40kW 60kW 80kW Wall-Mounted DC EV Charger Dual Gun Destination Charging Station

Product Overview: 40kW / 60kW / 80kW Wall-Mounted DC EV Charger with Dual Guns

What is this wall-mounted DC EV charger and which charging problems does it solve?

This 40kW, 60kW and 80kW wall-mounted DC fast charger converts an ordinary wall or structural column into a two-bay DC charging point. It exists because most sites do not have the floor area, the slab thickness or the planning consent for a freestanding pedestal, yet still need genuine DC charging rather than an overnight AC wallbox.

The cabinet accepts three-phase 380-415V AC and produces 150-1000V DC through two independently metered guns using CCS2, CCS1, GB/T or NACS connectors. Output reaches 200A per gun, peak efficiency is 95.5%, power factor exceeds 0.99 and harmonic distortion stays below 5%. Protection includes IP55 sealing, IK10 impact resistance, Type A RCMU with 6mA DC detection, surge arrestors and full insulation monitoring. OCPP 1.6J and OCPP 2.0.1 are both on board, with Ethernet, 4G and Wi-Fi connectivity.

For fleet and parking operators the benefit is throughput per square metre. One bracket, one AC feed and one network connection serve two parking positions, and the controller allocates power dynamically so that a tapering vehicle releases capacity to the second gun within seconds. Operators therefore install more charge points on the same electrical supply.

Product Overview and Strategic Positioning

The platform is offered in three power classes from one mechanical envelope. The 40kW version suits destination charging, dealership delivery bays and overnight depot top-ups where a two-hour session is acceptable. The 60kW version handles mixed retail and workplace traffic. The 80kW version targets taxi ranks, light commercial fleets and roadside service areas where dwell time converts directly into revenue per bay. Cabinet dimensions, mounting points, cable routing and the user interface are shared across all three, so a site can specify 40kW today and step up to 80kW later without re-engineering the installation or retraining staff.

Two guns are standard rather than optional. Each is managed by its own contactor and metering channel, so the charger either feeds two vehicles simultaneously at split output or directs the full 80kW to a single vehicle that can absorb it. That dual-gun layout is what makes the unit economically sensible per square metre: one wall bracket, one AC feed, one network connection and one OCPP identity serve two parking positions. Connector options cover CCS2, CCS1, GB/T or NACS outlets in any pairing, so the same product family addresses European, North American and Chinese fleets. Operators already running MIDA floor-standing hardware will recognise the control logic, because the wall version shares firmware, RFID whitelist handling and OCPP profiles with the larger dual-gun DC charging station range.

Sites that need DC charging usually fall into one of three situations. Either the ground is unavailable, as in basements, multi-storey decks and podium car parks; or the ground is available but too valuable to occupy, as at hotels, restaurants and retail frontage; or the ground is suitable but the electrical supply is tight, which is the case for most retrofits. The wall-mounted format answers the first two directly and the third through dynamic load balancing, which caps total site demand without reducing the number of charge points installed.

Technical Superiority and Topology Innovations

Power allocation runs through a dynamic distribution matrix rather than a fixed split. When two vehicles are connected and both request maximum current, the controller divides available output according to priority rules the operator defines in the back office: first-come-first-served, equal share, or time-weighted for high-turnover bays. As one vehicle tapers towards the end of its charge curve, the released capacity is reassigned to the second gun within about two seconds. A 60kW cabinet with a 40kW and a 20kW vehicle attached will therefore not sit at 30kW per side and waste the difference; it tracks each battery management request and pushes the full 60kW where it can be accepted.

Output voltage spans 150V to 1000V DC, which matters more than the headline kilowatt figure. Older 400V passenger cars draw full current only at the bottom of their pack voltage and taper early, while 800V platforms hold peak power across a much wider state of charge. A charger with a narrow voltage window will deliver rated power to one group and fall short on the other. The wide-range stage keeps the 40kW, 60kW and 80kW ratings honest across both vehicle generations, including light commercial vans, shuttle buses and depot trucks that frequently operate above 700V.

Thermal management is designed around the fact that a wall-mounted cabinet has no plinth duct and no chimney effect, so heat must be removed horizontally. Separate air paths serve the power modules and the sealed electronics compartment, and temperature-controlled fans remain idle below roughly 40 degrees Celsius internal. Dust, brake particulate and road salt pass through a replaceable filter rather than across the control board. Above 55 degrees ambient the controller applies controlled derating, and below minus 30 degrees an internal heater brings the screen and modules into operating range before accepting a session.

