NGI Debuts World's First 2400V High-Speed Load for Power Testing

Industry Background: Entering the Kilovolt High-Voltage Era

Driven by the rapid advancement of EV fast-charging technologies, vehicle voltage platforms are evolving from mainstream 400V and 800V architectures toward higher voltage levels. According to the national standard GB/T 20234.1-2023 Conductive Charging Connection Set for Electric Vehicles – Part 1: General Requirements, the rated DC charging voltage has been increased to 1500V. This milestone marks the official entry of high-voltage power modules—such as charging pile modules, onboard power supplies, data center power modules, and energy storage converters—into the kilovolt-class era.

Testing Challenges: High-Voltage Power Testing Under Increasing Pressure

As the industry advances toward higher voltage and higher power, the operating voltages of core power modules—such as DC fast-charging modules for EV charging stations, high-voltage bidirectional PCS, and data center HVDC power supplies—are transitioning from 400V / 800V / 1000V to 1200V and 1500V. While higher voltage enables improved efficiency and reduced losses, it also introduces significant challenges for performance verification and testing.

For testing power modules operating above 1500V, conventional load test solutions—primarily regenerative loads and resistive loads—exhibit clear limitations in dynamic response speed, current slew rate, accuracy, and continuous high-voltage adjustment capability.

Regenerative Loads

Modern high-voltage power modules based on third-generation semiconductors such as SiC and GaN impose extremely high requirements on load dynamic response speed and current slew rate. Due to inherent topology constraints, regenerative loads struggle to accurately simulate fast and transient load changes, falling short in both response speed and slew-rate control.

Resistive Loads and Conventional Electronic Loads

Traditional high-power resistive load banks are bulky, difficult to cool, and lack precise control. They cannot simulate the complex operating conditions required by modern power modules, nor can they meet stringent testing requirements for dynamic response and current slew rate.

Furthermore, conventional dissipative electronic loads are limited by device voltage withstand capability and typically support a maximum of 1200V, making them unsuitable for ultra-high-voltage load testing.

NGI Enables Performance Testing for Global Top-Tier Power Module Manufacturers

Customer Requirements

Customer A is a globally leading power module manufacturer, with products covering high-performance charging modules, battery swapping systems, and energy storage systems, providing professional solutions for charging, battery swapping, and energy storage applications.

In the early development stage, the customer required testing of the dynamic output characteristics of DC power modules, with the load equipment expected to meet stringent performance requirements.

NGI Solution: 2400V High-Performance Electronic Load

To precisely address the industry’s high-voltage evolution, NGI has introduced the world’s first 2400V / 1600V ultra-high-voltage, high-speed DC electronic load, fully meeting the testing requirements of power supplies operating above 1200V.

Ultra-High Voltage Coverage and High Power Density

The 2400V / 1600V high-voltage series is fully compatible with 1500V power module testing, while providing sufficient margin for future technology upgrades and ensuring testing safety headroom.

With a single-unit power rating of 5kW in a 3U chassis, the system supports multi-unit parallel operation, enabling easy expansion to tens or even hundreds of kilowatts.

The maximum current capability reaches up to 2500A, fully satisfying full-load current testing requirements for high-power charging modules.

Ultra-Fast Dynamic Response

With microsecond-level load transient and response speed, the system enables precise evaluation of key performance indicators such as dynamic response, control loop stability, and overvoltage/overcurrent protection behavior.

Ultra-High Accuracy with Multi-Range Design

U/I/P/R triple-range architecture

Voltage measurement accuracy: 0.015% + 0.015% F.S.

Current measurement accuracy: 0.04% + 0.04% F.S.

This design fully meets wide-range, high-precision testing requirements across diverse operating conditions.