480kW Isolated Air-Cooled DC Charging Station – Official Commercial BESS Technical Overview & Datasheet

PRODUCT OVERVIEW & SYSTEM POSITIONING

The 480kW Isolated Air-Cooled DC Charging Station represents a paradigm shift in high-power electric vehicle (EV) fleet and commercial depot charging infrastructure. Designed for demanding duty cycles, this platform integrates galvanically isolated DC fast charging with advanced thermal management, targeting heavy-duty vehicles, public transportation hubs, and logistics centers. Unlike conventional grid-tied chargers, this unit features an integrated isolated power stage that decouples the vehicle battery from grid transients, harmonics, and ground faults, ensuring maximum safety and battery longevity.

SYSTEM ARCHITECTURE & SAFETY ISOLATION

At the core of the station lies a modular, high-frequency isolated DC-DC converter topology utilizing silicon carbide (SiC) MOSFETs. This design provides complete electrical separation between the AC grid input and the DC output to the EV, eliminating common-mode leakage currents and enabling unrestricted operation on ungrounded or high-resistance grounded DC microgrids. The front-end active rectifier ensures a unity power factor (PF > 0.99) and low total harmonic distortion (THDi < 3%), while the isolated DC stage delivers stable, low-ripple charging current. KEY FEATURES - True Galvanic Isolation: 1500Vdc input-output isolation per IEC 61851-23, ensuring zero DC injection into the grid and protecting EV batteries from ground faults. - High-Density Air-Cooled Thermal Architecture: Forced-air cooling with IP54-rated fan arrays and redundant airflow path; operates from -30°C to +55°C without liquid coolant maintenance. - Dynamic Power Sharing: 480kW total power configurable across 2 to 6 independent DC output ports (CCS1, CCS2, or CHAdeMO), with automatic load balancing per ISO 15118. - Wide Output Voltage Range: 150Vdc to 1000Vdc, compatible with 400V and 800V class EV batteries, including future 1000V architectures. - Grid-Support Functions: Reactive power compensation, voltage ride-through, and export limitation as standard. - Cybersecurity Ready: Secure boot, encrypted communication (TLS 1.3), and role-based access control. TECHNICAL SPECIFICATIONS AC INPUT (Grid Side) - Nominal Voltage: 480V AC ±10%, 3-phase + PE - Frequency: 50/60 Hz ±5 Hz - Max Input Current: 600A - Power Factor: >0.99 (full load)
– THDi: <3% (full load) DC OUTPUT (EV Side) - Total Rated Power: 480 kW continuous - Output Voltage Range: 150 – 1000 Vdc - Max Output Current (single port): 500A (liquid-cooled cable) / 300A (air-cooled cable) - Voltage Accuracy: ±0.5% of full scale - Current Accuracy: ±1% of setpoint - Isolation Type: Galvanic, high-frequency transformer - Efficiency (Full Load): >94.5% (incl. auxiliary loads)

PROTECTIONS & COMPLIANCE

– Protections: Input over/under voltage, output overcurrent, short circuit (hardware and software), DC ground fault, overtemperature (winding and heatsink), reverse polarity, surge protection (Type 1+2 on AC, Type 2 on DC).
– Standards Compliance: IEC 61851-23 (DC charging), IEC 61851-24 (communication), ISO 15118 (plug & charge, V2G ready), UL 2202 (pending), IEC 61000-6-2/4 (EMC immunity/emission).
– Environmental: IP54 (indoor/outdoor installation), IK10 (impact resistant enclosure), altitude up to 2000m (derated above).
– Noise Emission: <65 dB(A) @ 1m (fan at full speed). OPERATIONAL & USER INTERFACE - Local HMI: 10.1" industrial touchscreen with fault diagnostics, energy metering per session, and RFID/NFC reader. - Remote Management: 4G/LTE, Ethernet (Modbus TCP, OCPP 1.6J/2.0.1), optional Wi-Fi. - Backend Compatibility: OCPP-compliant any central system (charge point management system). - Metering: MID-compliant DC energy meter (accuracy class B). - Firmware Update: Over-the-air (OTA) with rollback protection. MECHANICAL - Dimensions (W x H x D): 1600 x 2200 x 900 mm - Weight: 1250 kg (excluding cables and accessories) - Enclosure Material: Galvanized steel with anti-corrosion coating (C5-M optional) - Cooling: Forced air, rear intake / front exhaust, removable washable air filters. - Cable Management: Integrated hangers and strain relief for up to 6 DC cables (5m each, optional 10m).

INSTALLATION & DEPLOYMENT NOTES

– Minimum clearances: 800mm front (access), 300mm rear (air exhaust), 500mm each side.
– Electrical connection: Bottom entry AC cable (3x 240mm² + PE) and DC cables via gland plates.
– Foundation: Level concrete pad (min 1600 x 2200 mm) with anchor bolts.
– Ambient Conditions: -30°C to +55°C operational (derating >45°C), 5% to 95% RH non-condensing.
– Compliance: CE, UKCA, CB Scheme certificate ready. RCM, EAC available on request.