cable Retractor
Uses a retractable rope mechanism to support and manage the charging cable. Different configurations are available for various installation positions and cable requirements.
Spring Balancer
Provides vertical cable support using a spring-balanced mechanism, helping reduce the effort required to handle heavy charging cables during operation.
Retrofit Projects
Real Applications at Charging Stations
Cable Retractor Retrofit in Action
Watch this completed retrofit project featuring a cable retractor with a pivoting top mount. The mount allows the system to move as the cable is pulled, making cable handling more flexible and convenient.
PROJECT EVALUATION
How We Evaluate Your Project
01
Charging Cable
Cable length, diameter and weight
02
EV Charger
Charger structure and available mounting points
03
Working Range
Cable routing and required operating range
04
Solution
Select a suitable cable management solution
05
Installation
Determine the installation position and mounting configuration.
FAQ
Can a Cable Management System be retrofitted to an existing EV charger?
Yes, in many cases. The appropriate retrofit solution depends on the charger structure, available mounting position, cable length, cable diameter, cable weight, and required working range. BESSUN can evaluate the application and recommend a suitable Cable Management System based on the project requirements.
Will installing a Cable Management System affect my charger warranty?
It depends on the charger design, mounting method, and the charger manufacturer’s warranty requirements. BESSUN can provide external or free-standing installation options for suitable projects to help minimize modifications to the existing charger. If the system needs to be mounted directly to the charger, we recommend confirming the installation requirements with the charger manufacturer in advance.
What are the main benefits of a swing arm for existing charging stations?
The Swing Arm supports the weight of heavy DC charging cables, helps reduce cable dragging and ground contact, and reduces mechanical stress on connectors and cable glands.
Is the cable management system suitable for outdoor use?
Yes. BESSUN Cable Management Systems are designed for outdoor EV charging applications. The appropriate solution should be selected according to the installation environment and project requirements.
What are the advantages of the Spring Balancer compared to other systems?
Spring Balancers can often be integrated into existing charging stations without major structural changes. The actual installation method and requirements depend on the charger design and site configuration.
Does the retrofit solution require regular professional maintenance?
One of the main advantages of our Cable Management System is that it is designed for long-term operation with low maintenance requirements. Beyond periodic visual inspections and cleaning, the system is designed for high-cycle operation in outdoor EV charging applications, helping reduce maintenance requirements and service visits.
Can the CMS be moved or re-installed if the charger is replaced?
Yes. 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 provides greater flexibility for fleet operators and site owners when charging equipment or site layouts change.
START YOUR PROJECT
Discuss Your Retrofit Project
Share your charger and cable information with us, and we’ll help evaluate a suitable cable management solution for your application.
Cable length · Cable diameter · Cable weight · Charger photos · Installation position