Design and Engineering Highlights

Compact Wall-Mounted Architecture and Driver Interface

The front panel is an assembly rather than a lid. It hinges clear of the chassis on a captive stay, so a technician reaches terminations, filters and modules without holding it open or removing it entirely. The screen sits recessed behind a sacrificial bezel that absorbs knocks from trolleys and vehicle doors, and the status strips are diffused rather than bare light emitting diodes, so they stay legible in sunlight without dazzling drivers at night. A single keyed lock secures the cabinet, and the barrel is field-replaceable if a site changes maintenance contractor. Mounting slots accept M10 anchors on 400-millimetre centres, and the bracket levels independently of the cabinet.

Modular Power Stack and Thermal Management

Redundancy is a design decision rather than a marketing term. On the highest-power cabinet the modules share the load, and if one is isolated the controller continues serving both guns at reduced output instead of shutting the whole site down. Because modules are interchangeable across the entire range, a distributor can hold one spare and support a complete installed base. The DC bus uses laminated copper for low inductance, and the output stage applies current limiting per gun, so a fault on one channel cannot cascade into the other. Airflow is calculated with the cabinet door closed, which is how the unit will actually operate on site.

OCPP Networking, Metering and Cloud Operations

The charger ships with OCPP 1.6J and OCPP 2.0.1 firmware selectable from the service menu, plus Ethernet, 4G and Wi-Fi interfaces and RS485 and CAN for site integration. That combination connects directly to most European and North American charging management platforms without a proprietary gateway. Because both protocol versions are resident, a network can start on 1.6J and migrate to 2.0.1 when its central system supports it, without replacing hardware or visiting the site. Certificate handling for 2.0.1 is supported on the same board, and security updates are digitally signed before installation is permitted. Fleet-wide rollouts therefore become a configuration task rather than a hardware project.

Weatherproof Enclosure and Multi-Layer Electrical Safety

Weather protection is tested rather than assumed. The cabinet is sprayed from multiple angles to verify the door gasket and cable glands, and the display is assessed for condensation after rapid temperature change. Salt-spray testing covers coastal and winter-road environments where de-icing chemicals attack untreated steel. Because the enclosure is sealed and the electronics compartment is separate from the module air path, humidity inside the controller stays stable even when ambient conditions swing, which is the main cause of premature corrosion on cheaper wall units. Each production unit completes an insulation resistance test before packing, and results are archived by serial number.

Comprehensive Technical Specifications

The table below lists the factory configuration for the 40kW, 60kW and 80kW variants. Ratings are stated for a 380-415V three-phase supply, 25 degrees Celsius ambient and a battery voltage above 500V DC. Where a figure varies by connector standard or regional certification the notes explain the difference, and custom configurations for OEM projects are quoted on request.

Three entries deserve emphasis. Maximum output current is not fixed: it depends on pack voltage, so a vehicle sitting at 400V will not draw 200A from the 80kW cabinet even though the hardware permits it. The operating range of minus 30 to plus 55 degrees Celsius refers to ambient air around the cabinet, not to the battery, and derating begins earlier in unshaded direct sunlight. Standard warranty covers 24 months from delivery, with extended terms negotiated for fleet and OEM programmes.

Core Components and Reliability Engineering

Protection is layered rather than duplicated. The AC side carries a breaker, surge arrestor and phase monitoring. The DC side carries fuses, insulation monitoring and contactor weld detection. Between them the controller supervises temperatures at six points, comparing heatsink, module, cabinet, screen, cable and ambient readings against independent thresholds. If a sensor drifts out of range the controller flags it for maintenance rather than waiting for a shutdown, moving faults from reactive callouts to scheduled visits. Every session is logged with timestamps, energy delivered, peak current, stop reason and error codes, so technicians arrive with a history rather than a guess.

Mechanical reliability receives the same attention. The enclosure uses a powder-coated cold-rolled steel body with stainless fasteners, and the door gasket is a moulded profile rather than a glued strip, because glued gaskets are the most common source of water ingress after three or four years. Cable entries are glanded and strain-relieved. Firmware supports scheduled fleet-wide updates outside peak hours, rollback if a version misbehaves, and remote adjustment of load-balancing limits, and diagnostics are exposed through OCPP as well as the local service interface.

Manufacturing quality is verified per unit rather than per batch. Every charger completes a functional test that includes an insulation resistance check, a full-power burn-in, a simulated vehicle handshake across the voltage range, contactor and emergency-stop validation, and a metering accuracy check against a reference meter. Test results are archived against the serial number, so if a field issue appears the factory can retrieve the exact conditions the unit passed. That traceability shortens warranty investigations considerably.

