The 240kW dual-gun modular AC-DC fast charger targets highway service corridors, 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 The 240kW dual-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. Efficiency peaks at 96 percent and stays above 94 percent from light load to full output, cutting energy cost for high-utilisation sites. 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. Every cabinet is load tested before shipment and arrives with a wiring map covering contactors, fuses and surge arrestors for fast commissioning. Matching power modules are documented in the datasheet.

2. 200V-1000V Wide Voltage Output With Constant Power Pre-charge sequencing limits inrush current, shielding vehicle contactors and DC link capacitors from stress during every plug-in. Wide range voltage tracking keeps efficiency above 95 percent even when a deeply depleted pack pulls close to the 400A current ceiling. 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. Precision metering at the outlet delivers Class B accuracy, so billed energy matches what the vehicle actually receives.

3. 30kW Hot-Swap Power Modules and N+1 Redundancy A shared DC bus lets any module feed any outlet, removing the fixed pairing that limits conventional charging piles. Replacement modules ship pre-calibrated, and the controller recognises a new unit automatically once it is fully seated. N plus one redundancy keeps rated 240kW available even while one module is pulled for service, which matters on revenue-critical corridors. Each module reports voltage, current, temperature and fan speed to the controller, which derates or isolates any unit drifting out of tolerance. Power is delivered by 30kW hot-swappable modules, so a failed unit is exchanged in minutes without isolating the whole cabinet. 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 400A session or two lower-current sessions. Operators set allocation rules per site, per connector or per tariff window through the cloud portal, with no on-site reprogramming. Priority rules can reserve one outlet for emergency fleets while the other follows a normal queue, all configured remotely. 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. Site rules are tuned from the operator portal.

5. Outdoor IP55 Enclosure Built for Public Sites The enclosure is rated IP55, with filtered intake louvres and a sealed electronics compartment that shrugs off rain, dust and washdown. Cable management hooks keep CCS2 leads off the ground, extending connector life in busy public car parks. Surge protection, residual current detection and emergency stop are integrated, and the cabinet is engineered for a ten-year outdoor service life. Optional heating, ventilation and lighting kits extend operation to cold storage yards and dusty mining roads. Each unit is ingress tested at the factory and ships with CE documentation covering insulation and earth continuity checks. 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 The controller exposes smart charging profiles, so a central system can cap site load during peak tariff periods. OCPP 1.6J adds certificate handling and stronger message security for public networks that must satisfy national roaming rules. 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. Communication runs over OCPP 1.6J, so the station integrates with almost any back office without custom middleware. Every session produces a metered record covering start, stop and energy delivered, mapping directly to the operator’s billing engine. 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 output voltage range does the 240kW unit support?

The charger delivers 200V to 1000V DC at up to 400A, so it serves 400V passenger cars and 800V heavy vehicles from the same outlet. Constant power holds 240kW 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 240kW, 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.