DC Fast Charger

Overview

A DC fast charger delivers high-power direct current to an electric vehicle's traction battery, bypassing the vehicle's on-board AC charger. This 150 kW unit serves public and fleet charging, replenishing a typical EV from 20% to 80% state of charge in roughly 20–30 minutes. The charger rectifies grid AC, regulates a wide-range DC output to match the vehicle's battery voltage, and negotiates the charging session over the CCS control protocol.

How it works

Three-phase mains enters through the AC Input Stage, which provides metering, surge protection, and the input contactor. Power then flows to five Power Module (30 kW) units rated 30 kW each; every module performs active power-factor-corrected rectification followed by an isolated DC-DC stage, and the modules are paralleled to reach 150 kW. Their combined output is conditioned by the DC Output Stage stage, which provides the regulated, isolated DC bus, output contactors, and insulation monitoring.

Energy reaches the vehicle through the Charging Cable Assembly, a CCS2 cooled cable whose coolant lets it carry up to 375 A without an oversized conductor. The Liquid Cooling System circulates coolant through both the power modules and the cable, rejecting heat through a radiator and fans.

The Main Controller supervises the session: it reads the battery's voltage and current demand over the CCS PLC link, commands the modules, runs isolation and contactor-weld checks, and reports to the back office over OCPP. The driver interacts through the HMI / User Interface, which handles authentication, payment, and status, while the Emergency Stop provides a hardwired safety shutdown.

All components mount inside the Cabinet Enclosure, an IP54 outdoor enclosure with lockable service doors, supplemented by integrated Lighting Set for night-time use.