Directly engineered and manufactured for international CPOs, OEM automotive brands, and commercial charge-point operators.
Hangzhou Zap Charger Co., Ltd. is a premier, specialized EV charging solutions manufacturer and global ODM/OEM technology powerhouse dedicated to engineering high-performance connectors, ultra-flexible heavy-duty cables, high-power DC fast stations, and smart energy management systems for the rapidly expanding international e-mobility sector. Based in Hangzhou, Zhejiang Province—one of China’s top technological innovation and digital manufacturing hubs—the enterprise leverages a world-class regional electronics supply chain, an elite talent pool of power-electronics engineers, and advanced automated assembly lines.
Zap Charger delivers an exhaustive product architecture ranging from residential AC wallboxes (3.5 kW to 22 kW) and portable multi-current EV chargers to commercial Level-3 DC Superchargers (60 kW up to 320 kW+), automated battery swapping cabinets, dynamic power allocation terminals, and specialized fire-suppression devices. Engineered from the ground up for superior thermal resilience, mechanical durability, and seamless cross-platform interoperability, all products comply rigorously with international safety standards including IEC 61851-1, IEC 62196, UL 2202, UL 2594, CE, and RoHS.
With an unwavering commitment to R&D innovation, Hangzhou Zap Charger Co., Ltd. provides white-label custom manufacturing (OEM) and joint design manufacturing (ODM) services. Our team works hand-in-hand with commercial fleet operators, municipal utility providers, Charge Point Operators (CPOs), and Tier-1 automotive equipment distributors to deliver custom electrical designs, bespoke firmware integrations (OCPP 1.6J / OCPP 2.0.1, ISO 15118), and localized exterior branding tailored to specific regional grid requirements.
As the global battery electric vehicle (BEV) landscape transitions rapidly toward 800V and 1000V silicon-carbide (SiC) drive architectures, traditional legacy charging stations are encountering severe thermal limits and power throughput bottlenecks. Next-generation EV charging solutions require a fundamental shift in internal power electronics topology, thermal dissipation dynamics, dynamic matrix switching, and real-time cloud communications.
Our high-power DC fast-charging terminals (240 kW to 320 kW+) utilize advanced Silicon Carbide (SiC) MOSFET power conversion modules. SiC technology reduces switching losses by over 40% compared to traditional silicon IGBTs, achieving peak energy conversion efficiencies exceeding 96.5%. Operating smoothly across wide output voltage spans (200V DC to 1000V DC), these systems natively support ultra-fast charging for legacy 400V battery packs as well as modern 800V+ hypercar and commercial transport platforms.
Continuous high-current charging above 300A generates immense resistive heat ($I^2R$ losses) inside copper conductors and contact pins. Hangzhou Zap Charger implements proprietary active liquid-cooling technology featuring synthetic, dielectric, environmentally friendly coolant circulating through ultra-flexible TPU cabling. This keeps terminal connector contact temperatures below 50°C even under sustained 500A continuous charging, significantly reducing cable weight and boosting user convenience.
Static power distribution leads to stranded electrical capacity. Next-generation multi-gun DC charging hubs engineered by Zap Charger feature intelligent matrix switching backplanes. A 320 kW supercharging dispenser can dynamically reallocate power in 20 kW increments across up to four simultaneous charging outlets based on each connected vehicle’s state of charge (SoC), battery thermal limit, and real-time BMS request profiles.
By dynamically distributing DC output, commercial depot operators eliminate stranded power capacity, increasing throughput by up to 38% compared to legacy fixed-output stations, directly maximizing return on investment (ROI) for Charge Point Operators (CPOs).
As a direct custom OEM manufacturer, Hangzhou Zap Charger provides comprehensive hardware modularization, structural engineering, custom PCB design, and white-label firmware customization. Enterprise clients can tailor every component level of their hardware ecosystem to meet stringent regional demands.
| System Category | Technical Parameters & Standard Range | OEM / ODM Customization Scope |
|---|---|---|
| AC Smart Wallboxes | 3.5 kW (16A 1P), 7 kW (32A 1P), 11 kW (16A 3P), 22 kW (32A 3P); Type 2 / Type 1 / GB/T | Enclosure color, custom branding/logo, cable length (5m to 10m), RFID, 4G/Wi-Fi/Ethernet, PEN fault protection. |
| Commercial Fast DC Chargers | 60 kW, 120 kW, 180 kW, 240 kW, 300 kW, 320 kW+; Single/Dual/Quad CCS1, CCS2, NACS, GB/T guns | Custom cabinet geometry, dual-voltage output (200-1000V), liquid-cooling modules, 10-inch HD touch display UI, customized credit card POS integration. |
| Portable EV Chargers | 10A, 16A, 32A adjustable currents; 3.5 kW to 22 kW; CEE, Schuko, NEMA plugs | OLED screen status UI, interchangeable grid plugs, custom cable colors, rubber molding customization, waterproof travel bags. |
| Adapters & Connectors | GB/T to CCS2, NACS to CCS1/CCS2, Type 2 to Type 1; Up to 1000V DC / 500A peak output | Silver-plated tellurium copper terminals, ultrasonic wire welding, custom internal thermal sensors (PT100/NTC), anti-theft locking latch mechanism. |
| Energy Storage & Microgrid | Hybrid Energy Storage Systems (BESS), Battery Swapping Cabinets (Solar-integrated) | Modular lithium pack capacity scaling, fire-extinguishers (Perfluorohexanone), remote Cloud battery telemetry platform. |
Hangzhou Zap Charger integrates hardware-level Secure Access Modules (SAM) and Public Key Infrastructure (PKI) encryption into our next-gen controller boards. This enables seamless ISO 15118 "Plug & Charge" functionality, allowing vehicles to automatically authenticate, initiate charging, and settle billing without requiring physical RFID cards or mobile apps.
