360–960 kW Split-Type DC Charging Stack
Split architecture with centralised rectification in the cabinet and dispensers placed close to the bays: seven power ratings – 360 / 480 / 600 / 640 / 720 / 800 / 960 kW – up to 16 output circuits, 250 A per gun (400 A / 600 A optional), wide 200–1000 VDC platform, smart air cooling and IP54 outdoor deployment.
Overview
System OverviewThe WLEVDC-FG01 series is a newly developed DC charging system that builds on years of research, development and field operating experience to meet the demanding reliability, performance and energy-saving requirements of EV DC charging. The rectifier cabinet and the charging dispensers are installed separately: one cabinet serves several dispensers, and power is dispatched flexibly to each parking bay.
Separate cabinet and dispensers
Rectification and heat dissipation are centralised in the cabinet while dispensers stand next to the bays, shortening DC cable runs and saving space. Station expansion only requires additional dispensers.
Seven ratings · pooled dispatch
Seven power ratings from 360 to 960 kW share one platform. The power pool is allocated dynamically to the dispensers, with 250 A per gun (4 guns at 400 A or 600 A optional).
Smart air cooling
Both rectifier modules and dispensers use smart air cooling that adjusts fan speed to load and ambient temperature, ensuring stable operation from −30 °C to +55 °C.
Multi-dispenser networking
Up to 16 output circuits per cabinet. The 220 V supply and communication cables are led out from the host terminal block, then looped from the host to dispenser 1, dispenser 2 and so on.
Multi-layer protection
Over-voltage, under-voltage, short circuit, overload, over-temperature, grounding, leakage, surge and gun-temperature protection. External grounding 2-M8 with permanent grounding design.
Two dispenser forms
Air-cooled dual-gun, air-cooled single-gun and liquid-cooled single-gun dispensers can be combined according to bay count, current per gun and site conditions.
Features
Technical FeaturesModular rectification, power pooling, multi-dispenser networking and smart air cooling: a split-type solution for public fast-charging stations, bus depots, logistics parks and highway service areas, where the cabinet and dispensers can be invested in phases.
Seven ratings from 360 to 960 kW on one platform, planned once and expanded in phases.
One cabinet serves up to 16 output circuits, with flexible dispenser and gun combinations.
High-efficiency rectifier modules with power factor ≥0.99 at full load and lower conversion losses.
IP54 for outdoor use, −30 °C to +55 °C, derating above 2000 m altitude.
Eight technical highlights
Developed to meet the reliability, performance and energy-saving requirements of EV DC charging, with the cabinet and dispensers separated and power pooled, balancing O&M and expansion.
- Pooled power dispatchThe cabinet rectifies centrally and allocates power dynamically to dispensers, 250 A per gun (400 A/600 A optional)
- Separated layoutThe cabinet stays away from the bays while dispensers are installed nearby, giving shorter DC cables and a tidier site
- Modular rectificationDrawer-type rectifier slots: align and push in gently, with plug-and-socket contact verification
- Smart air coolingFan speed follows load and ambient temperature, reducing noise, energy use and component wear
- Multi-dispenser networkingUp to 16 output circuits, with supply and communication cables daisy-chained host → No.1 → No.2 …
- Wide voltage output200–1000 VDC with constant power from 300 to 1000 VDC, compatible with mainstream vehicles
- Multi-layer protectionOver/under-voltage, short circuit, overload, over-temperature, grounding, leakage, surge and gun-temperature protection
- Easy maintenanceFront 1200 mm, rear 500 mm and 1000 mm on each side of door-opening space
Dispenser forms
Terminal TypesThree dispenser types share the same rectifier cabinet and power pool: air-cooled dual-gun, air-cooled single-gun and liquid-cooled single-gun, configured by bay count, current per gun and site conditions.
Air-cooled dual-gun dispenser
DUAL GUNTwo guns from one cabinet, installed next to the bays, 250 A per gun. The body is 460 mm wide, 619 mm including side panels.
Air-cooled single-gun dispenser
SINGLE GUNA single gun occupies one bay, ideal for buses and logistics fleets with one vehicle per bay; same height and cable entry as the dual-gun dispenser.
