The charging module is one of the most important components inside a DC EV charger. For a charger manufacturer or system integrator, choosing a charging module is not simply about selecting 20 kW, 30 kW, or 40 kW. Input voltage, output voltage, efficiency, power factor, harmonic current, and thermal performance can all affect the final charging system.
Here are seven parameters worth checking before purchasing an EV charging module.
1: Output Power
2: Output Voltage Range
A module’s output voltage range determines which battery systems it can support.
For example, Huawei’s R100020G1 20 kW module provides a 150–1000 VDC output range, while its 40 kW R100040G2 module also supports 150–1000 VDC.
Infypower’s 30 kW REG1K0100G module also supports 150–1000 VDC and provides constant-power operation from 300 V to 1000 V.
This is important because a module with a wide output-voltage range can support a broader range of EV battery systems.
3: Efficiency
Efficiency directly affects energy loss and heat generation. The basic calculation is:
Power Loss = Output Power × (1 / Efficiency − 1)
For a 30 kW module:
- At 95% efficiency: Loss ≈ 30 × (1 / 0.95 − 1) = 1.58 kW
- At 96.5% efficiency: Loss ≈ 30 × (1 / 0.965 − 1) = 1.09 kW
That difference is about 490 W per module at full output. For a charging station operating many modules for long periods, this difference can become significant.
Current products on the market show why efficiency is an important comparison point. Huawei lists maximum efficiencies of 96.55% for its 20 kW module, 96.4% for its 30 kW module, and 96.25% for its 40 kW module, under specified test conditions. Sinexcel’s SER100040K3B 40 kW module specifies a peak efficiency of 97.03%.
4: Power Factor and Harmonic Current
Power factor is another important parameter for the AC side of the module. A high power factor means the module can use the available AC input more effectively.
For a three-phase system: P ≈ √3 × V × I × PF
If the charging module has poor power factor, the input current required for the same power will increase.
Harmonic current should also be checked. For example, Sinexcel’s SER100040K3B specifies:
- Power factor ≥0.99
- THDi ≤5%
- 40 kW output
- 323–456 VAC input
For projects that require IEC harmonic-current testing, buyers should also ask for the actual test conditions and test report, rather than relying only on a THDi value in a datasheet.
5: Input Voltage Range
Not all charging modules have the same input range. If a module is to be used in different countries, it is essential to verify the input voltage range against local grid conditions before selecting the model.
This is equally critical when a customer requires harmonic testing at a specific voltage (such as 380 VAC or 400 VAC).
6: Cooling and Operating Temperature
Charging modules continuously convert large amounts of electrical energy during operation, making thermal management critical.
Key factors to consider typically include:
- Forced-air cooling
- Fan control
- Operating temperature
- Temperature derating
- Dust and moisture protection
- Altitude
For outdoor charging projects or equipment installed in hot climates, these specifications are often more important than marginal differences in peak efficiency.
7: Size, Weight and Maintenance
To facilitate easy replacement, charging modules from major brands generally share the same dimensions and weight—particularly dimensions. However, buyers should still pay attention to this factor during procurement to avoid issues with dimensional inconsistencies in specific models.
A Simple EV Charging Module Comparison Checklist
Huawei, Infypower, Sinexcel and Other Module Options
There are several established Chinese brands whose charging modules are widely visible in the market.
Huawei HiCharger offers 20 kW, 30 kW and 40 kW modules, with output ranges extending up to 1000 VDC. Its published specifications emphasize efficiency, wide voltage operation and environmental reliability.
Infypower offers modules such as the 30 kW REG1K0100G, with 150–1000 VDC output, power factor around 0.99 and full-load efficiency above 95% according to its published product information.
Sinexcel offers SER-series modules including 20 kW and 40 kW models. Its 40 kW SER100040K3B lists a 50–1000 VDC output range, 97.03% peak efficiency, PF ≥0.99 and THDi ≤5% under specified conditions.
These specifications show why comparing modules by brand name or output power alone is not enough. The right choice depends on the complete requirements of the charging system.
For EV charging projects, Allblue can help source charging modules from established brands according to your required power, voltage range, efficiency, harmonic requirements and application conditions.