Application Scenarios and Fleet Deployment

Fleet depots benefit differently. Vans, taxis and light trucks return at predictable times and stay for hours, which is exactly the duty cycle a 40kW or 60kW unit handles best. Because each gun meters independently, a depot can attribute energy to the correct vehicle account automatically, and the RFID whitelist prevents unauthorised use outside working hours. Dynamic load balancing lets the depot add charge points without a transformer upgrade, smoothing demand so a 200A site supply can support several chargers that would otherwise trip the main breaker at shift change.

Destination charging is the third major use case. Hotels, restaurants, retail parks and dealerships want visible fast charging without a forecourt rebuild. A pair of wall-mounted cabinets on an external wall delivers four DC bays, enough to attract customers while keeping dwell times short enough that turnover stays healthy. Where a site already runs larger MIDA hardware, adding wall units extends coverage into tighter corners using the same DC EV charger range and the same back office.

Roadside and workplace sites use the 80kW variant where dwell time is measurable revenue. Two guns, a wide voltage range and 200A capability mean a modern long-range vehicle recovers a useful charge during a twenty-minute break, while older 400V cars still receive a full-power session. Operators planning hybrid sites often pair these cabinets with higher-power equipment, because the wall units can absorb demand when the main chargers are occupied.

Global Certifications, OEM/ODM Support and Warranty

OEM and ODM programmes are a core part of the offer rather than an afterthought. Buyers can specify housing colour and finish, printed branding, splash-screen artwork, connector pairing, cable length, power class and firmware defaults. For larger projects, output power can be capped in software to match a site supply, and the OCPP identity can be pre-registered on the customer network before the units leave the factory. Because the 40kW, 60kW and 80kW models share a chassis and controller, a mixed fleet looks uniform on site and is supported by one spare-parts list, materially reducing the inventory a distributor must carry.

Support covers remote diagnostics, firmware maintenance, spare module supply and technical training. Standard warranty is 24 months, with extended coverage and service-level agreements available for fleet and public-network customers. Consumables such as air filters and fans are field-replaceable, and the module-level design means the most expensive component can be swapped without replacing the cabinet. Models from 40kW to 80kW share the same interface, so operators can standardise on one product family as their requirements grow.

Frequently Asked Questions

Does a 40kW wall-mounted DC charger make sense when 60kW and 80kW units cost only slightly more?

For overnight depot charging and destination sites, yes. Vehicles that sit for two hours rarely accept the full output of a 80kW cabinet, so the extra peak power goes unused. A 40kW unit on a smaller breaker can also be added to a constrained supply without a service upgrade, which is often the deciding factor. Where dwell time is short and bay turnover matters, the 60kW or 80kW version earns its cost back faster.

Can the 60kW wall-mounted DC EV charger supply two vehicles at the same time?

It can, and that is the intended duty. Each gun has its own contactor and metering channel. With both vehicles connected the controller distributes output according to the priority mode configured in the back office, and it reallocates capacity as one vehicle tapers. If only one vehicle is connected, that vehicle receives the full 60kW available, subject to its own battery management limits.

What is the real charging speed of the 80kW unit on production vehicles?

Output current is the limiting factor at low pack voltage. On a 400V vehicle drawing close to 200A the charger delivers around 80kW and can add roughly 100 to 130 kilometres of range in thirty minutes for a typical 60kWh passenger car. On an 800V platform the cabinet holds nearer its rated power across a wider state of charge, so the practical result is better rather than worse. Cold batteries, a high state of charge and shared-gun operation all reduce the figure.

How does a DC-DC solar DC charging setup differ from this AC-input wall charger?

A DC-DC solar architecture feeds photovoltaic output directly into the charger, bypassing the AC conversion stage. That removes one conversion step, avoids double conversion losses and typically lifts usable solar yield by several percentage points, which matters on sites with limited array area. The wall-mounted AC-input charger described here connects to the grid and is the correct choice for parking structures and depots with an existing three-phase supply. Where a site has substantial on-site generation, MIDA supplies DC-coupled variants so solar energy reaches the vehicle battery with a single conversion. The two approaches are complementary: a depot might charge from the grid overnight and from solar during the afternoon peak.

Which OCPP version should be specified, and can it be changed later?

OCPP 1.6J remains the widest-supported profile across current charging management platforms and is the safe default for most commercial deployments. OCPP 2.0.1 suits new networks that need certificate-based security and richer device modelling. Firmware for both is installed on the charger and can be switched and updated remotely, so the decision is not permanently binding.

What maintenance does the unit require once installed?

Routine work is limited to replacing the air filter, inspecting cable and connector condition, and cleaning the touchscreen and status strips. The charger logs error codes and temperature history so technicians can plan interventions rather than react to failures. Power modules are hot-swappable, and because the 40kW, 60kW and 80kW models share components one spare module can service a mixed fleet.

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