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80kW EV Charging Module with 97.5 Peak Efficiency

80kW Megawatt Ultra-Fast Charging Module

80kW EV Charging Module with 97.5 Peak Efficiency

TH80F1KA1-WT Max

Peak efficiency ≥97.5%
High protection, with double-sided full potting process
Integrated magnetic design, downsizes winding components
Wide operating temperature range: -40℃ ~ +75℃

Power: 2

Low noise: 3

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Introduction about 80kW EV Charging Module

The 80kW AC/DC Charging Module delivers peak efficiency ≥97.5%. Built with double-sided gel-filling for high protection. Integrated magnetic design minimizes component size. It operates reliably between -40℃ and +75℃ for all kinds of extreme working scenarios.

Advantages about 80kW Module

Peak efficiency ≥97.5%
High protection, with double-sided full-gelling process
Integrated magnetic design, downsizes winding components
Wide operating temperature range: -40℃ ~ +75℃

Parametric Performance about the EV Charging Module

Model No.	TH80F1KA1-WT Max
Input	Input voltage range (line voltage)	270Vac~490Vac
	Max input current	150A
	Frequency	50/60Hz
	Power factor	≥0.99
	THD	≤5%
	Standby zero power mode	Active power: 0W Rective power: 0Var
Output	Voltage regulation range	50Vdc~1000Vdc
	Max output current	268A
	Constant power interval	300Vdc~500Vdc, 600Vdc~1000Vdc
	Current liｍiting range	0.5A~268A
	Voltage regulation accuracy	≤±0.5%
	Current regulation accuracy	≤±1%
	Voltage ripple: (peak to peak)	≤±1%
	Peak efficiency	≥97.5%
	Soft start time	≤5S
	Communication bus protocol	CAN
Other Parameters	Operating temperature	-40℃~75℃(output derating above 55℃)
	Relative humidity	5% RH ~ 95% RH,non-condensing
	Noise	≤65dB
	Altitude	≤2000m
	Dimensions(without handles)	437.5mm300mm125mm
	Weight	≤27KG
	MTBF	500000 hours
	Degree of protection	IP 20

Performance Curve of 80kW EV Charging Module

The80kW EV Charging Module delivers stable and efficient power conversion performance under a wide range of input voltage, output voltage, and current conditions. The performance curves demonstrate the module’s excellent adaptability, high power output capability, and reliable operation for advanced EV charging infrastructure.

The input voltage versus output power curve shows that the 80kW EV Charging Module can maintain a rated output power of 80kW across a wide input voltage range, ensuring continuous and efficient charging performance under different grid conditions. This wide operating range improves system stability and enables flexible deployment in various charging environments.

The output voltage versus output current curve highlights the module’s wide output voltage capability from 200Vdc to 1000Vdc and high current output performance up to 266A, supporting different electric vehicle battery platforms and fast charging requirements.

With optimized power conversion technology, intelligent control, and high reliability design, Tonhe’s 80kW EV Charging Module provides a scalable power solution for DC fast charging stations, highway charging hubs, fleet charging systems, bus and heavy-duty EV charging applications.

Applications of 80kW EV Charging Module

The80kW EV Charging Module is designed to provide efficient, reliable, and high-performance power conversion for a wide range of electric vehicle charging applications. With high efficiency, wide output voltage range, and advanced protection technology, it serves as a core power component for modern DC fast charging infrastructure worldwide.

This80kW EV Charging Module is widely used in public EV charging stations, highway fast charging hubs, commercial charging networks, fleet charging facilities, and heavy-duty electric vehicle charging systems. Its stable power output and intelligent control capability enable fast and reliable charging for passenger vehicles, buses, logistics vehicles, and other electric transportation applications.

ForDC fast charging stations, the module helps charging operators build high-power charging systems with improved energy efficiency and reduced operational costs. In fleet charging applications, it supports continuous charging operation for electric buses, delivery vans, and commercial fleets that require reliable charging performance. The module is also suitable for solar-storage-charging integrated systems, providing flexible power conversion solutions for sustainable EV infrastructure development.

With its high reliability, long service life, and global certification compliance, Tonhe’s 80kW EV Charging Module is an ideal solution for charging equipment manufacturers, charging operators, and system integrators seeking scalable and efficient EV charging solutions.

Certified EV Charging Power Module for Global Markets

Tonhe Technology’s EV Charging Power Modules are designed to meet international safety and performance standards, providing reliable solutions for global DC fast charging infrastructure. Certified with CE certification and compliant with IEC 61851-23:2023 standards, these high-efficiency charging modules ensure safe operation, excellent electromagnetic compatibility, and long-term reliability in various application environments.

Double-Side Gel Filling Technology – Enhanced Reliability for EV Charging Power Modules

Tonhe Technology applies advanced double-side gel filling technology to its EV Charging Power Modules, providing comprehensive protection for internal electronic components and significantly improving module reliability in harsh operating environments.

By using high-performance organic silicone material, the PCB boards and key components inside the charging module are fully covered on both sides, forming a protective layer with excellent electrical insulation, moisture resistance, corrosion resistance, and thermal performance. This advanced potting design effectively prevents damage caused by humidity, dust, salt spray, vibration, and temperature fluctuations, ensuring stable operation throughout the product lifecycle.

The fully automated gel filling production process guarantees consistent quality and precise protection for every module. Compared with traditional protection methods, Tonhe’s gel-filled EV charging modules achieve higher environmental adaptability, lower failure rates, and longer service life, making them ideal for DC fast charging stations, fleet charging systems, highway charging infrastructure, and other high-power EV charging applications.