Liquid-cooled single-gun dispenser
LIQUID COOLEDThe liquid-cooled cable supports 600 A fast charging. The cabinet is taller and narrower, with ≥700 mm of maintenance space front and rear.
Safety
General Safety PrecautionsTo protect people and equipment, follow all safety notices on the equipment and in the user manual during installation, operation, testing and maintenance. The "Notice", "Warning" and "Danger" items in the manual are reminders and supplements, not the complete list of safety rules to be observed.
Personnel
PERSONNEL REQUIREMENTSGrounding
GROUNDING REQUIREMENTSPersonal safety
PERSONAL SAFETYEquipment safety
EQUIPMENT SAFETYElectrical safety
ELECTRICAL SAFETYMechanical safety
MECHANICAL SAFETYCable laying
CABLE LAYINGFire sealing
FIRE SEALINGNever install or remove power cables while energised. An arc or spark may occur the moment the conductor touches, causing fire or eye injury. Always switch off the input (or upstream) power before installation or removal.
Wear protective gloves when handling the unit by hand to avoid cuts; a forklift or other mechanical aid is recommended. Signal cables must be bound separately from power or high-voltage cables, and severe impact or vibration must be avoided during laying.
After installation, all cable entry and exit openings must be sealed with fire putty at least 20 mm thick. Unsealed or poorly sealed openings cause condensation that shortens the service life of components and busbars.
Specifications
Technical ParametersTechnical data of the split-type DC charger are listed below. The seven power ratings – 360 / 480 / 600 / 640 / 720 / 800 / 960 kW – share one platform; they differ only in rated input current and maximum output circuits, while all other electrical and environmental data are identical.
Installation
Installation InstructionsA 200 mm base is recommended for the rectifier cabinet, with 1200 mm front, 500 mm rear and 1000 mm on each side of door-opening space. Dispensers are mounted on custom concrete foundations at least 200 mm above ground level, with a flat mounting surface.
Cabinet installation conditions
The cabinet is floor-mounted, with AC input entering from the bottom and DC output leaving from the top. Six M12 anchor bolts are embedded in the mounting surface and the cabinet is grounded externally at 2-M8. Keep enough space in front of the cabinet for door opening and servicing, away from walls and clutter.
- Door-opening spaceFront 1200 mm · rear 500 mm · 1000 mm each side
- AC input (A/B/C/N/PE)Vertical positions on the mounting surface 350 / 350 / 300 / 290 / 130 mm
- Recommended cable reserve450 / 450 / 450 / 390 / 230mm
- Incoming and outgoing configuration3 AC inputs · 3 DC outputs · 1290 mm wide incoming area
Dispenser installation conditions
The air-cooled dispenser weighs about 100 kg; a 200 mm base is recommended. Five DC leads (DC1+, DC1-, DC2+, DC2-, PE) enter through the bottom cable entry; the mounting surface must be level and load-bearing.
- Vertical positions of DC inputDC1+ 300 · DC1- 300 · DC2+ 300 · DC2- 300 · PE 250mm
- Recommended cable reserve400 / 400 / 400 / 400 / 350mm
- Single-gun dispenser inputDC+, DC- and PE, same vertical positions as the dual-gun dispenser
- Fixing4-12 bolts · external grounding 2-M8
Liquid-cooled dispenser installation conditions
The liquid-cooled dispenser supports 600 A fast charging. At least 700 mm of operating and maintenance space must be kept in front of and behind the unit, which must be mounted on a custom concrete foundation at least 200 mm above ground level.
- Maintenance space≥700 mm front and rear
- FoundationCustom concrete foundation · base ≥200 mm · level surface
- Vertical positions of DC inputDC+ 750 · DC- 750 · PE 200mm
- Recommended cable reserve850 / 850 / 300mm
- Fixing4-M12 bolts · external grounding 2-M8
Power cable installation
Power Cable InstallationFor AC cables, ZRC-YJV22-0.6/1 rated at 70 °C or above is recommended; for DC power cables, ZRC-YJV22-0.6/1 rated at 90 °C or above; communication cable is RVSP. The data below assume copper phase + neutral + earth conductors; for aluminium cables, increase the cross-section by one size.
