EV Charger and Charging Pile Cooling Cooling Solutions -- DC Fans | Herays
Application Solution

EV Charger and Charging Pile Cooling

Thermal support for charger modules, control boards, and power electronics

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Problem Space

Industry Challenges

Understanding the specific thermal and environmental demands of EV Charger and Charging Pile Cooling environments is the foundation of every Herays solution.

EV charging infrastructure operates continuously at the intersection of high power electronics, outdoor environments, and demanding duty cycles. A 60 kW DC fast charger dissipates 3–4.2 kW of heat continuously — at a duty cycle of 95%+ typical for public fast chargers, the thermal management system never rests. Getting the fan selection right directly determines system uptime and maintenance intervals.

EV charging equipment places unique demands that distinguish it from standard industrial cooling:

  • IP54 or higher — outdoor chargers face rain ingress, high-pressure cleaning, and coastal salt air. The fan assembly itself must be sealed against water and dust, not just the enclosure.
  • Wide voltage range (24V–48V DC) — EV charger controllers typically run on 24V or 48V control power. Fans that match these rails directly avoid efficiency losses from intermediate conversion.
  • PWM speed control — charging load varies with vehicle state of charge. PWM-controllable fans let the controller throttle fan speed under partial load, reducing noise and extending bearing life.
  • High MTBF at elevated temperature — charger enclosures in summer sun can reach 45–55°C ambient before the electronics add their heat load. MTBF ratings must be referenced at the actual operating temperature, not at 25°C.
  • CE, RoHS, and often FCC compliance — required for charger system-level approvals in most markets.

Herays industrial axial fans in the 120 mm range cover the airflow requirements for most EV charger power stages. All are available in 24V and 48V versions and carry CE and RoHS certification.

  • HR1225 24V — 120×120×25 mm, 134 CFM, CE/RoHS. Suitable for compact 7–22 kW AC chargers with moderate heat dissipation requirements.
  • HR1238 24V — 120×120×38 mm, 186 CFM. Higher airflow for DC fast charger power modules with dense component packaging.
  • HR1225 48V — same 134 CFM performance on a 48V bus. Simplifies integration with charger power architectures that consolidate on a single high-voltage control rail.

For chargers requiring tachometer feedback to detect fan failure — critical for systems that must alarm and de-rate before component temperatures exceed safe limits — specify the −SF (signal feedback) variants.

How long should a cooling fan last in a commercial EV charger? Plan for a minimum MTBF of 70,000 hours at operating temperature. At 95% duty cycle that is approximately 8 years before the first statistically expected failure. Ball-bearing fans significantly outperform sleeve-bearing designs at elevated temperatures and non-horizontal mounting angles.

Should I use PWM or voltage-variable speed control? PWM is strongly preferred. It provides linear speed control down to 20–30% minimum speed without the torque and startup issues associated with low-voltage operation, and allows proportional ramping with thermal load.

Herays supplies cooling fans to EV charger OEMs with custom cable lengths, connector types, and IP ratings. Request a sample or OEM quote to discuss your specific charger platform requirements.

Herays Approach

Our Solution

Precision-engineered DC fan technologies tailored to the performance and reliability requirements of EV Charger and Charging Pile Cooling applications.

Why Herays

Key Features for EV Charger and Charging Pile Cooling

Power module cooling

Airflow across charger heat sinks and power conversion electronics.

Cabinet ventilation

Fan options for outdoor charging cabinets and internal control areas.

OEM integration

Connector, wire, voltage, tachometer, and label customization.

Application Engineering

Ready to find the right cooling solution for EV Charger and Charging Pile Cooling?

Our application engineers are available to help you select the right product for your system requirements.

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