Have you ever wondered what factors contribute to the success of the energy transition?
One of these factors is certainly the adoption of electric vehicles. By replacing internal combustion engine vehicles with electric drivetrains, CO₂ emissions in the transportation sector can be significantly reduced. Electric cars not only help decarbonize, but also enable better integration of renewable energy into the power grid, as they can serve as flexible storage units.
To successfully complete this transformation, building a high-performance charging infrastructure is essential. In addition to enough public charging points, fast-charging stations along highways and in urban areas are especially necessary to alleviate range anxiety and ensure everyday usability. Furthermore, smart charging solutions must be implemented that support load management and bidirectional charging, thereby promoting grid stability and the use of green electricity.
An important technical standard in this context is IEC 61851, which defines the fundamental requirements, including safety, electric vehicle charging systems. For public charging systems, the charging modes Mode 3 and Mode 4 are particularly relevant:
- Mode 3 refers to charging via a permanently installed AC charging station, which enables secure communication between the vehicle and the charging point. This mode is now the standard for charging in private and semi-public areas.
- Mode 4, on the other hand, stands for DC fast charging, where the charging power is significantly higher and charging times can be greatly reduced. This mode is essential for long-distance journeys and use at highway rest stops.
Only by expanding both AC and DC charging infrastructure and consistently applying international standards such as IEC 61851, electromobility can reach its full potential and sustainably support the energy transition.
alfatec offers key components for charging stations - from low-power AC charging stations to high-power CCS2 DC charging stations and even Megawatt Charging Systems (MCS) for commercial vehicles. We also provide suitable components for systems with integrated energy storage.
We have illustrated these in two simplified interactive block diagrams:
AC – Charging Station (Mode 3)
The following simplified block diagram shows the typical functional blocks of an AC charging station:
- Input protection
- AC – Charging relay
- Current sensing
- Auxiliary power supply
- HMI (Human-Machine Interface)
- Output – Charging socket
Click here for the interactive diagram including product suggestions and data sheets:
Go To detailed Mode 3 View
Below you will find an overview of the most important aspects of Mode 3:
Relays / Sanyou
- AC charging relays from Sanyou (meets 3-kA short-circuit test according to IEC 62955 and positively guided auxiliary contact – IEC 61810-3)
- SPV40 / 2 main contacts 40A + 1 formB contact (auxiliary)
- SCP40 / 4 main contacts 40A + 1 formB contact (auxiliary)
- DSY2Y Series: for insulation monitoring
- SJ / SMIA / SMIC Series: for charging guns – interlock
Charging Connectivity / Yonggui
- Charging pile outlet: YG1418 (compliant with IEC62196-1 and IEC62196-2)
- AC charging gun: YG1509, 32 A, customizable (IEC61851-1)
- AC charging cable: YG-ENCP with two plugs at both ends, customizable
DC – Charger Pile (Mode 4)
The following simplified block diagram shows the functional blocks of an HVDC charger:
- EMC power filter
- Rectifier
- Power Factor Correction
- Auxiliary power supply and gate driving
- DC/DC converter
- Inverter current measurement
- Output filtering
- Output – Charging connection
Click here for the interactive diagram including product suggestions and data sheets:
Go To detailed Mode 4 View
Below you will find an overview of the most important aspects of Mode 4:
AC-Line Filter & Protection / Sunlord & Chemi-Con
- Common mode chokes
- CMC chokes made of amorphous or nanocrystalline materials
- ARCDC Series: available in 2-, 3-, and 4-phase for current ranges from 20 A to 48 A, impedance range from 1 kOhm to 4 kOhm.
