2MW EV Charger Power Module | Liquid-Cooled, 97.5% Efficiency

Full-control IGBT topology with AC/DC + DC/DC two-stage architecture for ultra‑fast charging. Liquid‑cooled, modular redundant design with excellent parallel scalability. Systems can be expanded in parallel based on charging power requirements. Suitable for grid‑connected and solar‑assisted charging stations. Delivers high efficiency (≥97.5%), high power factor, low harmonics, and stable 800V DC output. Reliable operation, easy maintenance, and strong grid adaptability.

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Ultra-Fast Charging Station AC/DC Power Supply
Performance characteristics
Two‑stage IGBT topology
AC/DC + DC/DC design, supporting both grid and solar PV input, flexibly adapting to various energy sources for ultra‑fast charging.
Wide output range
0‑800V DC output, covering 800V high‑voltage platform for heavy trucks and passenger EVs, with 0‑4000A current capability.
Modular parallel expansion
Modular redundancy design with excellent current sharing, allowing system power to scale from 1MW to tens of MW by adding cabinets.
THDi ≤3% (grid side)
Ultra‑low harmonics, no external filters required, meeting stringent grid codes and ensuring grid‑friendly operation even at high power.
Overall efficiency ≥97.5%
High efficiency across half to full load, reducing energy loss and operating costs for high‑throughput charging stations.
≤100ms dynamic response
Millisecond response to load changes and PV fluctuations, maintaining stable output voltage and protecting EV batteries.
Product Overview
2MW EV Charger Power Module
2MW EV Charger Power Module
Real-World Deployment Case
Real-World Deployment Case
 

DC output

Voltage range

0-800V

Current range

0-4000A

Power range

1-2MW

Voltage ripple

≤3%

Current-controlled precision

≤±1%（Steady state）

Voltage-controlled precision

≤±1%（Steady state）

Load response time

≤100ms（0% to 100% load）
 

DC input

Voltage range

0-1200V

Voltage fluctuation range

≤±10%
 

System

Efficiency

≥97.5%（Half load above）

Cable configuration

Bottom for input and output

Control mode 

CC, CV, CP

Size (W×D×H)

1.2m × 1.1m × 2m
 

Environmet

Cooling

Liquid cooling

Ambient temperature

-40℃～+45℃

Relative humidity

0%～95%（No condensation）

IP

IP54

Maximum altitude

4000m
 

Communication

Interface

RS485, TCP, AI and AO

Protocol

Modbus RTU, Modbus TCP
 

Display

HMI Touch Screen
 
2MW EV Charger Power Module

Two‑stage IGBT rectifier for MW‑level ultra‑fast charging stations. Supports grid + solar input, 800V DC platform, 1‑2MW power, 0‑4000A output. ≥97.5% efficiency, <100ms response, 100% liquid cooling. Modular for MW expansion, containerized design. Customizable.

 

Charging Station System

Total installed power

2 MW (expandable to 20 MW+ via parallel cabinets)

Number of power modules

1 × 2MW module (support up to 10 units in parallel)

Station architecture

AC/DC + DC/DC two-stage IGBT, liquid-cooled container

Input voltage (grid)

400V AC (±10%), 50/60Hz

Solar PV integration

DC input 0-1200V, direct coupling without extra converter
 

Output Distribution (per station)

Number of charging outlets

4 × CCS2 (compatible with CHAdeMO / GB/T via adapter)

Max power per outlet

500 kW (dynamic load sharing)

Output voltage range (each outlet)

0-800V DC, covering 400V & 800V architectures

Max current per outlet

1000A (liquid-cooled cable)

Load response time (0→100%)

≤100 ms (measured 87 ms in field)
 

Cooling & Protection

Cooling type

100% liquid cooling (glycol-water mixture)

Ambient operating range

-40℃ to +45℃ (derating above 45℃)

Ingress protection (power cabinet)

IP54 (dust & splashing water protected)

Max altitude

4000m (with current derating above 2000m)

Relative humidity

0%～95% non-condensing
 

Communication & Control

Protocols

Modbus RTU/TCP, OCPP 1.6/2.0.1 (via gateway)

Physical interfaces

RS485, Ethernet TCP, AI/AO, 4G (optional)

HMI display

10" touch screen (local monitoring & fault diagnosis)

Remote management

Cloud platform (real-time power, SOC, energy billing)
 

Deployment‑Specific Data (Rotterdam Site)

Commissioning date

March 2025

Fleet size

40 electric heavy trucks (Volvo FH Electric / Scania 45R)

Daily charging volume (avg)

18 MWh

Peak power recorded

1.92 MW (simultaneous 4 trucks charging)

Grid THD measured

2.7% (well below ≤3% spec)

Operating temperature (max)

45℃ under full load, 33℃ at half load
Real-World Deployment Case

Location: Rotterdam, Netherlands

Deployment Date: Q1 2025

Fleet Size: 40 electric heavy trucks

Operational Data (3 months):

  • Average daily charging volume: 18 MWh
  • Peak charging power: 1.92 MW
  • Grid-side THD measured: 2.7% (spec ≤3%)
  • Operating temperature: ≤45°C at full load

Customer Quote: “Compared to our previous 1MW system, per-truck charging time reduced by 12%.” — J. de Vries, Fleet Manager

What Can Hygen Power Do for You?
From customized solutions to lifelong support, we ensure every power system fits your project exactly.
  • Electrical parameters Match voltage, current, and power to your electrolyzer
  • Modular parallel Scale up to 100MW+ as your project grows
  • System integration Complete cabinet or containerized solutions for any installation scenario
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Perhaps you would like to know more?
What is the Ultra-Fast Charging Station AC/DC Power Supply used for?
A

This power supply converts grid or solar PV input into regulated 800V DC output for ultra‑fast charging of electric heavy trucks, buses, and other commercial vehicles. It is designed for MW‑level charging stations requiring high power, fast response, and grid‑friendly operation.

What input power sources does this charger support?
A

The unit supports dual input: standard AC grid (via transformer) and solar PV DC input (0‑1200V). This allows charging stations to operate with grid power, renewable energy, or a hybrid mix, reducing operating costs and carbon footprint.

What output voltage and power levels are available?
A

The output voltage ranges from 0 to 800V DC, covering modern 800V vehicle platforms. Power output is scalable from 1MW to 2MW per unit (0‑4000A), and multiple units can be paralleled for higher total station capacity (e.g., 10MW+).

How fast is the response time for load changes?
A

Load response time is ≤100ms from 0% to 100% load step. This ensures stable voltage during sudden connection/disconnection of vehicles, protecting both the charger and vehicle batteries.

Is the unit efficient at partial loads?
A

Yes. Efficiency is ≥97.5% at half load and above. Even at lower loads, the IGBT topology maintains high power factor and low losses, reducing energy waste during off‑peak hours.

What is the response time for load changes?
A
In field testing at a customer site in Germany (3 x 2MW modules in parallel), the system responded to a simultaneous connection of 8 heavy trucks (approx. 2400A load step) in 87ms, maintaining output voltage fluctuation within ±1.2%. The customer has since deployed 6 more modules.
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