25.2V 6A Li-ion Charger for 6S 22.2V Battery
For industrial drone docks, high-torque electric tools, and heavy portable field gear, the Phonix® FX2526000 (25.2V 6A) provides a ruggedized 151.2W heavy-current charging solution. Housed in a substantial 178X80X64mm industrial chassis, this 6A powerhouse utilizes its expanded enclosure surface area to maximize thermal dissipation without relying on a failure-prone internal fan. This sealed, non-ventilated block keeps fine workshop dust, metal fragments, and warehouse humidity completely away from the multi-layer PCB. Controlled by an intelligent MCU execution loop that manages precise multi-stage profile transitions, it balances accelerated fleet turnover times with absolute cell protection.
Description
Expanding Convective Surface Area and Optimizing EMI Suppression for 150W+ Topologies
Managing a sustained 6A current output without mechanical fan cooling requires a complete overhaul of the mechanical thermal pathway. The Phonix® FX2526000 handles its 151.2W continuous energy conversion inside a reinforced 178X80X64mm polymer enclosure, which uses an expanded surface area to maximize natural thermal radiation. Internally, large-mass aluminum heat sinks are coupled directly to the switching MOSFETs and secondary rectifiers via high-conductivity thermal pads, pulling internal heat outward before it can pool around sensitive feedback resistors. Because this heavy-duty 800g block runs completely unventilated, it bars abrasive carbon dust, conductive metal filings, and ambient humidity from building short-circuit paths across the traces. Additionally, to handle the higher electrical noise that comes with 6A bulk charging, the primary side features an upgraded dual-stage EMI filter network. This circuit layout effectively suppresses harmonic cross-talk and high-frequency line interference, ensuring stable operation alongside precision field equipment while keeping the absolute case temperature rise under < 40°C.
Technical Parameters
| Category | Technical Parameter | Engineering Specification | Remarks / Test Conditions |
|---|---|---|---|
| 1. Input Specs | Rating Input Voltage | 100-240 Vac | 50/60 Hz Universal Power Grid Global Distribution |
| Input Voltage Range | 90-264 Vac | Maintains dynamic output stability through severe line sags | |
| Rating Input Current | 1.0 A / RMS | @ 100V AC Input, Full Load (Optimized Power Baseline) | |
| Max Input Power | 176.0 W | Calculated primary input power limit at full electrical load | |
| 2. Output Specs | No Load Output Voltage | DC 25.2 V | Precision reference loop; absolute battery pack overcharge suppression |
| Output Voltage Range | DC 21.20-25.2 V | Dynamic closed-loop regulation tracking architecture | |
| Charging Current | 6 A ±10% | Constant Current (CC) heavy bulk charging injection phase | |
| Charging Voltage | DC 25.2 V ±0.2 V | Constant Voltage (CV) saturation safety tracking boundary | |
| Pre-charge Current | 0.6 A ±0.1 A | Automated low-voltage recovery window active when pack ≤ 18V | |
| Charge-end Current | ≤ 1.2 A ±10% | Strict 20% cutoff setting to suppress internal cell polarization | |
| Suitable Battery Type | 6S Li-ion / Li-Po Pack Formations | Calibrated hardware matching for 22.2V nominal industrial packs | |
| Max Output Power | 151.2 W | Continuous operational output power envelope (25.2V X 6A) | |
| Ripple Voltage | ≤ 168 mV | Full load, Peak-to-Peak (Vp-p high-frequency noise filtering) | |
| Efficiency (Natural Convection) | ≥ 85.0% | Full load @ 220V AC under completely unvented fanless conditions | |
| Efficiency (Forced Air Cooling) | ≥ 90.0% | Tested under integration with external forced airflow design | |
| 3. Protection & Indicators | Short-Circuit / Reversed Protection | Yes / Yes | Instant microsecond solid-state isolation cutoff and latching lockout |
| Power LED State | Red | Primary AC mainline input verified active | |
| Charging LED (No Battery) | All Off | Open-circuit standby verification status loop | |
| Charging LED (Active Charge) | Flashing One by One | Active sequential capacity tracking output indication | |
| Charging LED (Finished) | All On / Green On | 100% saturation reached; automated standby safety lock engaged | |
| Charging LED (Error State) | All Flashing | Fault status latch active (Over-temperature, output short, reverse connections) | |
| 4. Environmental | Operating Temperature | -10 to +40 °C | Sustained operation under full thermal stability saturation points |
| Storage Temperature | -40 to +70 °C | Protects component structural integration during shipping transit | |
| Operating / Storage Humidity | < 90% RH / 0-95% RH | Non-condensing atmospheric evaluation limits | |
| Cooling Mechanics | Natural Convection | Zero mechanical noise; zero moving part wear vectors | |
| Vibration Resistance | 5 MM / 50 HZ / 600 S | Meets non-operating equipment transit shock thresholds | |
| Impact Resistance | 1-meter drop test, 3 times | Chassis structural impact retention verified | |
| 5. Mechanical | Net Weight | 800 g | Ruggedized, heavy-duty industrial chassis mass |
| Dimensions | 178X80X64 mm | Expanded thermal profile shell built for high continuous output stability | |
| Output Connector | Refer to Order Guide | Custom terminal options tailored to specific enterprise hardware arrays | |
| 6. Safety & Reliability | Max Temperature Rise | < 40 °C on casing | Tested under maximum continuous load saturation metrics |
| Safety Approvals | CE, TUV, FCC, PSE, CCC | Direct global shipping compliance authentication | |
| MTBF | 50,000 Hours | Calculated component lifecycle stress profiles | |
| ESD Immunity | 8.0 KV | Electrostatic arc safety separation line | |
| Dielectric Leakage Threshold | ≤ 0.25 mA | Audited leakage parameters under peak operating stress | |
| Hi-Pot Insulation | i/p to o/p: 3000V (1 min) | Galvanic primary to secondary safety barrier isolation |
Industrial Grid Scaling & Heavy-Duty Terminal Deployments
The integrated sequential LED tracker gives production operators immediate feedback when supervising parallel multi-bay charging setups or high-volume depot banks. For industrial ground nodes or stationary equipment arrays requiring extreme-rate fast charging to minimize downtime, procurement leads can scale up to our ultra-high-output 25.2V 10A industrial charger schematics. Phonix® provides complete modular customization for enterprise OEM/ODM orders, allowing hardware leads to designate heavy-duty connector setups—including multi-pin locking XLR assemblies, high-current Anderson blocks, or rugged copper clamps certified to comply with global TUV safety engineering frameworks.
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