Modules for Battery Charging Applications

Electric vehicles and e-mobility solutions are the future of transportation in a world aiming to reduce its carbon footprint. To make battery-powered vehicles cost-efficient, electric vehicle chargers must be highly efficient and economical. While power conversion stages at the multi-kW level are improving with the latest topologies and semiconductor technologies, auxiliary AC/DC power supplies must also match EV charger requirements in terms of conversion efficiency and value.

Charging wall boxes and stations are often installed in overvoltage category three (OVC III) environments with potential for significant dips, surges, and transients from lightning strikes, which the power supplies must also withstand. Additionally, temperature variations can be extreme, and the AC supply voltage may be three-phase 480VAC or 277VAC. Auxiliary AC/DC modules must operate reliably in this environment, along with switching regulators and DC/DC converters that provide internal voltage conversion and isolation.

These 3W to 60W AC/DC converter modules support 85–528VAC input for line-to-neutral connections in 100/115/230/277VAC single-phase systems or line-to-line in 400/480VAC systems. The cost-optimized, fully certified parts are available with multiple output options. They support a wide operating temperature range of -40 to +85°C for harsh conditions, making them suited for auxiliary supplies in battery charging and monitoring systems. These series comply with EMC standards without requiring external filters and offer low no-load and standby power consumption.

Several RACxx products are compatible with direct connection to OVC III systems. Models such as RAC03E-K/277, RAC04NE-K/277, RAC10-K/277, RAC20NE-K/277, RAC20E-K/277, and RACM60-K are designed as auxiliary internal power supplies for EV charging systems. These modules are EN IEC 61558-2-16, EN IEC 61558-1, and EN IEC 60335-1 certified, with a wide input voltage range of 85–305VAC to maintain stable output voltage even with variable input.

For both line-to-phase and line-to-line configurations in 277/480VAC systems, the RACxx-K/480 AC/DC converter series offers isolated 5W, 15W, or 25W outputs at 5, 12, 15, or 24VDC from 85 to 528VAC input. The modules are EMC compliant (Class B) without external components and support an operating temperature range of -40 to +80°C. They are directly compatible with OVC III systems, making them suitable for auxiliary converters in outdoor EV charging stations and general industrial environments.

The RACPRO1-S480 delivers 480W of output power with up to 95% efficiency, making it ideal for DC charging systems and control applications with high load demands. Its wide input voltage range, 150% power boost, and compact design allow for easy integration into charging infrastructure and industrial applications.

The RACPRO1-Txxx series includes compact three-phase DIN rail mounting power supplies for demanding battery charging use in extreme environments. Features include extended surge immunity, reinforced isolation, and built-in EMC filtering for long lifespan. Inputs support 3AC mains (3P + E) or 450–850VDC. The 480W and 960W models offer a charging mode selector switch for 24V or 48V battery charging in low-voltage EVs like golf carts, personnel carriers, or automated guided vehicles (AGVs).

Battery charging circuits often require DC/DC converters for auxiliary rails and isolated power to communication interfaces. High-efficiency, board-mounted models like the 4:1 input 40W RP40 series and 20W REC20 series feature six-sided shielded 2”x1” packages—optimized for control circuitry in charging stations and battery management systems.

For lower power battery management, the 4:1 input 8W RP08-AW series includes models with 160V input ranges, ideal for battery strings. When a low-power 5V isolated rail is needed—such as for -5V analog supplies or isolated interfaces in smart EV chargers—the RFMM-0505 or RKE series offer 1W output, 4kV isolation, and full safety certifications.

Non-isolated switching regulators serve as high-efficiency alternatives to linear regulators in battery charging designs. The R-78E-1.0 series achieves up to 97% conversion efficiency, delivering 1-amp output from 3.3V, 5V, or 12V with input up to 28V. For higher output power up to 3kW, the half-brick RBBA3000-50 buck-boost converter offers a 9–60V input range and 0–60V adjustable output. This enables use with either higher or lower input voltages. It is suited for battery voltage conversion in EVs and stabilization in UAV/drone charging systems.

RECOM Power Systems specializes in high-spec custom power supply solutions including battery chargers, balancers, and conditioners for mobile and fixed systems. These solutions use platform-based designs proven in extreme applications, including defense-grade conditions. Inputs support single or three-phase power, and outputs are configurable to 30kW or higher. Bidirectional units are available for energy recovery. All products feature intelligent monitoring, control, and complete protection.