DC Charging Module
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What Is a DC Charging Module
DC Charging Module, often referred to as the core power unit of a DC fast charger, is the heart of modern electric vehicle charging infrastructure. Unlike traditional chargers that rely on integrated power conversion, a DC Charging Module converts AC power from the grid into regulated DC power and delivers it directly to the vehicle’s battery.
This high-efficiency conversion process allows for significantly higher power outputs, typically ranging from 15kW to over 60kW per module. As a result, a DC Charging Module enables scalable charging solutions — multiple modules can be combined to achieve total power from 30kW to over 400kW. At Mekel, our DC Charging Modules are engineered to bridge the gap between high-demand energy needs and sustainable mobility.
Key Features of DC Charging Module
High-Power Conversion Performance
Our DC Charging Module minimizes energy loss during AC-to-DC conversion, supporting high-current delivery that meets the needs of modern high-capacity EV batteries.
Smart Connectivity & Load Balancing
Integrated with OCPP 1.6J (upgradable to 2.0), our DC Charging Module allows for remote monitoring, firmware updates, and dynamic load balancing to prevent grid overload.
Hot-Swappable Modular Design
The power units inside our DC Charging Module are hot-swappable, ensuring that if one module malfunctions, other modules remain operational. This design minimizes downtime and simplifies maintenance.
Advanced Safety & Compliance
Safety is our non-negotiable priority. Every DC Charging Module undergoes rigorous testing to ensure global compatibility and protection.
Protection Levels
Built-in protection against over-voltage, under-voltage, short-circuit, and leakage (Type B RCD) with IP54 or IP55 rating for outdoor use.
Wide Voltage Output Range
Our DC Charging Module supports an output voltage range of 150V to 1000V DC, making it compatible with both low-voltage and high-voltage EV battery systems — from passenger cars to electric buses and trucks.
Parameter of DC Charging Module
| Feature | Specification |
|---|---|
| Product Name | DC Charging Module |
| Input Voltage | 3-phase 380V/400V/480V AC (±15%) |
| Power Output (Per Module) | 15kW / 20kW / 30kW / 40kW / 60kW |
| Output Voltage Range | 150V - 1000V DC |
| Output Current Range | 0A - 200A (Model dependent) |
| Efficiency | ≥ 96% at nominal output power (Peak ≥ 97%) |
| Connector Compatibility | CCS Combo 1/2, CHAdeMO, GB/T (via charging station) |
| Cooling Method | Forced Air Cooling / Liquid Cooling (Optional) |
| User Interface | Remote monitoring via OCPP / Optional LCD display |
| Communication | Ethernet / 4G / Wi-Fi / OCPP 1.6J / CAN bus |
| Enclosure Material | Galvanized Steel / Aluminum Alloy (Anti-corrosion) |
| Protection Degree | IP54 / IP55 (Outdoor rated) |
| Operating Temperature | -30°C to +60°C (Derating above 50°C) |
| Dimensions (W×D×H) | 420×280×130mm (30kW model - varies by power) |
Scale Your EV Infrastructure with High-Efficiency Charging Solutions
Why Choose Mekel's DC Charging Module
Proven Field Reliability
Our DC Charging Modules have been deployed in thousands of charging stations across 30+ countries, with a field failure rate of less than 0.5%. Every module is tested for 1,000+ hours before leaving our factory.
Flexible Scalability
Whether you need a 30kW standalone charger or a 400kW ultra-fast hub, our DC Charging Module allows you to scale power by simply adding more modules — no redesign or complex re-engineering required.
Energy-Saving Operation
With peak efficiency of 97% and intelligent standby mode that reduces idle power consumption to less than 10W, our DC Charging Module helps station operators save thousands of dollars in electricity costs annually.
Easy Maintenance & Support
Our modular design means any faulty DC Charging Module can be replaced in under 10 minutes by a single technician. We also provide 24/7 remote technical support and a standard 5-year warranty.
Application
Mekel’s DC Charging Module are versatile and engineered for high-traffic environments:
Public Fast Charging Stations
Mekel DC Charging Modules power highway and urban charging hubs, enabling 20-80% charge in 20-40 minutes with 60kW to 400kW+ total output.
Commercial Fleet & Bus Depots
Ideal for electric buses, trucks, and ride-hailing fleets. Wide voltage range (150V-1000V) and hot-swappable design ensure minimal downtime for commercial operations.
Off-Grid & Renewable Energy Charging
Perfect for remote areas with weak grid connections. Our modules work with solar, battery storage, or diesel generators, featuring intelligent load management for stable operation.
FAQ
What is the difference between a DC Charging Station and a DC Charging Module?
The primary difference is the scope of integration. A DC Charging Station is a complete charging unit including cabinet, cables, and user interface. A DC Charging Module is the core power conversion unit inside the station — multiple DC Charging Modules can be combined to scale total power output from 30kW to over 400kW.
Can your DC Charging Module be used to upgrade existing charging stations?
Yes, our DC Charging Module is designed for easy integration into existing charging stations. You can replace old power units with Mekel DC Charging Modules to enhance efficiency and reliability without replacing the entire station.
Is Mekel’s DC Charging Module compatible with all types of electric vehicles?
Yes, when integrated into a proper charging station, the DC Charging Module supports all major EV protocols including CCS Combo 1/2, CHAdeMO, and GB/T. Our DC Charging Module works seamlessly with modern electric vehicles.
How long is the lifespan of a DC Charging Module?
A Mekel DC Charging Module has a typical operational lifespan of 8-10 years under normal use, with over 10,000 hours of rigorous testing to ensure long-term reliability. Regular maintenance can extend the life of your DC Charging Module even further.
Can multiple DC Charging Modules work together in one charging station?
Yes, multiple Mekel DC Charging Modules can work in parallel to scale total power output. For example, four 60kW DC Charging Modules can be combined to create a 240kW fast charger. This modular design allows station operators to start small and expand capacity by adding more DC Charging Modules as demand grows, without replacing the entire charging station.
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