FAQ: Choosing a 96V onboard charger for lead/lithium (CAN, IP65) – criteria + SG3/ICL/CT3.3

96V constraints

In embedded applications, charging must remain stable despite variable mains quality (workshop outlets, extension leads, generator sets) and thermal constraints. On a 96V bus, DC currents become significant: cable cross-sections, ohmic losses, and thermal derating directly impact machine availability. Integration must also account for real-world sealing (housing + connectors + harness), as well as EMC constraints when traction power and communications (CAN) share the same wiring harness.

Lead vs lithium

Lead: multi-stage

Lead-acid batteries (AGM, GEL, etc.) rely on multi-stage charging (bulk/absorption/float) with maintenance control and, depending on the use case, equalization phases. Field performance depends on voltage/current regulation accuracy and on phase durations that match the battery technology and real duty cycles.

Lithium: BMS control

For lithium, the charger must execute a clean CC/CV profile while remaining subordinate to the BMS: charge enable, current/voltage limits, safe shutdown on cell/temperature faults, and state reporting for diagnostics and maintenance. A usable CAN interface reduces commissioning ambiguity and supports robust fault handling.

Type 2 charging

In electric mobility, the Type 2 interface is not only about the connector: it drives the charging user experience, integration compliance, and the complexity level on the vehicle side. Depending on the charger architecture, Type 2 handling can be native (integrated control and interlocking) or require an external module acting as the interface/EVSE.

- In a mobility-oriented integration, the CT3.3 can be deployed with a “natural” Type 2 approach, using an architecture aligned with modern onboard charging use cases.
- By contrast, more “classic” chargers such as SG3 and ICL1500 are typically integrated via an external Type 2 module (pilot control, charge enable, interlocks).
- In retrofit and multi-platform projects, the goal is to standardize the charging interface independently of the selected charger, in order to reduce harness/control variants.
- EVEA has developed an adaptation system that makes any onboard charger Type 2 ready: the conversion is implemented at the interface and control-logic level, without changing the charger power sizing.
- At integration level, it remains essential to address: AC protection, connector/harness sealing, water paths, vibration robustness, and EMC compatibility between power stages and pilot signals.

Comparison

The rating below (★ to ★★★★★) is intended for “design office integration”: environmental robustness, input range, system functions, and CAN usability. It does not replace proper sizing (charge time), but it accelerates selection against project constraints.

ZIVAN SG3

The SG3 positions itself as a versatile onboard charger in the 3.3 kW class, with PFC (power factor stated at 0.98) and a stated efficiency ≥90%. From an integration standpoint, it fits classic motive environments: charge-profile management, auxiliary I/O, and fault handling via a detailed alarm table.

• AC input 110–230 Vac ±10%, 50/60 Hz; stated max input current 15 Arms.
• Power 3.3 kW absorbed (Pmax), 3000 W delivered to the battery (Pmax).
• Environment IP55, -20 to +50°C; installation with clearance around fan/heatsink for full power.
• Charging configurable profiles (lead stages, dedicated modes), adjustable cable voltage-drop compensation.
• Interface CAN (Superseal connector) and auxiliaries (AUX1/AUX2, PT100/NPT100-type sensor, remote LED).

Delta-Q ICL

The Delta-Q ICL1500 is designed for OEM lithium integration: a usable CAN interface, CANopen and J1939 protocol support, and a structured diagnostic approach (states, faults, history) useful for industrialization and maintenance. IP66 (NEMA4) and the -40…+65°C temperature range make it a robust option for harsh environments.

• AC input 85–270 Vac, 50/60 Hz; power factor >0.99 (120 Vac) and >0.98 (230 Vac).
• Power 1500 W max; lithium final charge voltage variants 36–58V / 55–85V / 80–120V depending on model.
• Max current up to 33.3 A (~58 V variant), 25 A (85 V), 18.7 A (120 V) at Vin > 200 Vac.
• Protection reverse polarity (Poka-Yoke terminals + auto-reset protection), electronic current limiting on short circuit.
• Interface CAN, dry-contact interlock (0.3 A), DC connection via ring lugs (Neg M6 / Pos M8).

ZIVAN CT3.3

The CT3.3 targets “platform” architectures where the objective is to reduce the number of enclosures: 3.3 kW traction charger, integrated 500 W DC-DC for low-voltage supply, and an EVSE interface option depending on version. IP67, extended temperature capability, and liquid-cooling availability are decisive advantages when packaging is constrained or exposed.

• AC input 85–270 Vac; stacking possible 3.3 / 6.6 / 9.9 kW and beyond for scalable power.
• HV variants 58.8 V / 65 A; 65 V / 65 A; 120 V / 40 A (depending on version).
• AUX DC 13.7 V nominal configurable 12–14.5 V; 500 W in drive mode and 70 W in charging mode.
• Environment IP67; -40 to +70°C (full power up to 50°C); fan-cooled or liquid-cooled versions.
• Integration BMS wake-up, multi-pin signal connector, cybersecurity-oriented approach (AES128 stated).

Wiring & EMC

On 96V systems, charger integration is often decided by harness quality and EMC performance more than by nominal power. Design office and workshop best practices:

- Physically separate HV power (AC/DC) and signals (CAN, interlock, sensors); avoid long parallel runs.

- Size DC cable cross-sections based on charge current, allowable heating, and voltage drop; leverage cable-drop compensation where available.

- Engineer the CAN topology: lengths, termination, shield continuity, and a chassis/shield grounding strategy consistent with the vehicle.

- Reduce ground loops, stabilize 0V/control ground references, and document the grounding policy (star point, chassis, islands).

- Manage vibration: strain relief, bend radii, clamps, anti-abrasion zones, and locking connectors.

Quick choice

• Need 3.3 kW and multi-chemistry flexibility: ZIVAN SG3, suited to mixed fleets and legacy lead strategies with CAN and I/O integration.
• Lithium only + IP66 + structured OEM integration: Delta-Q ICL1500, relevant when the BMS drives charging and diagnostics/logs are central.
• Modern platform + IP67 + integrated DC/DC + scalable power: ZIVAN CT3.3, coherent for an integrated and industrializable architecture.