To prevent vendor lock-in, all intelligent chargers produced at our factory are natively compatible with Open Charge Point Protocol (OCPP) versions 1.6-JSON and 2.0.1. Our firmware supports remote over-the-air (OTA) updates, diagnostic telemetry, smart load balancing, and third-party CPO backend platform integration (e.g., ChargePoint, Greenlots, EVConnect, Hubject).
Global B2B procurement managers faced with aggressive deployment schedules and tight budget constraints require a manufacturing partner capable of delivering uncompromised engineering quality combined with high-volume cost efficiencies. Based in Hangzhou, Zap Charger leverages China's unmatched automotive and power-electronics industrial ecosystem.
Charging hardware must adapt seamlessly to distinct regional electrical grid specifications, climate conditions, and commercial application models. Hangzhou Zap Charger’s hardware matrix is optimized for global versatility.
Fleet electrification demands rapid overnight turnarounds. Our 240 kW – 320 kW ultra-fast DC stations, paired with dual-gun CCS2 / GB/T heavy-duty dispensers, enable simultaneous fast charging for heavy electric trucks and municipal transit buses, integrated with local load management software to avoid peak utility demand surcharges.
Engineered for continuous 24/7 public use, our high-power Level-3 stations incorporate rugged IK10 anti-vandalism enclosures, high-brightness daylight-readable touchscreens, integrated contact-less payment terminals (credit card POS), and advanced weather sealing (IP65) for extreme rain, snow, and desert conditions.
For apartment complexes, corporate campuses, and hospitality venues, our 7 kW to 22 kW smart AC wallboxes offer sleek wall-mounted or pedestal-mounted aesthetics. Equipped with dynamic load balancing (DLB), they dynamically prevent building main-breaker trips while providing flexible RFID access control and billing options.
Safety and regulatory compliance represent the bedrock of enterprise EV infrastructure investments. Hangzhou Zap Charger integrates multi-layered safety mechanisms into every hardware device.
High-voltage DC fast stations operate under elevated thermal stress. To neutralize thermal runaway risks, our advanced DC charging cabinets feature integrated Perfluorohexanone (FK-5-1-12) automated fire extinguishing modules. In the unlikely event of an internal short circuit or arc fault, specialized sensors automatically trigger targeted chemical discharge, extinguishing flames in milliseconds without damaging sensitive electronics.
Our full product lineup complies with major international electrical certifications, enabling effortless customs clearance and rapid grid connection approvals worldwide:
As the e-mobility industry matures, charging infrastructure is transitioning from simple grid-to-vehicle power delivery into interconnected smart-energy microgrids. Hangzhou Zap Charger is actively developing and deploying next-gen solutions across four key frontiers:
Designed for heavy-duty electric semi-trucks, commercial aircraft, and marine vessels, MCS technology supports charging currents up to 3000A at 1250V DC (up to 3.75 MW output), drastically reducing commercial fleet downtime.
Vehicle-to-Grid (V2G) technology transforms electric vehicles into distributed mobile energy storage units. Our bi-directional AC/DC converters allow fleet operators to sell stored energy back to the grid during peak pricing hours.
Combining photovoltaic (PV) solar arrays, high-capacity stationary battery energy storage systems (BESS), and intelligent DC fast dispensers to create autonomous off-grid or grid-assisted green charging hubs.
For custom branding, logo printing, and customized packaging on standard AC wallboxes and portable chargers, our MOQ starts at 50 to 100 units. For full structural ODM redesigns, custom enclosure color schemes, or custom PCB controller modifications, prototype samples are delivered within 15–20 days, followed by mass production scaling within 30 days.
Our products are engineered in strict accordance with IEC 61851-1, IEC 62196, UL 2202, and UL 2594 guidelines. We maintain an in-house compliance laboratory equipped with surge generators, environmental thermal chambers, rain/water ingress testing rigs, and automated high-voltage insulation testers. Third-party testing and certification are conducted via accredited global bodies including TÜV, SGS, and Intertek.
Yes. All smart charging hardware produced by Hangzhou Zap Charger natively supports the Open Charge Point Protocol (OCPP 1.6-JSON and OCPP 2.0.1). We provide full API documentation, WebSocket configuration guidelines, and remote engineering support to ensure seamless handshaking between our hardware and your proprietary Cloud backend management system.
For DC charging stations up to 180 kW, we utilize high-efficiency forced air-cooling systems featuring intelligent variable-speed fan arrays and isolated dust-proof air channels (IP54/IP65). For supercharging stations rated from 240 kW to 320 kW+, we employ active liquid-cooling modules with closed-loop dielectric fluid heat exchangers to maintain safe operating temperatures under continuous peak loads.
Silver possesses the highest electrical conductivity of any metal. Applying a thick silver plating (typically 3 to 5 microns) over tellurium copper terminals reduces contact resistance by up to 60%, significantly minimizing heat accumulation during high-current charging, preventing contact surface oxidation, and extending connector mechanical plug-in life beyond 10,000 insertion cycles.
Perfluorohexanone (FK-5-1-12) is an electrically non-conductive gaseous clean extinguishing agent. Installed inside our high-power DC fast chargers and battery swapping cabinets, thermal sensor tubes automatically burst at critical temperature thresholds, discharging the agent instantly. It rapidly absorbs thermal energy and extinguishes localized electrical fires without causing electrical short circuits or leaving corrosive residue.
Comprehensive power conversion accessories, mobile fast chargers, adapters, and smart energy storage infrastructure.
Zap Charger
