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Charging Stations

Boyard DC compressors and chillers for charging stations are designed to provide effective cooling for electric vehicle (EV) charging infrastructure. These compressors ensure the reliable operation of charging stations by maintaining optimal temperatures, preventing overheating and ensuring safety. Boyard compressors are trusted by EV charging providers for their performance and energy efficiency.

Thermal Management Challenges in EV Charging Stations

High-power fast charging generates intense heat due to energy conversion inefficiencies in both the charger and battery interfaces. For instance, a 120kW DC fast charger can dissipate over 15kW of waste heat during full operation, with multi-gun configurations (e.g., 4-gun 480kW systems) amplifying thermal loads exponentially. Unmanaged heat accelerates component aging (e.g., capacitor degradation, insulation breakdown) and elevates the risk of thermal runaway in batteries—an increasing concern as lithium-ion cells reach higher energy densities.

Compounding these issues are the spatial constraints of urban charging stations: tight enclosures, underground garages, and crowded parking lots leave little room for large cooling systems. Additionally, noise restrictions in residential or commercial areas (e.g., 60dB limits) and diverse power infrastructures (AC 220V/115V, DC 24V/48V/96V/312V) further complicate deployment. Traditional solutions fail to reconcile these demands, creating a gap for a compact, efficient, and adaptable cooling solution.

​Boyard Mini Chiller: Engineered for EV Charging Excellence

1. Ultra-Compact Form Factor: Space Optimization in Dense Environments

Boyard Mini Chiller redefines space efficiency with a miniaturized compressor design, reducing footprint by 60% compared to conventional water-cooled systems. Weighing just 50–80kg, it integrates seamlessly into confined spaces—from charging pile clusters in shopping mall basements to narrow service areas along highways. For example, in Shanghai’s underground charging hubs, operators have deployed Boyard Mini Chillers adjacent to charging posts without disrupting traffic flow, enabling a 30% increase in charger density. Its slim profile also facilitates wall-mounted or rack-mounted installations, minimizing floor space occupation.

2. High Cooling Efficiency: Tackling Fast-Charging Heat Loads

At the core of the Boyard Mini Chiller is a high-performance mini compressor paired with optimized heat exchangers, delivering 1–2kW of continuous cooling capacity (up to 3kW for high-performance models). This matches the thermal demands of multi-gun fast chargers, maintaining critical components (charging modules, battery connectors) at safe temperatures (40–50°C) even during peak loads. In field tests, a 4-gun 480kW charger with Boyard Mini Chiller cooling maintained module temperatures 15°C lower than air-cooled systems, reducing thermal stress and extending equipment lifespan by 20%.

3. Low-Noise Operation: Compatible with Urban and Commercial Spaces

Noise pollution is a key concern for charging stations in residential or retail areas. Boyard Mini Chiller addresses this with a dual-cylinder compressor design and sound-dampening enclosure, achieving operational noise levels below 45dB—equivalent to indoor air conditioners. This meets strict municipal noise regulations (e.g., 55dB nighttime limits in European cities) and prevents user complaints. In a high-end Berlin residential charging facility, the chiller’s low vibration and noise levels eliminated disruptions to nearby apartments, earning operator praise for “silent reliability.”

4. Multi-Power Compatibility: Adapting to Global Infrastructure

EV charging networks span diverse electrical environments—from AC 220V/50Hz in Asia to DC 96V/312V in off-grid solar stations. Boyard Mini Chiller supports ​multi-power inputs: AC 220V/50Hz, AC 115V/60Hz, and DC 24V/48V/96V/312V—enabling seamless integration with grid-connected, backup, or renewable energy systems. This flexibility is critical for remote charging sites, such as African solar microgrids, where DC 96V compatibility allows direct coupling with photovoltaic storage systems, eliminating the need for grid expansion.

5. Industrial-Grade Reliability: Ensuring 24/7 Uptime

Charging stations operate around the clock, requiring cooling systems to withstand extreme temperatures (-40°C to +60°C), high humidity (90% RH), and corrosive environments (e.g., coastal salt fog). Boyard Mini Chiller leverages 20+ years of HVAC expertise and undergoes 100% factory testing before shipment, ensuring resilience under harsh conditions. Its robust construction—with corrosion-resistant components and industrial-grade sensors—minimizes downtime, a critical factor for operators where revenue loss from outages can exceed $10,000 daily. Smart protections (overload shutdown, high-pressure alarms) and IoT-enabled remote monitoring further reduce maintenance costs by 70%, enabling proactive fault resolution.

​Application Scenarios: From Urban Hubs to Remote Sites

  • ​Urban Fast-Charging Stations: Deployed in dense city centers, Boyard Mini Chillers enable high-density charger clusters in limited spaces while meeting noise and space constraints.
  • ​Commercial Charging Hubs: Malls, hotels, and highway rest stops use “1:4” (1 chiller for 4 chargers) configurations to optimize costs and space.
  • ​Off-Grid/Rural Stations: Solar or diesel-powered sites rely on its multi-power compatibility to maintain cooling without grid reliance.
  • ​Heavy-Duty Charging: Logistics parks and truck charging depots benefit from its high reliability under continuous heavy loads.

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