The 160kW multi-gun DCDC solar-battery fast charger targets bus depots and logistics yards, 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. DCDC Solar-Battery Power Topology and Conversion Chain Every cabinet is load tested before shipment and arrives with a wiring map covering contactors, fuses and surge arrestors for fast commissioning. The 160kW multi-gun unit is built around a DCDC solar-battery topology that rectifies three-phase AC input onto a regulated DC bus before power reaches the vehicle inlet. Input power factor stays above 0.99 and the wide input window keeps operation stable on weak rural feeders and long industrial spurs. 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. Matching power modules are documented in the datasheet.

2. 200V-1000V Wide Voltage Output With Constant Power Voltage and current limits are negotiated over the control pilot, then confirmed by the battery management system before the DC contactors close. 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. Continuous insulation monitoring isolates the outlet whenever leakage approaches the configured threshold, protecting technicians and vehicles alike. A 1000V ceiling future-proofs the investment, because the same DC fast charging station serves today’s 400V fleets and tomorrow’s 800V platforms.

3. 30kW Hot-Swap Power Modules and N+1 Redundancy Modules slide out from the front, so service engineers never need rear clearance in tight parking layouts or wall-adjacent installations. Power is delivered by 30kW hot-swappable modules, so a failed unit is exchanged in minutes without isolating the whole cabinet. Speed-controlled fans and intelligent airflow keep acoustic noise near 65 dB, which suits residential, hospital and retail locations. A shared DC bus lets any module feed any outlet, removing the fixed pairing that limits conventional charging piles. N plus one redundancy keeps rated 160kW available even while one module is pulled for service, which matters on revenue-critical corridors. Compatible EV charging connectors are listed separately.

4. Dynamic Power Allocation Across Dual Outlets Matrix switching allows any module to serve any gun, so one cabinet can run a single 250A session or two lower-current sessions. Scheduling profiles prioritise buses in the morning and light vehicles in the evening without manual intervention. Because capacity follows demand, the DC fast charging station avoids the idle-outlet penalty that drags down utilisation on paired connectors. Priority rules can reserve one outlet for emergency fleets while the other follows a normal queue, all configured remotely. 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 Each unit is ingress tested at the factory and ships with CE documentation covering insulation and earth continuity checks. Ambient range runs from minus 30 to plus 55 degrees Celsius, with internal heaters protecting the 7-inch display in freezing conditions. Surge protection, residual current detection and emergency stop are integrated, and the cabinet is engineered for a ten-year outdoor service life. Front and side service access is available, and the base frame accepts either anchor bolts or a concrete plinth. Optional heating, ventilation and lighting kits extend operation to cold storage yards and dusty mining roads. 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 Multi-language interface, configurable tariff screens and branded start pages help operators monetise the charging session itself. Drivers authenticate by RFID card, mobile app, QR code or ISO 15118 plug and charge, with an optional POS terminal for bank card payment. Local storage keeps sessions running if connectivity drops, then synchronises records once the link returns. Remote diagnostics, firmware updates and tariff changes are pushed over the air, cutting truck rolls for routine maintenance. Communication runs over OCPP 1.6J, so the station integrates with almost any back office without custom middleware. An open API and Modbus TCP option let the DC fast charger link with solar, storage and building management systems. 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 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.

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 DCDC solar-battery 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 160kW, 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.

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.