The 120kW multi-gun modular AC-DC fast charger targets public parking hubs and retail destinations, where uptime and quick service access decide revenue. With CCS2 and CCS1 outlets, a 200V-1000V DC window and OCPP 1.6J connectivity, it delivers predictable high-power charging while keeping installation and commissioning simple. This DC fast charging station pairs high utilisation with low maintenance overhead.

1. Modular AC-DC Power Topology and Conversion Chain The 120kW multi-gun unit is built around a modular AC-DC topology that rectifies three-phase AC input onto a regulated DC bus before power reaches the vehicle inlet. Galvanic isolation between grid and vehicle protects both sides during fault events and meets the insulation requirements behind CE and IEC 61851 compliance. Bidirectional-ready bus design lets the same platform accept solar or battery energy storage input without a second conversion stage. Power conversion is separated from control logic, so firmware updates and diagnostics never interrupt an active charging session. Input power factor stays above 0.99 and the wide input window keeps operation stable on weak rural feeders and long industrial spurs. Matching power modules are documented in the datasheet.

2. 200V-1000V Wide Voltage Output With Constant Power A 1000V ceiling future-proofs the investment, because the same DC fast charging station serves today’s 400V fleets and tomorrow’s 800V platforms. Wide range voltage tracking keeps efficiency above 95 percent even when a deeply depleted pack pulls close to the 250A current ceiling. Cable assemblies rated 250A to 400A are matched to each outlet, and CCS2 and CCS1 leads are available in lengths from 4 to 8 metres. Precision metering at the outlet delivers Class B accuracy, so billed energy matches what the vehicle actually receives. Pre-charge sequencing limits inrush current, shielding vehicle contactors and DC link capacitors from stress during every plug-in.

3. 30kW Hot-Swap Power Modules and N+1 Redundancy Replacement modules ship pre-calibrated, and the controller recognises a new unit automatically once it is fully seated. Power is delivered by 30kW hot-swappable modules, so a failed unit is exchanged in minutes without isolating the whole cabinet. N plus one redundancy keeps rated 120kW available even while one module is pulled for service, which matters on revenue-critical corridors. Modules slide out from the front, so service engineers never need rear clearance in tight parking layouts or wall-adjacent installations. Speed-controlled fans and intelligent airflow keep acoustic noise near 65 dB, which suits residential, hospital and retail locations. Compatible EV charging connectors are listed separately.

4. Dynamic Power Allocation Across Dual Outlets Because capacity follows demand, the DC fast charging station avoids the idle-outlet penalty that drags down utilisation on paired connectors. Matrix switching allows any module to serve any gun, so one cabinet can run a single 250A session or two lower-current sessions. Load balancing also watches site demand, trimming total draw when the transformer or building load approaches its limit. Operators set allocation rules per site, per connector or per tariff window through the cloud portal, with no on-site reprogramming. When a second connector activates, the controller splits output according to state of charge rather than a fixed schedule. Site rules are tuned from the operator portal.

5. Outdoor IP55 Enclosure Built for Public Sites Front and side service access is available, and the base frame accepts either anchor bolts or a concrete plinth. The bonded anti-glare touchscreen stays readable in direct sunlight and remains responsive through gloved operation. Surge protection, residual current detection and emergency stop are integrated, and the cabinet is engineered for a ten-year outdoor service life. Ambient range runs from minus 30 to plus 55 degrees Celsius, with internal heaters protecting the 7-inch display in freezing conditions. Cable management hooks keep CCS2 and CCS1 leads off the ground, extending connector life in busy public car parks. A powder-coated steel body with anti-corrosion treatment suits coastal, industrial and roadside installations. Installation drawings cover plinth and cable routing.

6. Smart Payment, OCPP Management and Energy Integration An open API and Modbus TCP option let the DC fast charger link with solar, storage and building management systems. Communication runs over OCPP 1.6J, so the station integrates with almost any back office without custom middleware. The controller exposes smart charging profiles, so a central system can cap site load during peak tariff periods. Every session produces a metered record covering start, stop and energy delivered, mapping directly to the operator’s billing engine. Multi-language interface, configurable tariff screens and branded start pages help operators monetise the charging session itself. Remote diagnostics, firmware updates and tariff changes are pushed over the air, cutting truck rolls for routine maintenance. Backend integration follows the OCPP specification.

Deployment Support and Accessories

Projects usually pair the cabinet with Type 2 to Type 2 cables and a OCPP protocol controllers, all supplied from one factory. Engineering teams can review the company profile before order, while commercial questions go through the contact our team page. Standard builds ship in four to six weeks, and documentation covers wiring, grounding and network setup.

Frequently Asked Questions

How does DCDC architecture differ from a conventional AC-DC charger?

A DCDC stage accepts a DC bus from solar or battery storage and converts it directly, skipping one rectification step. That raises round-trip efficiency and lets the modular AC-DC platform operate during grid outages when paired with a BESS cabinet.

Can the two guns charge at the same time at full power?

Yes, with dynamic allocation. Total capacity is shared, so one vehicle can take the full 120kW, or two vehicles can split it according to state of charge. Matrix switching means any module can serve either outlet, and rules are configured remotely.

Which OCPP version should an operator choose?

OCPP 1.6J covers the widest installed base of back offices today. OCPP 1.6J is specified here for certificate handling, plug and charge support and stronger message security. Both profiles work with standard roaming hubs, and the protocol controller datasheet explains the mapping.

What protection level is needed for roadside installation?

IP55 is the baseline for outdoor public sites, combined with surge arrestors, residual current detection and an emergency stop. Coastal or dusty locations should add the anti-corrosion coating and filter service kit.

How is maintenance handled when a power module fails?

Modules are hot-swappable from the front. A technician isolates the affected unit, slides it out and seats a pre-calibrated replacement while the second outlet keeps serving traffic. N plus one redundancy keeps rated output available throughout.

Does the station support solar and battery storage integration?

The DC bus is storage-ready. Solar MPPT or a BESS cabinet can feed the link directly, and the controller can cap grid import during peak tariffs. This suits microgrid and carport projects where demand charges dominate operating cost.

As a commercial DC fast charger, the platform is specified for operators who need predictable uptime from a DC fast charging station.

Fleet managers comparing a DC fast charging station against split systems value the single-cabinet service model of this DC fast charger.

The DC fast charging station ships with commissioning support, and every DC fast charger is backed by regional spares.

Choosing a DC fast charger with documented test reports keeps procurement audits simple for any commercial EV charger project.