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Technical Deep Dive

How the Charger Works

From mains AC power to a fully-charged battery - a complete walkthrough of every stage inside the Solterra on-board charger, including PFC, DC conversion, protection systems, and thermal management.

System Overview

The Solterra on-board charger (OBC) is a sealed, high-efficiency power converter that takes single-phase or three-phase AC from a wall outlet and delivers regulated DC to the vehicle's battery pack through the BMS.

It operates in two broad configurations: CAN-enabled (communicating with the BMS via CAN bus) and Non-CAN (voltage-based termination only). CAN-enabled operation provides closed-loop control and full fault visibility.

Product Family
STTL A Series Domestic/ South Asia
STTL B Series Export EU Series
STTL C Series Export US Series
OBC Series LEV, Bus, Truck, E-LCVs
OBC = On-board P = Portable L suffix = Li-ion
Power Flow Architecture

Inside the Charger Power Path

A stage-by-stage view of how mains AC is filtered, corrected, isolated, and delivered to the battery, with BMS feedback shown as the control loop.

AC input path Power conversion stages Battery-side delivery BMS feedback path
~400 V DC DC output PWM ctrl /DIGITAL Control BMS data EV Battery Charger External Systems L N PE ⏚ AC INPUT · 230 V / 50-60 Hz EMI FILTER & PROTECTION X/Y caps · CM/DM choke Fuse · NTC · SPD PFC BOOST STAGE Active power factor correction ~400 V DC bus PF > 0.98 DC-DC ISOLATED STAGE LLC half-bridge resonant Galvanic isolation High efficiency OUTPUT STAGE LC filter · Output relay OVP · OCP · HVIL AUXILIARY SUPPLY Isolated SMPS Powers all control ICs CONTROL SYSTEM (MCU) PFC + DC-DC closed-loop Fault detection · Protection CAN transceiver THERMAL MANAGEMENT NTC sensors Fan speed regulation CAN Bus BATTERY PACK Li-ion cells + BMS CC / CV charge mode SOC & fault reporting EXTERNAL CONTROL SYSTEM BMS · Vehicle ECU Charge requests · SOC Fault status reporting
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Daily Operation

These are the everyday limits and charge-order rules that matter most in the field.

Area Requirement Practical Note
AC supply 150 Vac to 270 Vac L-N | Single phase L+N+E | 50 Hz | 16A max Use a healthy, properly earthed socket sized for the charger current.
Environment -30 C to 65 C | 5% to 95% RH | below 2000 m altitude Full output is available up to 45 C ambient, then output reduces until 65 C.
Charge order Connect DC to vehicle first, then AC to the socket, then switch on At end of charge, switch off AC first, then remove the DC connector.
Ventilation Minimum 10 cm clearance on all sides Never cover the vents or insert objects into them.
Standard Charge Procedure
1
Connect the charger output DC connector to the vehicle inlet.
2
Connect the charger input 16A plug to the supply socket.
3
Switch on the socket power supply.
4
Confirm charging status in the vehicle app, battery display, or LED panel.
5
At end of charge, switch off the socket power supply first.
6
Remove the DC connector from the vehicle inlet.
7
Wrap the cables carefully and store the charger in a dry, clean place.
Normal behavior: when the green LED is steady, charge is complete. Periodic restart after full charge can still be normal maintenance mode as the charger tops up self-discharge.

Stage-by-Stage Breakdown

01

EMI Filter & Inrush Protection

AC Side

The first thing mains power encounters is an EMI (electromagnetic interference) filter - a combination of X/Y capacitors and common-mode chokes that suppresses high-frequency noise from propagating back onto the grid or into the charger. An NTC thermistor (negative temperature coefficient) limits inrush current at power-on, protecting both the charger and the supply fuse. The AC input stage also includes 6 kV surge protection so line transients are absorbed before they can stress the downstream PFC and DC-DC stages. A fuse on the input provides overcurrent protection.

Protects: grid + chargerNTC inrush limiter6 kV surge protection
02

PFC Stage - Power Factor Correction

Critical Stage

The PFC (Power Factor Correction) stage is an active boost converter that converts the rectified AC (which has a sinusoidal shape) into a stable high-voltage DC bus, typically around 400V. It simultaneously shapes the input current to be sinusoidal and in-phase with the input voltage, achieving a power factor >0.98. This minimises reactive power draw from the grid.

Why two fault types? The charger distinguishes between PFC Internal Fault (failure inside the PFC controller, gate drivers, or MOSFET) and PFC External Fault (bad AC input voltage - too high, too low, wrong frequency, or poor plug contact). External faults are field-fixable; internal faults require factory service.

PFC Internal -> return to factoryPFC External -> check AC input
03

DC-DC Stage - Isolated Converter

Galvanic Isolation

The DC-DC stage takes the ~400V PFC bus and converts it to the battery's required voltage (typically 48-96V for two-wheeler packs) using a high-frequency LLC resonant converter with a transformer providing galvanic isolation. This isolation is safety-critical - it means the battery pack is never directly connected to mains potential.

Charging follows a CC/CV (Constant Current / Constant Voltage) profile: the charger pushes a regulated constant current until the battery reaches its target voltage (CV phase), then holds the voltage while current tapers to zero. For CAN-enabled chargers, the BMS dictates exact current and voltage setpoints in real time.