- Ferrite cores / Chemi-Con
- CMC ring cores (nanocrystalline) / Chemi-Con
FW Series, various core types available in sizes from 28 mm to 66 mm
Contact us for your specific requirements
- Metal oxide varistor SV Series, non-flammable & THB types, UL, CSA, VDE, and CQC certified, for example:
- TND14SV Series for 275 V / 420 V with max. peak current 5 kA, max. energy up to 200 J (2 ms)
- Large sizes up to TND20SV Series with max. peak current 6.5 kA, max. energy up to 400 J (2 ms)
Current and Temperature Measurement / S4sensors & Sunlord
- HALL effect current sensor "S4-CSA02" / S4sensors – Sensors with adjustable magnetic sensitivity range from 5 to >800 mV/mT and no hysteresis error. Easy integration into existing busbar designs with integrated stray field immunity
- NTC chip thermistors / Sunlord (SDNT Series): Rated power ¼ W, resistance values from 4.7 kΩ to 220 kΩ, package sizes EIA01005 to EIA0805
AC-Relays / Sanyou
- Magnetic latching relays, WJ Series 1~3-phase, rated current up to 120 A, configurable with various coil configurations and connection types. The withstand voltage of the relays is 4 kV (contact to contact) and meets IEC62052-31 UC3 clause.
- SMI(x) Series for rated voltages of 250 VAC and rated currents of 10 to 50 A, specially developed for inverter applications (e.g., SMIC-G: 250VAC/45A)
- SPV Series high-voltage AC relays with rated voltages of 480 VAC / 690 VAC or 1000 VAC and rated currents up to 270 A
EMI Suppression Capacitors – Safety Capacitors / Faratronic
- Safety capacitors (Class X2): The C42, C4V, and C4H series are available for operating temperatures up to 125 °C and capacitances up to 25 µF. Standard rated voltage ranges from 275 VAC to 400 VAC. For harsh environments, these series are also available as THB or automotive type.
- Faratronic C45 and C46 Series (Class X1), C47 Series (Class Y1), and C43 Series (Class Y2): Class X1 capacitors are available for voltages up to 760 VAC and capacitances up to 15.0 µF. Class Y1 and Y2 capacitors are available up to 500 VAC. These series are also available as AEC-Q200 versions.
DC – Output
DC Smoothing / Faratronic & Chemi-Con
- Film capacitors / Faratronic
- C3C / C3D box type capacitors with rated voltages up to 1200V (soon up to 2000V) and capacitances up to 140 µF.
- C3C / C3D box type capacitors with rated voltages up to 1200V (soon up to 2000V) and capacitances up to 140 µF.
- MLCC / Chemi-Con
NTS stack version with X7R / X7S ceramic and rated voltages up to 500 V, e.g., rated voltage 500V/1.2 µF [EIA3025]
HVDC Relays / Sanyou
- High-voltage DC relays
- SEF Series rated voltage 450 VDC, rated current 20 ~ 200 A
- SEC Series rated voltage 750 VDC, rated current 150 A to 350 A with auxiliary contact
- SEL Series rated voltage 750 to 1000 VDC, rated current 100 A to 600 A
- SEP Series rated voltage 1500 VDC, rated current up to 400 A
DC Charging Connectivity / Yonggui
- YG-ENHPC: Charging gun (CCS2), rated current up to 375 A
- YG-ENHPC: Liquid-cooled charging gun (CCS2), rated current 600 A
- YG-SAMCS: Charging gun (MCS), rated current up to 1500 A
- TF000176: Charging gun (NACS), rated current up to 600 A
- YG-GBHPC charging gun (GB/T), oil-cooled, rated current up to 800 A
- Charging sockets available for all common standards
Please contact us for further details.
Fuses / Sinofuse (Synoelec) (according to IEC60269/UL248)
- RS309-MM Series: Fast-acting fuse (bolt type), rated current 5 A ~ 1200 A, rated voltage 750 ~ 1000 VDC
- RSZ307 Series: Fast-acting fuse up to 1500 VDC, rated current 100 A to 3000 A and a breaking capacity up to 250 kA (also suitable for battery storage systems)
Let's become another factor in a successful energy transition!
Create with us your custom electronic solutions – made for you.
You can also find our entire portfolio in our current LineCard!
For more detailed information about our products mentioned above and all others, please feel free to contact us.
Stay up to date!
By subscribing to our newsletter, you won’t miss any news: