Electric vehicle adoption in California continues to grow, and with it comes a surge in residential and commercial EV charger installations. However, a large number of these installations fail electrical inspections on the first attempt — leading to delays, rework, additional costs, and frustration for property owners.
The problem is not the chargers themselves. Most failures happen because California electrical and permitting requirements are misunderstood or ignored.
This article breaks down the most common reasons EV chargers fail inspections in California, references real code requirements, and explains how professional installation prevents these issues from the start.
EV Charger Installations in California Are Regulated — Strictly
In California, EV charger installations fall under multiple regulatory frameworks, including:
- California Electrical Code (CEC) — based on the NEC with state amendments
- Local city or county building departments
- Utility provider requirements (PG&E, SCE, SDG&E, etc.)
In most jurisdictions, a permit and inspection are mandatory for Level 2 and Level 3 chargers — and often for Level 1 if a new circuit is added.
Skipping or mishandling any part of this process is one of the fastest ways to fail inspection.
1. Incorrect Electrical Panel Capacity and Load Calculations
One of the most common inspection failures involves insufficient panel capacity.
Under CEC Article 220, electricians must perform load calculations to verify that the existing electrical service can safely support the additional continuous load of an EV charger. EV chargers are considered continuous loads, meaning they draw power for three hours or more.
Common violations inspectors flag:
- No documented load calculation
- Overloaded 100A or 125A panels
- Chargers added without considering HVAC, dryers, ranges, or solar backfeed
How to avoid it:
A professional installer evaluates the entire electrical system before installation and determines whether a panel upgrade, subpanel, or load management solution is required.
2. Improper Breaker and Wire Sizing
EV chargers require precise breaker and conductor sizing.
According to CEC Article 625, EV supply equipment must be installed on a dedicated circuit sized at 125% of the charger’s continuous load.
Common inspection failures include:
- Undersized conductors
- Incorrect breaker amperage
- Mismatch between charger rating and circuit capacity
For example, a 40A charger requires a 50A circuit, not a 40A one.
How to avoid it:
Proper circuit design based on manufacturer specifications and code requirements — not assumptions.
3. Lack of GFCI Protection Where Required
Recent NEC and California amendments expanded GFCI requirements for EV chargers, particularly in garages and outdoor locations.
Inspectors often fail installations for:
- Missing GFCI protection
- Incorrect GFCI breaker type
- Improper placement
This requirement varies slightly by charger type and location, which is why local code knowledge matters.
How to avoid it:
Install GFCI protection exactly as required by local jurisdiction and charger manufacturer instructions.
4. Missing or Incorrect Disconnecting Means
In some installations, especially commercial or higher-powered systems, inspectors require a local disconnecting means within sight of the charger.
Failures occur when:
- No disconnect is installed
- The disconnect is not readily accessible
- Incorrect disconnect rating is used
How to avoid it:
Verify disconnect requirements early in the design phase based on charger type and jurisdiction.
5. Improper Mounting Height and Physical Installation
Inspectors also check physical installation details, including:
- Mounting height
- Protection from vehicle impact
- Cable management
- Environmental ratings (indoor vs outdoor)
A charger mounted too low, too high, or without proper protection can fail inspection even if the electrical work is correct.
6. Permit Issues and Incomplete Documentation
Many failures have nothing to do with the hardware — they stem from paperwork.
Common issues include:
- Installing before permit approval
- Incorrect permit scope
- Missing single-line diagrams
- Mismatch between permit and actual installation
In California, inspectors compare the approved permit documents directly to the installed system.
How to avoid it:
Submit accurate plans, follow approved scope exactly, and schedule inspections properly.
7. Ignoring Utility and HOA Requirements
In multi-unit buildings or properties with solar, battery storage, or shared service, additional approvals may be required.
Failures occur when:
- Utility coordination is skipped
- HOA requirements are ignored
- Load management systems are not disclosed
These issues often surface after installation, causing delays or forced changes.
Why Professional Installation Makes the Difference
At EV Install BA, failed inspections are not “part of the process” — they are preventable.
Our approach includes:
- Full load calculations under CEC requirements
- Proper circuit and breaker design
- Permit preparation and submission
- Installation that matches approved plans
- Inspection coordination with local authorities
The result: clean installs that pass inspection the first time.
EV charger inspections in California are strict for a reason — EV charging introduces sustained electrical loads that must be handled safely. Most inspection failures are not bad luck.They are the result of shortcuts, incomplete planning, or lack of local code knowledge. If you’re installing an EV charger in California, the smartest step is starting with a professional who understands how inspectors actually evaluate these systems. Learn more at evinstallba.com.
