Description

BIDC1K0135S2 Charging Module Product Details

I. Product Overview

The BIDC1K0135S2 is a high-performance DC/DC charging module developed by Imax Power (Shenzhen) Co., Ltd. specifically for electric vehicle (EV) charging stations. Its primary function is to convert DC input into stable DC output, providing rapid DC charging current for batteries. The module’s internal circuitry is divided into two main sections: the first section rectifies the DC input voltage into an internal high-voltage bus, while the second section transforms, isolates, and rectifies the internal high-voltage bus to output the corresponding DC voltage/current based on different monitoring settings. This module boasts advantages such as high efficiency, high protection performance, high power density, a wide constant power range, and low noise. It supports an input of up to 950Vdc and offers a DC output voltage range of 150~1000Vdc with a power rating of 40KW.

II. Product Features

Energy Efficiency and Environmental Protection

• High Efficiency Across Full Load Range: Operates with ultra-low standby power consumption and achieves an efficiency exceeding 95.5%.

Ultra-Wide Input/Output Range

• DC Input Voltage Range: 300Vdc to 950Vdc, accommodating various input environments.
• Output Voltage Range: 50Vdc to 1000Vdc, meeting the fast-charging needs of multiple EV and battery pack types.

Wide Constant Power Output

• Constant Power Range: 300Vdc to 1000Vdc, satisfying the fast-charging requirements of various EVs.

Low Voltage, High Current Output

• Maximum Output Current Below 300Vdc: Maintains up to 133.3A, meeting the fast-charging needs of more devices.

High Power Density

• Power Density: Greater than 65W/in³, saving space within charging piles and reducing their footprint.

Safety and Reliability

• Emergency Stop Function: Quickly responds to system emergency shutdown commands to ensure safety.
• Multiple Protection Functions: Includes built-in discharge circuits for automatic residual charge dissipation, battery reverse flow protection, and protections against output overvoltage, overtemperature, short circuits, and fan failures.

Low Noise

• Adjustable Noise Modes: Three noise modes can be set to meet noise control requirements in different environments.

Intelligent and Convenient

• Fan Speed Reporting: Facilitates user adjustment of the overall charging pile fan speed based on module fan speed for optimized noise levels.
• Intelligent Air Duct Detection: Automatically detects air duct flow and limits power while issuing alarms if the air duct is obstructed.
• High Environmental Reliability: Key circuits are potted, significantly improving resistance to salt spray, humidity, and mildew.

III. Product Functions

Hot-Swappable

• Hot-Plug Technology: Enables easy installation and maintenance. The system’s output voltage remains undisturbed when the module is plugged in or removed during standby.

Advanced Current Sharing Technology

• Automatic Current Sharing: Modules automatically share current with an imbalance of less than ±5% of the rated current.

Input Power Limiting

• Output Power Correlation with Input Voltage: Different input voltage ranges correspond to different output power modes.

Output Power Limiting

• Maximum Allowable Output Power: Varies with different output voltage ranges at rated input voltage; the module features adjustable current limiting points.

Temperature-Based Power Limiting

• Output Power Restrictions: Vary based on ambient temperature, with a detailed temperature-power limiting curve provided.

Output Voltage Adjustment

• Continuous Adjustment: The output voltage can be continuously adjusted from 100Vdc to 1000Vdc with a minimum step size of 0.1Vdc via an external monitoring module.

Fan Control

• Automatic Speed Adjustment: The built-in processor adjusts fan speed based on ambient temperature, internal temperature, and output current.

Input Overvoltage/Undervoltage Protection

• Protection Indicators: Light up when input voltage is abnormal, and the module stops working. It can resume operation after fault clearance or with monitoring intervention.

Output Overvoltage Protection

• Adjustable Protection Points: Can be set via the monitoring module; manual intervention or module disconnection is required for reset after triggering.

Overtemperature Protection

• Automatic Shutdown: The module shuts down when the ambient temperature is too high and requires a startup command to resume operation after temperature recovery.

Internal Bus Fault Protection

• Automatic Shutdown: The module shuts down automatically when the internal bus voltage is abnormal, with a fault indicator lighting up. Monitoring is required for restart after short-circuit clearance.

Communication Interruption Protection

• Shutdown Protection: The module shuts down for protection if communication is interrupted for more than 10 seconds, with the indicator flashing. It resumes operation with default parameters after recovery; monitoring is required for restoration after more than 20 seconds.

Emergency Stop Protection

• Immediate Shutdown: The module shuts down with no voltage output and the alarm indicator remaining lit when an emergency stop signal is received. Monitoring is required for restart after signal withdrawal.

IV. Monitoring Performance

The charging module employs CAN bus communication, allowing the system monitor to issue various control commands/signals such as module on/off and output current ramp-up settings. It can also collect comprehensive information from the charging module, including input and output voltages. For detailed communication interaction information, refer to the relevant technical documentation.

