EV Charging Electrical Solutions
Comprehensive component selection and configuration for new energy charging stations — from button switches and power supplies to circuit breakers and charging modules.
Charging Station Component Selection & Configuration
Detailed selection requirements, configuration points, and working condition adaptation for button switches, switching power supplies, and circuit breakers.
Button Switches
Emergency Stop Switch
Complies with GB/T 18487.1 standard. Rated current ≥ 10A (AC220V), contact configuration ≥ 1NO+1NC, CCC mandatory certified. Installed 1.2–1.5 m from ground, red mushroom head with yellow background, one-click cutoff ≤ 100 ms response.
Charging Gun Lock Switch
Miniature limit switch, rated 1–5A, lifespan ≥ 50,000 cycles, IP67 protection. Built into charging gun head — locks after insertion, unlocks after charging, supports emergency release on malfunction.
Mode Switch
Toggle/boat type switch, rated 10–25A, IP54 or above. For selecting charging modes and operational states on the charging pile control panel.
Switching Power Supply
Selection Requirements
Ultra-thin metal shell industrial grade. Full voltage input 90V–264V, efficiency ≥ 89%, no-load consumption ≤ 0.1W. Output adapted for 24V/12V charging pile control circuits with full overvoltage, overcurrent, and overheat protection.
Configuration & Deployment
Concentrated in the charging pile control cabin, providing stable low-voltage power for BMS communication, indicator lights, relays, and auxiliary control circuits — isolated from strong electrical interference.
Working Condition Adaptation
Supports full range: 7 kW AC slow charging to 200 kW DC fast charging. 24-hour uninterrupted standby operation with strong resistance to grid voltage fluctuations.
Circuit Breakers
AC Side Leakage Protection
Complies with GB 14048.2. Leakage action current 30 mA, action time ≤ 0.1 s. B-type leakage preferred — detects smooth DC leakage that standard AC-type breakers miss.
DC Side Main Circuit Breaker
Molded case breaker with breaking capacity covering maximum short-circuit current. DC-dedicated breakers mandatory for high-power DC piles — AC switches strictly prohibited as substitutes.
Branch Circuit Breakers
Compact MCB with leakage protection — 30–50% smaller than standard products, suitable for tight cabinet layouts. Input side: primary breaker for overload, short circuit & leakage of entire machine. Each charging gun independently equipped.
Core Power Components & Distribution Protection
Engineering-grade charging module selection, distribution protection configuration, and mandatory core parameter requirements.
Core Power Component Selection
Charging Module (Power Module)
The "heart" of the charging station — accounts for ~50% of hardware cost. DC stations need efficient AC→DC conversion. Prefer wide-voltage output models compatible with different vehicle voltage platforms.
- Protection level: ≥ IP20 (standard), IP54+ (high-power liquid cooling)
- Efficiency: > 95%
- Special scenarios: 60–600W sealed wireless charging, IP67, >90% efficiency
On-Board Charger (OBC) Matching
Prioritize integrated silicon carbide (SiC) solutions. Supports 11 kW / 22 kW high-power AC charging, compatible with bidirectional V2G charge/discharge. Adapted to 800V high-voltage vehicle architecture — reduced space and operational losses.
Distribution Protection Configuration
Circuit Breakers
Main circuit: Molded case breaker with leakage protection (e.g. CDM6HL-125L) — full overload, short circuit, undervoltage & leakage protection with remote status monitoring.
Branch: Knight series CDB6HLES miniature RCD, covering A-type & AC-type residual current specs. Compact size saves 30–50% cabinet space.
Contactors & Fuses
High-voltage DC contactor: CDEV6I series with high/low voltage insulation separation — controls HV on/off via LV for safe connection/disconnection.
Fuses: Matched to maximum short-circuit current, breaks tens of times rated current, rapid arc extinguishing to prevent fault propagation.
Surge & Auxiliary Power
Surge protectors at power inlet resist lightning and grid surges. Auxiliary switching power supply: ultra-thin metal shell, 90V–264V full voltage input, efficiency ≥ 89%, no-load ≤ 0.1W — energy-saving compliant.
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