AC incoming cable selection
AC Incoming Cables · ZRC-YJV22-0.6/1 · ≥70℃DC and auxiliary cable selection
DC & Auxiliary Cables · ZRC-YJV22-0.6/1 · ≥90℃AC input wiring requirements
AC INPUTDC wiring requirements
DC CONNECTIONCommissioning and maintenance
Commissioning & MaintenanceInform our technical staff before testing; system commissioning must be carried out by trained personnel. Before power-on, complete the installation safety check and confirm that the AC input switch is open, the equipment is reliably grounded and all internal wiring and screws are tight.
Module installation
Take the rectifier module out of its plastic bag and insert it into the slot in the cabinet. Align the module and push it in gently, checking that the module plug and the cabinet socket are properly engaged.
- De-energised workConfirm the AC input switch is open and the system is de-energised before inserting or removing modules
- Contact checkAfter pushing home, check the plug and socket for skew or jamming
- Quantity checkVerify the number of modules against the power rating; missing modules reduce output capability
Power-on commissioning
Inform our technical staff before testing; commissioning must be carried out by trained personnel. Remove rings, watches and other metal objects that may cause short circuits. Beware of high voltage and ensure good grounding before power-on.
Pre-power-on checklist
Complete the following four steps in order: confirm cabinet grounding and internal tightness, then measure insulation and three-phase voltage, and finally close the secondary-circuit leakage breaker and the AC input switch.
Dust filter maintenance interval
DUST NET INTERVALSSet the cleaning interval according to the dust level at the installation site: the heavier the dust, the shorter the interval. Take care not to damage the filter, and confirm the seal after refitting.
O&M precautions
OPERATION NOTESDo not touch internal parts while the system is running. Maintenance and repair require isolation and voltage verification before work starts; restore sealing and door locks afterwards.
Packaging · Transport · Storage
Packaging, Transportation & StorageOn arrival, check the equipment against the packing list for correctness and completeness. Modules and cabinets are packed separately; for short- or long-term storage keep them in a dry, well-ventilated indoor area.
Packaging
PACKAGINGModules are packed individually in cartons with foam padding and desiccant; the cabinet is bagged, foam-supported on all sides, fixed to a pallet and packed in an outer carton.
Transport
TRANSPORTATIONThe product must not be subjected to severe vibration, impact or inversion during transport; handle with care, preferably with a forklift or other mechanical aid.
Storage
STORAGEStore in a dry, well-ventilated indoor area, away from heat, humidity, dust and metal powder. Storage temperature −40 °C to +75 °C.
After-sales service
AFTER-SALESProvided the user complies with storage, use, installation and operating rules, contact the manufacturer promptly for commissioning, repair or replacement of parts if the product is damaged or fails to work properly due to defective manufacturing.
Ordering information
Before ordering, clarify the application and purpose of the equipment and submit system parameters and panel configuration requirements based on the site plan, so that we can calculate the cabinet and dispenser configuration, cable specifications and copper lug quantities.
- ApplicationClarify the scenario and purpose of the equipment
- Equipment informationEquipment name, model, specifications, system parameters and panel configuration
- System parametersInput/output voltage range, maximum power, etc.
- Special requirementsFor special environments and technical requirements, please negotiate an agreement with our factory engineers
Full charge for every journey
360–960 kW split-type DC charging stack: separate cabinet and dispensers, up to 16 output circuits, 250 A per gun (400 A/600 A optional), 200–1000 VDC wide range and IP54 outdoor protection. Contact us for a site networking plan and quotation.
A service provider of wind-solar-storage-charging integrated energy systems — an industrial, comprehensive, high-tech group company.
Company address
- WOLUN New Energy Group Co., Ltd.: Room 2602, Unit 1, Building 5, No. 8 Liuli Road, Jinjiang District, Chengdu, Sichuan
- Sichuan Wolun Electric Manufacturing Co., Ltd.: No. 108 Tianyuan Street, Xinmin Town, Da'an District, Zigong, Sichuan
Contact
- Group hotline: +86 028-68938363
- Plant hotline: +86 0813-5308858
- Sales: 188 2887 1858
- After-sales hotline: 400 604 1668
- Overseas sales hotline: +86 188 2888 5328
- Overseas sales e-mail: wolunhw@wolungroup.com