LLC resonant topologyHigh-freq transformerCC -> CV charging profile
04

Output Filter, Relay & Protections

Battery Side

Before output voltage reaches the connector, it passes through LC output filtering to reduce ripple, then through an internal relay. The relay opens instantly on any fault condition - overvoltage, overcurrent, short circuit, or overtemperature. Output voltage ripple is kept below 0.5% of full load at nominal conditions.

Relay Fault: If the internal relay fails to open or close correctly, the charger enters Relay Fault mode. This requires factory service - the output path is compromised.

Thermal Management

The charger uses active fan cooling and three independent thermal sensors to protect both internal stages and the surrounding environment.

TEMP

External Temperature Sensor

Monitors ambient temperature at the charger's intake. If ambient exceeds the rated limit, the charger triggers an External Temperature Fault and shuts down output to prevent thermal damage to surroundings or the battery.

DC

DC Stage Thermal Sensor

Monitors the DC-DC converter heatsink temperature. The charger operates at full rated current up to 45C ambient, then stepwise derates output current as temperature rises toward 65C, then shuts down. The internal temperature shall never exceed 85C.

PFC

PFC Stage Thermal Sensor

Monitors the PFC section. Overtemperature here indicates high ambient, blocked vents, or excessive input-side losses. Clear dust from vents every 3-6 months to prevent this fault.

Derating behaviour: When ambient temperature is between 45°C and 65°C, output current is automatically reduced to keep junction temperatures safe. Charging continues at reduced rate rather than stopping entirely - unless the temperature exceeds the upper limit.

Protection Systems

Multiple layers of protection are active simultaneously during operation.

Protection Type Trigger Condition Response User Action
Overcurrent (AC) Input current exceeds rated limit PFC shuts down; NTC thermistor absorbs inrush Check supply fuse and wiring gauge
Overvoltage (DC Out) Output voltage exceeds setpoint + margin Output relay opens; fault LED Check battery voltage and BMS setpoints
Short Circuit (DC) Near-zero impedance at DC output Immediate relay open; fault mode Not protected in Activation Mode (see Activation page)
Under-voltage (Battery) Battery voltage below minimum threshold Output withheld; UV fault LED See Activation Function
Overtemperature Any of 3 thermal sensors exceed limit Output derates then shuts down Improve ventilation; reduce ambient temp
Precharge Timeout Output current = 0 for extended period Fault mode after timeout Check battery and connections; may need replacement
Reverse Polarity DC output connected backwards Not protected in Activation Mode Verify connector polarity before plugging in
Activation Mode Risk: During the activation (wakeup) pulse, the charger produces a forced output with no reverse polarity or short circuit protection. Always verify connector orientation before connecting to a deeply discharged battery. Reverse polarity damage during activation is excluded from warranty.

Preventive Maintenance

Most repeated field faults come from airflow restriction, damaged cables, or poor connector condition rather than charger hardware failure.

Interval Task What To Do
Every charge Visual inspection Check the AC plug, DC connector, and both cables for damage, corrosion, fraying, or heat marks before connecting.
Monthly Connector check Inspect for loose pins, heat discoloration, or corrosion at all accessible connectors.
Every 3-6 months Vent cleaning Clear cooling fins and ventilation slots using a dry cloth, dry brush, or gentle compressed air.
Every 3-6 months Cable inspection Check strain-relief points and the full cable run for cracks, chafing, or crush damage.
Every 6 months Battery health test Run a capacity or discharge test so weak packs are found before they become field failures.
Annually Torque check Re-torque mounting and battery-side connections to the specified values.
Dust accumulation in cooling fins and vents is one of the biggest causes of repeated thermal faults. A dry cleaning every 3 to 6 months has outsized impact on reliability.

Non-CAN Charger: Important Risks

Non-CAN chargers use only voltage-based termination. There is no communication loop with the BMS. This creates uncontrollable risks that Solterra users should understand:

BMS Protection Failure: If the battery protection board fails, the charger has no feedback mechanism. If the stop-charge condition is never met, the charger will continue delivering power indefinitely - potential overcharge or thermal event.
MOSFET Damage Scenario: If a BMS MOSFET is damaged and the protection board issues a cut-off command, the command cannot execute. The charger continues charging - cannot receive the stop instruction from a non-communicating battery.

Solterra Technologies Pvt Ltd accepts no liability for property or personal injury resulting from these Non-CAN scenarios. CAN-enabled operation is strongly recommended for all new deployments.

Internal Links

Related Technical Guides

Keep moving between the support guides below to narrow the issue faster.

Related Page

How RCDs Work

Learn how an RCD compares live and neutral current, why imbalance trips it, and which wiring mistakes create confusion.

Related Page

Activation / Wakeup Function

See how Solterra chargers wake deeply discharged batteries and what risks apply during activation.

Related Page

CAN Bus Communication Guide

Follow the charger-BMS handshake flow, message types, and CAN fault diagnosis guidance.

Related Page

3000A / 3000BG 120/220V Operation Mode

See how special-firmware 3000A and 3000BG chargers latch into 120V or 220V mode across an 85-270VAC input range.

Related Page

Step-by-Step Troubleshooting

Pick a symptom and follow the correct field checks before escalating to service.

Next: Activation Function