The 80kW dual-gun modular AC-DC fast charger targets bus depots and logistics yards, 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 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. Busbar layout, magnetic components and cooling channels are shared across the 80kW family, which shortens lead times and simplifies spare part stocking. 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. 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 Pre-charge sequencing limits inrush current, shielding vehicle contactors and DC link capacitors from stress during every plug-in. Constant power operation holds the full 80kW from roughly 500V upward, so an 800V pack charges at rated rate instead of tapering early. Cable assemblies rated 250A to 400A are matched to each outlet, and CCS2 leads are available in lengths from 4 to 8 metres. A 1000V ceiling future-proofs the investment, because the same DC fast charging station serves today’s 400V fleets and tomorrow’s 800V platforms. Voltage and current limits are negotiated over the control pilot, then confirmed by the battery management system before the DC contactors close.

3. 20kW Hot-Swap Power Modules and N+1 Redundancy N plus one redundancy keeps rated 80kW available even while one module is pulled for service, which matters on revenue-critical corridors. Thermal design holds junction temperatures stable at 50 degrees ambient, so the DC fast charger sustains rated output in hot climates. Replacement modules ship pre-calibrated, and the controller recognises a new unit automatically once it is fully seated. Speed-controlled fans and intelligent airflow keep acoustic noise near 65 dB, which suits residential, hospital and retail locations. Module-level diagnostics flag degrading fans and capacitors long before they cause a stoppage, enabling condition-based maintenance. Commissioning takes under an hour with the guided setup wizard. Compatible EV charging connectors are listed separately.

4. Dynamic Power Allocation Across Dual Outlets When a second connector activates, the controller splits output according to state of charge rather than a fixed schedule. Because capacity follows demand, the DC fast charging station avoids the idle-outlet penalty that drags down utilisation on paired connectors. Load balancing also watches site demand, trimming total draw when the transformer or building load approaches its limit. Session logs record delivered energy per outlet, which simplifies billing, reconciliation and fleet cost allocation. Matrix switching allows any module to serve any gun, so one cabinet can run a single 125A session or two lower-current sessions. 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 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. Ambient range runs from minus 30 to plus 55 degrees Celsius, with internal heaters protecting the 7-inch display in freezing conditions. Each unit is ingress tested at the factory and ships with CE documentation covering insulation and earth continuity checks. The enclosure is rated IP55, with filtered intake louvres and a sealed electronics compartment that shrugs off rain, dust and washdown. 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 Drivers authenticate by RFID card, mobile app, QR code or ISO 15118 plug and charge, with an optional POS terminal for bank card payment. Every session produces a metered record covering start, stop and energy delivered, mapping directly to the operator’s billing engine. Multi-language interface, configurable tariff screens and branded start pages help operators monetise the charging session itself. 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. Local storage keeps sessions running if connectivity drops, then synchronises records once the link returns. 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 80kW unit support?

The charger delivers 200V to 1000V DC at up to 125A, so it serves 400V passenger cars and 800V heavy vehicles from the same outlet. Constant power holds 80kW 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 80kW, 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.