V. Technical Specifications

Environmental Conditions

• Operating Temperature: -40℃ to +75℃ (derating required above 55℃)
• Storage Temperature: -40℃ to +70℃
• Relative Humidity: ≤95%RH, non-condensing
• Cooling Method: Forced air cooling
• Altitude: Below 2000m (derating required above 2000m; recommend derating by 10-15% per 1km increase)
• Atmospheric Pressure: 79kPa to 106kPa
• Protection Level: IP20

DC Input

• Input System: DC+/DC- and PE
• Voltage Range: 300Vdc to 950Vdc
• Maximum Static Voltage Withstand (Non-Operating): 1000Vdc
• Rated Voltage and Maximum Current: 800Vdc, 66.6A

DC Output

• Standby Power Consumption: <20W @ rated 800Vdc input
• Voltage Range: 150Vdc to 1000Vdc
• Current Range: 0 to 133.3A (current limiting point adjustable)
• Rated Current: 40A (when setting current limiting point)
• Voltage Regulation Accuracy: <±0.5% (150-1000V, 0-20MHz)
• Current Regulation Accuracy: ≤±1% (output load from 20% rated current to maximum current)
• Load Regulation: ≤±0.5%
• Startup Overshoot: ≤±3%
• Voltage Ripple Factor: ≤2% (150-1000V, 0-20MHz)

Surge and EMC Indicators

• EFT: Meets the general technical specifications for non-vehicle-mounted DC chargers for electric vehicles, NB/T 33001-1-2018, NB/T 33008-1-2018
• ESD: 8kV/15kV (Reference standards: NB/T 33001-1-2018, NB/T 33008-1-2018, GB/T 18487.2-2017)
• Conducted Immunity: 3Vrms, 0.15-80MHz (Reference standards: NB/T 33001-1-2018, NB/T 33008-1-2018, GB/T 18487.2-2017)
• Radiated Immunity: 10V, 80-2GHz (Reference standards: NB/T 33001-1-2018, NB/T 33008-1-2018, GB/T 18487.2-2017)
• Power Frequency Magnetic Field: 30A/m (Reference standards: NB/T 33001-1-2018, NB/T 33008-1-2018, GB/T 18487.2-2017)
• Conducted Emissions: Class A, meeting the general technical specifications for non-vehicle-mounted DC chargers for electric vehicles, NB/T 33001-1-2018, NB/T 33008-1-2018
• Radiated Emissions: Class A, meeting the general technical specifications for non-vehicle-mounted DC chargers for electric vehicles, NB/T 33001-1-2018, NB/T 33008-1-2018

Other Specifications

• Safety Requirements: Meets IEC61851-1, IEC61851-23, UL2202
• Efficiency: ≥97% @ 800V ≤ input side ≤ 865Vdc, 50%-100% load
• Current Sharing: Current sharing error ≤ ±5% of rated output current within 10%-100% load
• Temperature Coefficient (1/℃): ≤ ±0.01%
• Startup Time: Normal startup mode: delay from DC power-on to module output ≤ 3s; output current ramp-up: startup time can be set via the monitoring module, with a default startup time of 3-8s for output current
• Noise Level: ≤65dB(A) (1m away from the front panel)
• Grounding Resistance: ≤0.1Ω, capable of withstanding a current ≥80A
• Insulation Strength: Leakage current ≤3.5mA
• Surge Protection: Meets IEEE C62.41-1991 Class B3 level, 6kV/3kA (1.2/50μs impulse voltage and 8/20μs impulse current mixed wave)
• Insulation Resistance: ≥10MΩ between DC input part, DC output part, and housing, as well as between DC input part and DC output part

Specific Test Requirements

• DC Input Terminal to Housing: 3110V DC voltage for 1 minute, no breakdown or arcing, steady-state leakage current <1mA
• DC Output Terminal to Housing: 3110V DC voltage for 1 minute, no breakdown or arcing, steady-state leakage current <1mA
• CAN to Housing: 707V DC voltage for 1 minute, no breakdown or arcing, steady-state leakage current <1mA
• DC Input Terminal to CAN: 6220V DC voltage for 1 minute, no breakdown or arcing, steady-state leakage current <1mA
• DC Output Terminal to CAN: 6220V DC voltage for 1 minute, no breakdown or arcing, steady-state leakage current <1mA

ROHS Compliance

• Materials: ROHS-compliant materials + lead-free solder
• Certification: Complies with the EU ROHS Directive (Directive 2011/65/EU) and its additional directive (EU) 2015/863, as well as the EU REACH Regulation (EC) No 1907/2006 and its supplementary provisions.

Mechanical Parameters

• Dimensions: 84mm (height) × 300mm (width) × 395mm (depth) (excluding handles and sockets)
• Weight: ≤15.5kg