Reliable Global Shipping & Delivery Support for EV Charging Power Modules

Tonhe Technology provides reliable global delivery solutions for EV Charging Power Modules and DC fast charging components, ensuring safe and efficient transportation from factory to customers worldwide. With professional export experience, strict packaging standards, and stable logistics partnerships, Tonhe supports customers in Europe, Asia, North America, and other global markets with on-time shipment and secure product delivery.
Each EV charging module shipment is carefully inspected, protected with industrial-grade packaging, and prepared according to international transportation requirements. From production scheduling and quality inspection to container loading and final delivery, Tonhe’s complete supply chain management system ensures product safety throughout the entire logistics process.

Advanced Manufacturing Strength of Tonhe Technology

Tonhe Technology has established strong manufacturing capabilities with advanced intelligent production systems and automated manufacturing facilities, providing reliable EV charging modules and power electronics solutions for global customers.
As a professional EV charging module manufacturer, Tonhe integrates automated production lines, strict quality management, and advanced manufacturing technologies to ensure high product consistency, stable performance, and efficient delivery. The company operates complete in-house manufacturing processes, including automatic soldering, wave soldering, final assembly, packaging, special-shaped component insertion, and gel-filling production, covering key stages from component processing to finished product delivery.
With highly automated production equipment and intelligent manufacturing management, Tonhe improves production efficiency while maintaining strict control over every manufacturing process. Advanced automation technologies help achieve precise assembly, consistent product quality, and reliable large-scale production capacity to meet the growing demands of global EV charging infrastructure.
Tonhe Technology follows internationally recognized quality management standards, including IATF16949, ISO 9001, ISO 14001, and ISO 45001 certifications. Through comprehensive quality control and reliability testing systems, Tonhe ensures that every charging module delivers excellent durability, safety, and long-term operational reliability.
By combining advanced manufacturing capabilities, automated production lines, professional engineering expertise, and strict quality assurance, Tonhe Technology continues to provide dependable EV charging solutions and become a trusted manufacturing partner for customers worldwide.

Frequently Asked Questions (FAQ) – 80kW AC/DC Charging Module

1. What is an 80kW AC/DC Charging Module used for?

The 80kW AC/DC Charging Module is a core power conversion component designed for high-power EV charging stations. It converts AC power from the grid into stable DC power for electric vehicle charging. It is widely used in DC fast charging stations, charging hubs, highway charging stations, fleet charging systems, and commercial EV charging infrastructure.

2. What are the key advantages of Tonhe Technology’s 80kW Charging Module?

Tonhe Technology’s 80kW EV Charging Module features high efficiency, high reliability, and advanced thermal protection. The main advantages include:

Peak efficiency ≥97.5%
Double-sided full potting protection technology
Integrated magnetic design for higher power density
Wide operating temperature range from -40℃ to +75℃
Stable performance for long-term operation in harsh environments

These features help charging operators improve energy efficiency and reduce maintenance costs.

3. How does the double-sided full potting technology improve module reliability?

The double-sided full potting technology provides enhanced protection for internal electronic components by filling and sealing critical areas with high-performance insulating materials.

This technology helps to:

Improve moisture and dust resistance
Enhance vibration resistance
Protect PCB and power components from environmental impact
Extend the service life of the EV charging power module

It is especially suitable for outdoor DC fast charging applications.

4. What is the efficiency of the 80kW EV Charging Module?

The Tonhe 80kW AC/DC Charging Module achieves a peak efficiency of ≥97.5%, helping reduce power losses during the charging process.

Higher efficiency means:

Lower electricity consumption
Reduced operating costs
Improved charging station profitability
Better thermal management performance

5. What applications are suitable for this 80kW charging module?

This high-power EV charging module is designed for various charging infrastructure applications, including:

Public DC fast charging stations
EV charging stations for commercial vehicles
Electric bus charging systems
Fleet charging solutions
Highway ultra-fast charging stations
Charging stations integrated with renewable energy systems

6. Can this EV charging module operate in extreme environments?

Yes. The 80kW AC/DC Charging Module is designed for reliable operation under challenging environmental conditions.

With a wide operating temperature range of -40℃ to +75℃, the module can maintain stable performance in cold regions, hot climates, and outdoor charging environments.

7. Does Tonhe Technology provide customization services for EV charging modules?

Yes. Tonhe Technology provides professional customization services based on customer requirements, including:

Output voltage and current customization
Communication protocol adaptation
Mechanical structure optimization
Charging system integration support

Our engineering team can support different EV charger manufacturers and charging infrastructure projects worldwide.

8. What certifications does Tonhe EV Charging Module have?

Tonhe Technology’s EV charging modules are developed according to international charging standards and have obtained relevant certifications to support global market applications.

Certification support helps customers ensure:

Product safety compliance
Reliable operation
Easier market access
Improved project acceptance

Specific certificates can be provided according to different product models and market requirements.

9. How does Tonhe Technology ensure product quality before shipment?

Tonhe Technology applies strict quality control throughout the manufacturing process, including:

Incoming material inspection
Automated production testing
Performance testing
Aging testing
Final quality inspection before shipment

Each EV charging module is carefully tested to ensure reliable performance before delivery to global customers.

10. What is the ordering and delivery process for Tonhe 80kW Charging Module?

The typical purchasing process includes:

Customer requirement confirmation
Technical specification discussion
Product quotation and agreement
Sample testing (if required)
Mass production
Quality inspection
Shipment arrangement

Tonhe Technology provides reliable global delivery services and supports customers with professional technical assistance throughout the cooperation process.