The 160kW dual-gun modular AC-DC fast charger targets public parking hubs and retail destinations, where uptime and quick service access decide revenue. With CCS2 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 Power conversion is separated from control logic, so firmware updates and diagnostics never interrupt an active charging session. Efficiency peaks at 96 percent and stays above 94 percent from light load to full output, cutting energy cost for high-utilisation sites. Galvanic isolation between grid and vehicle protects both sides during fault events and meets the insulation requirements behind CE and IEC 61851 compliance. A single controller supervises rectification, isolation and metering, which keeps the power path short and trims conversion losses across the whole load range. Bidirectional-ready bus design lets the same platform accept solar or battery energy storage input without a second conversion stage. Matching power modules are documented in the datasheet.

2. 200V-1000V Wide Voltage Output With Constant Power Constant power operation holds the full 160kW from roughly 500V upward, so an 800V pack charges at rated rate instead of tapering early. Wide range voltage tracking keeps efficiency above 95 percent even when a deeply depleted pack pulls close to the 250A current ceiling. Voltage and current limits are negotiated over the control pilot, then confirmed by the battery management system before the DC contactors close. Cable assemblies rated 250A to 400A are matched to each outlet, and CCS2 leads are available in lengths from 4 to 8 metres. Output spans 200V to 1000V DC, covering 400V and 800V vehicle architectures from compact city cars to heavy-duty tractors.

3. 30kW Hot-Swap Power Modules and N+1 Redundancy Speed-controlled fans and intelligent airflow keep acoustic noise near 65 dB, which suits residential, hospital and retail locations. Replacement modules ship pre-calibrated, and the controller recognises a new unit automatically once it is fully seated. Each module reports voltage, current, temperature and fan speed to the controller, which derates or isolates any unit drifting out of tolerance. N plus one redundancy keeps rated 160kW available even while one module is pulled for service, which matters on revenue-critical corridors. A shared DC bus lets any module feed any outlet, removing the fixed pairing that limits conventional charging piles. Compatible EV charging connectors are listed separately.

4. Dynamic Power Allocation Across Dual Outlets Session logs record delivered energy per outlet, which simplifies billing, reconciliation and fleet cost allocation. Priority rules can reserve one outlet for emergency fleets while the other follows a normal queue, all configured remotely. Load balancing also watches site demand, trimming total draw when the transformer or building load approaches its limit. Because capacity follows demand, the DC fast charging station avoids the idle-outlet penalty that drags down utilisation on paired connectors. When a second connector activates, the controller splits output according to state of charge rather than a fixed schedule. Scheduling profiles prioritise buses in the morning and light vehicles in the evening without manual intervention. Site rules are tuned from the operator portal.

5. Outdoor IP55 Enclosure Built for Public Sites A powder-coated steel body with anti-corrosion treatment suits coastal, industrial and roadside installations. 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. The enclosure is rated IP55, with filtered intake louvres and a sealed electronics compartment that shrugs off rain, dust and washdown. Each unit is ingress tested at the factory and ships with CE documentation covering insulation and earth continuity checks. Front and side service access is available, and the base frame accepts either anchor bolts or a concrete plinth. Installation drawings cover plinth and cable routing.

6. Smart Payment, OCPP Management and Energy Integration Multi-language interface, configurable tariff screens and branded start pages help operators monetise the charging session itself. Every session produces a metered record covering start, stop and energy delivered, mapping directly to the operator’s billing engine. OCPP 1.6J adds certificate handling and stronger message security for public networks that must satisfy national roaming rules. Remote diagnostics, firmware updates and tariff changes are pushed over the air, cutting truck rolls for routine maintenance. The controller exposes smart charging profiles, so a central system can cap site load during peak tariff periods. Communication runs over OCPP 1.6J, so the station integrates with almost any back office without custom middleware. 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

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.

What payment options are available for public drivers?

RFID card, mobile app, QR code, ISO 15118 plug and charge and an optional POS terminal for contactless bank cards. All methods write to the same metered session record, so reconciliation stays simple. Connector options are listed on our EV charging connector page.

What output voltage range does the 160kW unit support?

The charger delivers 200V to 1000V DC at up to 250A, so it serves 400V passenger cars and 800V heavy vehicles from the same outlet. Constant power holds 160kW from about 500V upward, which shortens charging time on modern high-voltage packs.

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.

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