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 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. Power conversion is separated from control logic, so firmware updates and diagnostics never interrupt an active charging session. 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. Commissioning takes under an hour with the guided setup wizard. Matching power modules are documented in the datasheet.

2. 200V-1000V Wide Voltage Output With Constant Power 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. 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. Constant power operation holds the full 120kW from roughly 500V upward, so an 800V pack charges at rated rate instead of tapering early. 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 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. Module-level diagnostics flag degrading fans and capacitors long before they cause a stoppage, enabling condition-based maintenance. Replacement modules ship pre-calibrated, and the controller recognises a new unit automatically once it is fully seated. A shared DC bus lets any module feed any outlet, removing the fixed pairing that limits conventional charging piles. Commissioning takes under an hour with the guided setup wizard. 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. Priority rules can reserve one outlet for emergency fleets while the other follows a normal queue, all configured remotely. Scheduling profiles prioritise buses in the morning and light vehicles in the evening without manual intervention. 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. Dynamic power allocation distributes available capacity across outlets in real time, letting a single vehicle draw the full 120kW. Site rules are tuned from the operator portal.

5. Outdoor IP55 Enclosure Built for Public Sites 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. The bonded anti-glare touchscreen stays readable in direct sunlight and remains responsive through gloved operation. Front and side service access is available, and the base frame accepts either anchor bolts or a concrete plinth. The enclosure is rated IP55, with filtered intake louvres and a sealed electronics compartment that shrugs off rain, dust and washdown. 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. OCPP 1.6J adds certificate handling and stronger message security for public networks that must satisfy national roaming rules. 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. 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

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 120kW 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 120kW 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.