The 160kW multi-gun modular AC-DC fast charger targets highway service corridors, 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 160kW 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. Input power factor stays above 0.99 and the wide input window keeps operation stable on weak rural feeders and long industrial spurs. An active front end feeds isolated DC/DC stages inside each cabinet, so grid harmonics stay low while output voltage follows whatever the battery management system requests. A single controller supervises rectification, isolation and metering, which keeps the power path short and trims conversion losses across the whole load range. Matching power modules are documented in the datasheet.

2. 200V-1000V Wide Voltage Output With Constant Power Wide range voltage tracking keeps efficiency above 95 percent even when a deeply depleted pack pulls close to the 250A current ceiling. Continuous insulation monitoring isolates the outlet whenever leakage approaches the configured threshold, protecting technicians and vehicles alike. Precision metering at the outlet delivers Class B accuracy, so billed energy matches what the vehicle actually receives. Constant power operation holds the full 160kW from roughly 500V upward, so an 800V pack charges at rated rate instead of tapering early. 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 Power is delivered by 30kW hot-swappable modules, so a failed unit is exchanged in minutes without isolating the whole cabinet. Thermal design holds junction temperatures stable at 50 degrees ambient, so the DC fast charger sustains rated output in hot climates. Modules slide out from the front, so service engineers never need rear clearance in tight parking layouts or wall-adjacent installations. A shared DC bus lets any module feed any outlet, removing the fixed pairing that limits conventional charging piles. Each module reports voltage, current, temperature and fan speed to the controller, which derates or isolates any unit drifting out of tolerance. Compatible EV charging connectors are listed separately.

4. Dynamic Power Allocation Across Dual Outlets 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. Session logs record delivered energy per outlet, which simplifies billing, reconciliation and fleet cost allocation. Scheduling profiles prioritise buses in the morning and light vehicles in the evening without manual intervention. Priority rules can reserve one outlet for emergency fleets while the other follows a normal queue, all configured remotely. 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. Front and side service access is available, and the base frame accepts either anchor bolts or a concrete plinth. 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. Cable management hooks keep CCS2 and CCS1 leads off the ground, extending connector life in busy public car parks. Installation drawings cover plinth and cable routing.

6. Smart Payment, OCPP Management and Energy Integration Every session produces a metered record covering start, stop and energy delivered, mapping directly to the operator’s billing engine. An open API and Modbus TCP option let the DC fast charger link with solar, storage and building management systems. 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. Local storage keeps sessions running if connectivity drops, then synchronises records once the link returns. OCPP 1.6J adds certificate handling and stronger message security for public networks that must satisfy national roaming rules. 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

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 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 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.

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.

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.