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APPLICATIONS • EV CHARGING

Powering Reliable EV Charging Infrastructure

High-voltage DC contactors, fuses, magnetics and thermal solutions for charger architectures where switching reliability, protection, efficiency and thermal performance are critical.

Explore EV Charging Products → Request Design Support →
DC Fast Charging Fleet & Depot Charging Battery-Buffered Charging Power Conversion
HIGH POWER DC CHARGER HVDC GRID → POWER CONVERSION → HVDC OUTPUT → VEHICLE
Engineer-first component selection Match voltage, current, breaking duty, thermal conditions and life requirements before design-in.
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High-Voltage DC Switching Contactor families extend to 2000 VDC

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Coordinated Protection Fuse selection matched to real fault conditions

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Power Conversion Components Magnetics for PFC, filtering and DC/DC stages

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Thermal Management Cooling for continuous high-power operation

APPLICATION ARCHITECTURE

Inside a DC Fast Charger

A charging system is more than a high-power converter. It is a coordinated electrical and thermal system where switching, protection, magnetic design and heat removal directly influence uptime, safety margin and service life.

Component Basics supports engineers across these critical points with application-focused selection, cross-reference support and custom configurations where standard parts do not fully match the requirement.

Architecture shown is illustrative. Exact topology and component placement vary by charger design.

Typical power path

Where our components can fit
Stage 01 AC Input

Grid connection, surge and front-end protection.

Stage 02 EMI / PFC

Filtering, power-factor correction and magnetic energy storage.

Stage 03 DC Link

High-energy DC bus with significant stored capacitance.

Stage 04 Isolated DC/DC

Voltage conversion, transformer isolation and output regulation.

Stage 05 HVDC Output

Controlled connection, isolation and protection to the vehicle.

SWITCHING DC Contactors Output isolation, controlled make/break and safety disconnect.
PROTECTION Fuses Protect high-energy DC paths against damaging overcurrent and faults.
POWER Magnetics PFC inductors, chokes, transformers and current-sensing functions.
THERMAL Fans / Cooling Move heat away from power stages and maintain component temperature margin.
OUR SOLUTIONS FOR EV CHARGING

Four component decisions that matter.

The right component is not simply the one with a matching current or voltage headline. Charger duty cycle, fault energy, ambient temperature, switching topology and service-life expectations all matter.

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CBVAC • SWITCHING

HV DC Contactors & Relays

For controlled connection and disconnection of high-voltage DC circuits, including charger output and internal DC-bus functions.

  • Rated operational voltage and current
  • Making / breaking duty and load type
  • Coil voltage, auxiliary contact and mounting
  • Mechanical / electrical life and environment
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CBVAC PROTECT

Fuses & Fuse Holders

For fast, predictable interruption when fault energy exceeds safe limits in the DC link, power module or output path.

  • DC voltage rating and interrupting capability
  • Time-current curve and I²t coordination
  • Thermal derating and continuous loading
  • Mechanical format, busbar and holder integration
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CBVAC POWER

Magnetics & Current Sensing

Inductors, transformers, chokes and sensing solutions for the PFC, isolated conversion, filtering and control stages.

  • Switching frequency and topology
  • RMS / peak current and saturation margin
  • Core loss, copper loss and temperature rise
  • Isolation, creepage and custom winding requirements
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CBVAC AIR • THERMAL

Fans & Thermal Solutions

Cooling solutions sized for actual airflow resistance, temperature rise and continuous charger operating conditions.

  • Airflow versus static-pressure requirement
  • System impedance and enclosure restriction
  • Operating temperature and reliability
  • Power, acoustics and control requirements
WHY SELECTION MATTERS

A datasheet rating is only the starting point.

High-power EV chargers combine elevated DC voltage, continuous current, repeated switching, large DC-link capacitance and demanding thermal conditions. A component can appear suitable on one headline rating and still be wrong for the real duty.

One example: contactor closing into a capacitive DC bus.

A large, uncharged capacitor bank can draw a very high transient current at contact closure. Without an appropriate pre-charge strategy, that inrush can overstress the contact system and increase the risk of contact welding. This is why load type and system architecture matter—not just the continuous current rating.

DC Contactor
Check operational voltage, continuous current at real ambient and conductor size, make/break duty, polarity where applicable, coil range, auxiliary-contact logic, expected electrical life and whether a pre-charge path is required.
Fuse
Check DC voltage capability, available fault current, required clearing behavior, time-current coordination, I²t, thermal derating, cycling profile and coordination with semiconductors, busbars and contactors.
Magnetics
Match topology, switching frequency, peak/RMS current, ripple, saturation margin, inductance tolerance, isolation requirements, core/copper losses and acceptable temperature rise.
Cooling
Size to the actual pressure curve and enclosure impedance—not free-air CFM alone. Consider operating temperature, filter loading, redundancy, power consumption, acoustics and expected service life.
Engineering note

Component Basics contactor documentation specifically calls out the need for pre-charge when switching charge/discharge circuits with significant capacitive load, because transient closing current can cause contact sticking/welding. Exact implementation must be validated at system level.

APPLICATION ENGINEERING WORKFLOW

From charger requirement to validated shortlist.

01 • Share architecture & duty
02 • Shortlist suitable families
03 • Review critical parameters
04 • Sample & validate
HOW WE HELP

We help engineers select for the application, not only the part number.

Send us your charger voltage, current, topology, expected duty cycle, ambient conditions, fault-current information and any target competitor part. We can help narrow the right Component Basics family and highlight the parameters that deserve validation before production design-in.

Application review
Cross-reference support
Custom configurations
Sample support
Datasheet / CAD support
Design-in coordination
Request Design Support → Request Samples →

Final component suitability remains dependent on the customer’s complete electrical, mechanical, thermal and safety requirements and the latest model-specific documentation.

EV CHARGING USE CASES

Built around the needs of modern charging.

Different charger architectures create different component stresses. The page structure is intentionally application-led so engineers can reach relevant products faster.

PUBLIC INFRASTRUCTURE

DC Fast Charging

High-voltage, high-power conversion with demanding availability and protection requirements.

COMMERCIAL

Fleet & Depot Charging

Repeated daily duty cycles, multi-port systems and uptime-sensitive operations.

GRID + STORAGE

Battery-Buffered Charging

Chargers integrated with BESS where DC-bus energy, protection and switching coordination are especially important.

NEXT-GENERATION

Bidirectional Charging

Power stages designed for controlled energy flow in both charging and export-capable architectures.

START WITH THE REQUIREMENT

Designing an EV charger?

Share the electrical architecture and target duty. We’ll help you identify the right switching, protection, magnetics and thermal solutions.

Request Samples → Talk to Engineering →