320V Battery Platform high voltage
6.6kW AC/DC Dual input On-board Charger 80V
The 6.6kW AC/DC Integrated On-board Charger is designed for 80V electric vehicle platforms, supporting both AC and DC charging inputs in one compact unit. Featuring CAN 2.0 communication, AUTOSAR architecture, UDS diagnostics, GB/T 20234 compliance, and optional air or liquid cooling, it provides a reliable and flexible charging solution for commercial EVs and specialty electric vehicles.
Product Introduction
PO‑AC‑6G‑80 is a 6.6 kW AC/DC dual‑input integrated on‑board charger, designed for an 80 Vdc voltage platform. It supports both air‑cooling and liquid‑cooling solutions, with total weight less than 6.5 kg. Developed on the AUTOSAR architecture, this unit features CAN2.0 communication, UDS diagnosis and BootLoad for UDS program flashing. It complies with signal detection and control requirements of GB/T 20234. Suitable for new‑energy vehicle and energy‑storage power systems, it accepts both AC mains and DC input, delivering stable performance under harsh on‑vehicle operating conditions.
Key Features
- Dual‑input design: accepts both AC and DC input, compatible with AC charging piles and DC power supplies for multiple application scenarios.
- AUTOSAR‑based software architecture; supports CAN2.0, UDS diagnosis and BootLoad program flash for convenient vehicle debugging and future upgrades.
- Fully supports signal detection & control defined by GB/T 20234 standard.
- Two cooling options: air‑cooling or liquid‑cooling to match different vehicle thermal designs.
- Comprehensive protection functions including OVP/UVP, short‑circuit, reverse‑polarity and over‑temperature; most faults support auto‑recovery for high reliability.
- High power factor ≥0.99, maximum efficiency ≥92%, low standby power ≤5 W.
- Passed full‑set on‑vehicle reliability tests: vibration, salt‑spray, anti‑corrosion, insulation & dielectric strength.
- CAN‑bus control: starts charging upon receiving charge command; enters standby mode without command.
Electrical Specifications
AC Input
- Input Voltage: 90‑265 Vac
- Frequency: 45‑65 Hz
- Max Input Current: 32 A
- Power Factor: ≥0.99 (@220 Vin, full load)
- Standby Power Consumption: ≤5 W
- Starting Impulse Current: ≤32 A
DC Input
- Input Voltage: 400 Vdc
- Input Current: 15 A
- Standby Power Consumption: ≤5 W
- Starting Impulse Current: ≤30 A
Output Parameters
- Output Voltage Range: 0‑105 Vdc
- Output Current Range: 0‑80 A
- Rated Output Power: 6600 W
- Constant Voltage Accuracy: ±1 %
- Constant Current Accuracy: ±0.5 A (Io ≤10 A); ±5 % (Io＞10 A)
- Maximum Efficiency: ≥92 %
- Off Response Time: ≤200 ms
- Voltage Ripple Factor: ≤1 %
Protection Functions
- Input & Output OVP / UVP Protection: Shuts down on over‑voltage or under‑voltage; auto‑recovery after fault removal.
- Output Short‑circuit & Reverse‑polarity Protection: Shuts down under output short‑circuit or reverse‑battery connection; auto‑recovery after fault elimination.
- Over‑Temperature Protection (OTP): Output power derates when heat‑sink temperature＞75 °C; circuit cuts off above 95 °C; charger resumes output when temperature drops below 85 °C.
Environmental Conditions
- Internal cavity operating temperature of integrated system: ‑40 ℃ ~ +85 ℃
- Cooling liquid temperature (liquid‑cooling system): ≤65 ℃
- Storage Temperature: ‑40 ~ 95 ℃
- Cooling Method: Air‑cooling / Liquid‑cooling optional
- Communication: CAN‑bus control
- Operation Logic: Normal charging with charging command; standby status without command.
Safety & Reliability
- Dielectric Strength
- Input‑Output: 2000 Vac /10 mA /1 min, no breakdown or flashover
- Input‑Chassis: 2500 Vdc /1 mA /1 min, no breakdown or flashover
- Output‑Chassis: 2500 Vdc /1 mA /1 min, no breakdown or flashover
- Insulation Resistance: Primary‑secondary ≥50 MΩ
- Harmonic current complies with GB17625.1‑2003 Clause 6.7.3.1
- Passed X/Y/Z‑axis swept‑frequency vibration test; no component damage or fastener loosening, refer to GB/T15139‑1994 Clause 6.5
- Metal parts with qualified anti‑corrosion coating; salt‑spray performance refers to GB/T 2423.17
- Performance meets or exceeds relevant requirements of GB/T 24347‑2009
EMC Characteristics
- Electromagnetic Interference: Complies with GB/T 18487.3 Clause 11.3.1
- Electromagnetic Immunity: Complies with GB/T 18487.3 Clause 11.3.2
Interface Overview
- AC Input Connector: Zhilv CL‑HVC530 series high‑voltage connector
- High‑voltage DC Output Connector: Amphenol HVSL3620 series high‑voltage connector
- Signal Control Connector: Molex 5018203231. Integrates dual‑channel CAN, CC/CP charging pilot, wake‑up input, LED status indicator, 12 V /5 V auxiliary power and other signal pins.
Mechanical Information
- Weight: ＜6.5 kg
- Two mechanical versions available: air‑cooled version and liquid‑cooled version. Refer to specification drawing for detailed mounting dimensions.
