GB-COMPLIANT INTEGRATED DC CHARGER · USER MANUAL

GB 240-480kW Integrated Dual-Gun DC Charger

240/320/360/400/480kW integrated DC charger in five power ratings: dual-gun output, 200~1000VDC wide voltage platform, modular configuration, IP54 outdoor protection, multiple safety protections and intelligent temperature control, compatible with mainstream EV models.

Dual-gun output · 0~300A per gun Output voltage 200~1000VDC Peak efficiency 96.5% IP54 outdoor protection

480kW Max. Power

1000VDC Output Voltage

96.5% Peak Efficiency

300A Single-Gun Current

Product Overview

System Overview

The 240/320/360/400/480kW series DC chargers are independently developed based on years of R&D and equipment operation experience to meet the high-reliability, high-performance and energy-saving requirements of EV DC charging, featuring high system stability and reliability.

Structure

Integrated dual-gun structure

INTEGRATED DUAL-GUN

Integrated cabinet with dual charging guns, front-door design, floor-mounted ready to use, highly adaptable to outdoor deployment.

Dimensions 1110×999×1713mm

Protection rating IP54 (outdoor)

Module

Modular configuration

MODULAR DESIGN

Compatible with mainstream charging modules, flexibly configured by power rating for customized applications.

Rated power 240~480kW

Output current 0~300A per gun

Thermal

Intelligent temperature control

SMART COOLING

The intelligent temperature control system improves energy efficiency and extends component life, with forced-air cooling.

Cooling method Forced-air cooling

Operating temperature -30~+55℃

Platform

Seamless multi-platform compatibility

MULTI-PLATFORM

High network stability, one-click terminal switching, simplified O&M; Ethernet and 4G communication.

Communication Ethernet · 4G

Auxiliary power 12V & 24V

Safety

Multiple safety protections

MULTI-PROTECTION

Multiple protection design against overvoltage, undervoltage, overcurrent, leakage, lightning surge, emergency stop, fire and flame retardance.

Protection design Over/under-voltage · short circuit · overload · over-temperature · gun temperature

Emergency stop protection One-click cut-off of the AC contactor

Options

Multiple optional configurations

OPTIONS

Supports optional tilt detection, smoke alarm, water immersion detection, heater and more; exterior color and LOGO customizable.

Options list Tilt · smoke · water immersion · heater

Customization Exterior color · LOGO

Technical Highlights

Technical Features

Modular configuration, intelligent temperature control, multi-platform compatibility and high protection design: a highly reliable DC fast-charging solution for public charging stations, logistics parks, bus depots and more.

54IP

High-protection design IP54 Outdoor

IP54 protection rating, highly adaptable to extreme environments, reliable long-term outdoor operation.

96.5%

Peak efficiency Peak Efficiency

High-efficiency rectifier modules deliver lower conversion losses and better energy savings.

1000V

Wide voltage platform Wide Voltage

200~1000VDC output with constant-power range 300~1000VDC, compatible with mainstream models.

2Gun

Dual-gun rotation charging Dual Guns

One station, two guns with flexible power dispatch to increase site utilization and revenue.

001

01 FEATURES

Eight technical highlights

Key Technical Features

Independently developed with advanced design technologies to meet the high-reliability, high-performance and energy-saving requirements of EV DC charging systems.

Power rating 240~480kW

Number of guns Dual guns

Output voltage 200~1000VDC

Protection IP54

Modular configuration Compatible with mainstream modules, customized applications, flexible adaptation
Intelligent temperature control Intelligent temperature control improves energy efficiency and extends component life
Multi-platform compatibility High network stability, one-click terminal switching, simplified O&M
High-protection design IP54 protection rating, highly adaptable to extreme environments
Vehicle-charger adaptation optimized Wide compatibility with mainstream models, future-proofing reserved, high adaptability
Multiple safety protections Over/under-voltage, overcurrent, leakage, lightning surge, emergency stop, fire and flame retardance
Multiple options Tilt detection, smoke alarm, water immersion detection, heater and more
Custom development Exterior color and LOGO customizable to user requirements

Integrated Dual-Gun DC Charger · Isometric View

Technical Specifications

Technical Parameters

Technical parameters of the GB 240/320/360/400/480kW integrated DC charger are as follows; the five power ratings share one platform, select by site requirements.

Input Voltage 380VAC±15% three-phase+N+PE

Input Frequency 50±1Hz

Rated power 240 / 320 / 360 / 400 / 480kW

Input Current 388A / 517A / 582A / 646A / 775A

Output current (per gun) 0~300A

Output Voltage 200~1000VDC (constant-power range 300~1000VDC)

Voltage regulation accuracy ≤±0.5%

Current regulation accuracy ≤±1%

Voltage ripple factor ≤0.5%

Harmonic current limit (THD) ≤5% (above 50% load)

Peak Efficiency 96.5%

Noise ≤75dB

Altitude 2000m (derating above)

Operating temperature -30~+55℃

Operating humidity 5%RH~95%RH non-condensing

Cooling method Forced-air cooling

Protection design Over/under-voltage, short circuit, overload, over-temperature, grounding, leakage, lightning surge, gun temperature, etc.

Safety standards GB/T 20234 · GB/T 18487 · GB/T 27930 · NB/T 33001 · NB/T 33008

Protection rating IP54 (outdoor)

Dimensions 1110×999×1713mm L×W×H

Auxiliary power 12V & 24V

Communication Ethernet · 4G

Installation Guide

Installation Instructions

The charger must be installed on a prefabricated base: base height preferably 200mm, length and width not smaller than the cabinet, vertical inclination not exceeding 5%; concrete or channel-steel foundation allowed, mounting surface must be flat.

