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What Is PCB Board
The Mekel EV Charger PCB board is the intelligent control center inside Mekel’s portable and wallbox chargers. It manages everything from power delivery and temperature monitoring to communication with the vehicle and user interface. Without a reliable charger PCB, even the best hardware can’t deliver safe, efficient charging. Designed for 7–22 kW AC chargers, this PCB boardintegrates seamlessly with Type 2, NACS, and Type 1 connectors — making it the core component for a wide range of EV charging products.
Whether used in a home wallbox, a portable charger, or a commercial AC station, the Mekel charger PCB ensures stable performance, real-time protection, and smooth communication with the vehicle’s battery management system. It handles CP/PP signaling, RCD protection, temperature monitoring, and OCPP communication on a single compact board. Mekel’s PCB board is the result of thousands of hours of field testing — reliable, safe, and ready for volume production.
Key Features of PCB Board
Integrated CP Signal Processing
The charger PCB handles Control Pilot (CP) and Proximity Pilot (PP) signals according to IEC 61851-1 standards. It negotiates charging current with the vehicle, detects cable connection, and manages the latch status. No external controller needed — the PCB board does it all.
Real-Time Temperature Monitoring
Multiple NTC thermocouple inputs on the PCB boardmonitor temperatures at key points: connector pins, cable, and internal power components. If any sensor detects overheating, the charger PCB reduces current or shuts down the session automatically.
LED and Display Control
The PCB board drives status indicators — LED rings, RGB lights, or small LCD screens. Users see charging status, fault codes, and current settings at a glance. The charger PCB supports common display protocols (I2C, SPI, UART) for easy integration.
RCD and Ground Fault Protection
Built-in residual current detection (RCD) meets IEC 62955 requirements for DC leakage (6 mA or higher). The charger PCB also monitors ground continuity and triggers an emergency stop if a fault is detected — all in milliseconds.
OTA Firmware Updates
The charger PCB includes a Wi-Fi or 4G module (optional) that supports over-the-air firmware updates. New features, bug fixes, or compliance updates can be pushed remotely. No need to open the charger or swap the PCB board in the field.
Compact, Single-Board Design
The Mekel PCB board integrates all control, protection, and communication functions on a single 150 x 100 mm board. Reduces assembly time, lowers BOM cost, and improves reliability compared to multi-board designs.
Parameter of PCB Board
| Parametro | Specifiche |
|---|---|
| Tensione di ingresso | 230V AC (single phase) / 400V AC (three phase) |
| Max Current Handling | 32 A (continuous) |
| Control Pilot (CP) Output | ±12V, PWM variable duty cycle (5–100%) |
| Monitoraggio della temperatura | 4 × NTC inputs, -25°C to +125°C range |
| Protection Features | RCD (6 mA DC), Over-current, Over-voltage, Ground fault |
| Communication Interfaces | Wi-Fi / 4G / Ethernet (optional) / CAN bus |
| Protocol Support | OCPP 1.6J (upgradable to 2.0), ISO 15118 (ready) |
| User Interface Support | LED / RGB / 7-inch LCD via SPI/UART |
| Temperatura di esercizio | Da -30°C a +70°C |
| Temperatura di stoccaggio | -40°C to +85°C |
| Board Dimensions | 150 mm × 100 mm × 25 mm |
| Power Supply for Peripherals | 12V DC / 5V DC output for display, sensors, fans |
| Certificazione | CE / UKCA / FCC (pending) |
Scalare l'infrastruttura EV con soluzioni di ricarica ad alta efficienza
Why Choose Mekel's PCB Board
One Board, Full Control
The Mekel PCB board replaces multiple discrete modules. It handles CP/PP signaling, RCD protection, temperature monitoring, LED control, and network communication. No need to source separate boards for each function. This charger PCB simplifies assembly and reduces failure points.
Built for Real-World Conditions
The PCB board is conformal coated to resist moisture, dust, and corrosion. It operates reliably from -30°C to +70°C — whether in a sun-baked parking lot or a freezing garage. Mekel's charger PCB is tested for vibration and thermal cycling beyond typical EV charger requirements.
Remote Updates, Lower Service Cost
OTA firmware support means the PCB board can receive updates without opening the charger. Fix bugs, add features, or update communication protocols remotely. For fleet operators or charge point owners, this charger PCB reduces expensive site visits.
Flexible Integration
The PCB board works with Type 2, NACS, and Type 1 connectors. It supports single-phase and three-phase inputs. Mekel provides full documentation and technical support for integration into existing charger housings. Custom firmware versions available for OEM customers.
Applicazione
Mekel’s PCB Boards are versatile and engineered for high-traffic environments:
Hub di ricarica pubblici
Ideale per i luoghi in cui gli autisti hanno bisogno di un rapido rifornimento durante i viaggi a lunga distanza, garantendo un elevato fatturato e una buona redditività.
Parcheggio per il commercio al dettaglio e l'ospitalità
Attirate i conducenti di veicoli elettrici di alto valore nel vostro centro commerciale, hotel o ristorante offrendo servizi premium di ricarica rapida in corrente continua.
Luoghi di lavoro e campus aziendali
Fornite velocità di ricarica di livello dirigenziale a dipendenti e visitatori, migliorando il vostro profilo di CSR aziendale.
FAQ
Can the Mekel PCB board be used in both single-phase and three-phase chargers?
Yes. The Mekel PCB board automatically detects the input voltage configuration and adjusts its PWM signaling accordingly. The same charger PCB works with 230V single-phase (up to 7.4 kW) and 400V three-phase (up to 22 kW). No hardware change is needed — just a different firmware configuration.
Does the PCB board support OCPP for remote management?
Yes. The charger PCB includes OCPP 1.6J as standard, with the ability to upgrade to OCPP 2.0 via OTA update. The PCB board communicates with central management systems over Wi-Fi, Ethernet, or 4G (depending on the connectivity module installed). Session data, fault logs, and remote start/stop commands are all supported.
What happens if the temperature sensor on the PCB board detects overheating?
The charger PCB is programmed with multiple response levels. If a moderate temperature rise is detected, the charger PCB reduces charging current to lower heat generation. If temperature continues to rise past a critical threshold (typically 85°C at the connector pins), the PCB boardimmediately stops the charging session and sends a fault alert to the user and any connected management system. Charging resumes only when temperatures return to safe levels.
Can I get a custom firmware version for the Mekel charger PCB?
Yes. Mekel offers firmware customization for OEM customers. The charger PCB can be programmed with specific current limits, unique LED patterns, localized language support for displays, or special authentication requirements. Contact Mekel’s engineering team with your requirements — typical lead time for custom firmware is 4–6 weeks.
How long does the Mekel PCB board typically last in field use?
The charger PCB is designed for a service life of 10+ years under normal operating conditions. Key components are derated to reduce stress. The PCB board has no moving parts, so the primary wear factors are thermal cycling and humidity. Conformal coating and quality component selection ensure the charger PCB outlasts most chargers it’s installed in.
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