002

02 DIMENSIONS

Outline dimensions

Equipment Dimensions

Charger outline dimensions L×W×H = 1110×999×1713mm, front-door design; four-side views and isometric drawing shown below.

Length L 1110mm

Width W 999mm

Height H 1713mm

Door Front door

Front height 1713mm (incl. base · body 1680mm)
Front width 1110mm (body 980mm)
Side depth 999mm

Outline Dimensions

003

Base Hole Dimensions

03 MOUNTING

Cabinet Placement & Base

Pile Layout & Base

Embed 4 M12 stainless steel bolts in the mounting surface with threads protruding 40±3mm above ground, or embed 4 M12 (GB/T 22795-2008) sleeve-reinforced expansion bolts; the charger is front-door, so reserve operating space on all sides.

Base Concrete / channel steel · height 200mm · flat surface
Anchor bolts M12 × 4 · protruding 40±3mm
Clearance Sides ≥800mm · Front ≥900mm · Rear ≥100mm
Vertical inclination Not exceeding 5%

Mounting hole spacing (lateral) 1070mm · overall hole width 1120mm

Mounting hole spacing (longitudinal) 629mm · edge distance 185mm

Cable entry position 80mm / 345.1mm (front center)

Cable entry height 320mm / 453mm

Cable Configuration & Installation Key Points

Cables & Key Points

Input power cable POWER INPUT

Entered from cabinet bottom · trench depth 400mm

Three-phase five-wire A/B/C/N/PEOutdoors: cable trench + conduit burial

Cable spacing SEPARATION

Parallel spacing between power and communication cables ≥0.1m

Copper-core cable · cross-section matched to loadRecommended ZRC-YJV22-0.6/1kV · ≥70℃ temperature rating

Reserved cable length RESERVED LENGTH

Phases A/B/C 500mm

N/PE wires 750mmTerminal height A/B/C 400mm · N/PE 650mm

Fire sealing FIRE SEALING

Seal cable entry holes with fireproof mud · 1~2kg per hole

Thickness must exceed 20 mmPoor sealing causes condensation and shortens component life

Fire protection FIRE PROTECTION

Dry-powder extinguisher / automatic fire ball

In compliance with electrical distribution fire codesThe station shall have dedicated fire lanes and firefighting facilities

Unpacking inspection INSPECTION

Check against the packing list

Confirm correctness and completenessInspect items for damage

Commissioning & Maintenance

Commissioning & Maintenance

Power-on commissioning must be performed by trained personnel with our technicians notified; maintenance includes routine maintenance, periodic inspection and technical retrofitting, following industry norms and local regulations.

004

04 COMMISSIONING

Commissioning

Power-on Commissioning

Before power-on, confirm the AC input switch is off, the equipment is reliably grounded, and internal wiring and screws are tightened; measure phase-to-phase and phase-to-ground insulation resistance with a megohmmeter, verify normal three-phase grid voltage with a multimeter, then close the switch to power on.

Pre-power-on checks Cabinet reliably grounded · wiring screws tightened
Insulation measurement Measure phase-to-phase and phase-to-ground insulation with a megohmmeter
Grid verification Multimeter confirms normal three-phase voltage
Power-on sequence Secondary-circuit leakage breaker → AC input switch

Side View

005

Cable Entry Dimensions

05 MAINTENANCE

Routine Maintenance & Inspection

Daily & Inspection Maintenance

Routine maintenance covers four items: charging gun, cabinet, functions and data records; inspection focuses on internal cables, screws, terminals, breakers and power modules, with dust filters cleaned regularly according to environmental dust.

Charging gun Return to holster to prevent damage · keep dry · no rough dragging
Cabinet inspection Shell rust or water leakage · screen · indicators · door lock · emergency stop
Function check Charging function · backend connection · screen operation and version configuration
Dust-filter interval Near construction sites 15 days · roadside 1 month · stations/residential areas 3 months · underground parking 6 months

Using the emergency stop button

EMERGENCY STOP

In case of leakage, fire, electric shock or other abnormal conditions, or when the charger malfunctions and charging cannot be stopped or internal wiring is short-circuited, press the emergency stop immediately; it directly cuts off the AC contactor and de-energizes the modules. After the emergency is cleared, rotate the emergency stop switch clockwise to reset.

Action Cuts off AC contactor · modules de-energized

Reset Rotate the emergency stop switch clockwise

Operating precautions

OPERATING PRECAUTIONS

In humid weather, confirm the gun head and vehicle socket are dry before charging; do not use the gun or cable if defective, cracked, damaged or exposed; do not unplug directly or move the vehicle during charging; wait until the interface fully switches before unplugging after charging.

Personnel Charging operators · safety officers (trained)

Fire requirements Dedicated firefighting equipment beside the charger

Full charge for every journey

WOLUN INTEGRATED DC CHARGING

GB 240-480kW integrated dual-gun DC charger: modular configuration, multiple safety protections, IP54 outdoor protection. Contact us for station solutions and quotations.

Sichuan Wolun Electric Co., Ltd. SICHUAN WOLUN ELECTRIC CO., LTD.

A wind-solar-storage-charging integrated energy system provider — an industrial, integrated, high-tech group.

Address

WOLUN New Energy Group Co., Ltd.: Room 2602, 26F, 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
Factory hotline: +86 0813-5308858
Domestic sales: +86 188 2888 5368
Domestic e-mail: wolunxs@wolungroup.com
Overseas sales: +86 188 2888 5328
Overseas e-mail: wolunhw@wolungroup.com
Aftersales: 400 604 1668