RW Energy Shijiazhuang 480 kW Split Type DC Fast Charging System Case Study

Empowering the upgrading of charging infrastructure in Shijiazhuang with high-power split fast charging technology, this solution leverages the architectural advantages of 480kW centralized power supply and distributed deployment. It delivers robust high-concurrency processing, all-scenario protection and comprehensive safety control, effectively easing charging congestion and consolidating core energy supply nodes along urban arterial roads.

01 Project Overview

1.1Project Background

With the rapid increase in electric vehicle (EV) ownership, Shijiazhuang City in Hebei Province is accelerating the construction of public charging infrastructure to build a "15-minute charging circle." As a vital energy node on a major urban thoroughfare, this public fast-charging station primarily serves ride-hailing cars, social vehicles, and industrial park fleets. These users demand high power, high reliability, and the ability to charge multiple vehicles simultaneously. Located in an open public area, the site faces extreme weather—hot, rainy summers and cold, windy, sandy winters—placing strict requirements on equipment protection, fire safety, and all-weather stability.

The project faced three core challenges:

• High-concurrency Pressure: Concentrated traffic during peak hours leads to long queues if chargers have low power or inefficient allocation.
• Harsh Outdoor Conditions: Long-term exposure to large temperature swings, dust, and humidity fluctuations leads to equipment aging and protection failure.
• Safety and O&M Difficulty: Open sites often lack intelligent monitoring and standardized fireproof sealing, leading to high maintenance costs and safety risks.

Since commissioning, the RW Energy 480 kW Split-type DC Fast Charging System has operated stably under Shijiazhuang’s complex climate. Utilizing a "Power Pool Sharing + Multi-terminal Distributed Deployment" architecture, the system efficiently handles high-concurrency charging while establishing a comprehensive safety and smart O&M framework.

1.2 Core Technical Parameters

1.3 Project Drawings

The project includes complete electrical and civil construction drawings covering the primary circuit of the rectifier cabinet, DC output circuits, secondary control and protection logic, communication interfaces, grounding systems, and fire-stop sealing designs. All designs comply with national DC fast-charging station standards, ensuring stable high-power output and remote monitoring in harsh outdoor environments.

02 Core Technology and Functional Advantages

2.1 Core Technical Performance

• Split-type Power Pool Architecture: The 480 kW rectifier cabinet is centrally deployed, while charging terminals are distributed across parking spaces. This supports intelligent dynamic power allocation, significantly improving utilization. With a maximum output of 250 A+ per gun, it meets ultra-fast charging needs for up to 12 vehicles simultaneously.
• High Protection and Environmental Adaptation: The IP54 design and sealed cabinet structure effectively resist dust and rain. Core components use wide-temperature insulation and anti-aging materials, ensuring stable operation from -30 °C to +55 °C, perfectly suited for Northern China’s climate.
• Standardized Fire-stop Sealing Design: The equipment features pre-sealed cable inlets, and on-site execution strictly follows electrical fireproofing standards. All cable holes are tightly sealed with fire-resistant boards and organic/inorganic materials to prevent fire spread, enhancing the station’s inherent safety.

• Comprehensive Safety Framework: Real-time monitoring of voltage, current, insulation, and connector temperature provides millisecond-level alerts. Built-in protections for overvoltage, overcurrent, short circuit, leakage, and emergency stop, combined with smart air cooling, protect vehicles, equipment, and personnel.
• Smart Connectivity and Remote O&M: Supports OCPP 1.6J for seamless integration with charging platforms, enabling remote start/stop, status monitoring, fault location, and automated billing. This reduces on-site inspection frequency and operational costs.

03 Rigorous Testing: Ensuring Stability

• Wide Voltage Range Load Test: Simulated battery pack fluctuations from 200V to 1000V DC to verify stable current output for all EV types.
• Multi-brand Compatibility Test: Completed interoperability verification with 20+ mainstream EV brands according to GB/T 27930 and OCPP 1.6J, ensuring a 100% handshake success rate.
• 480 kW Continuous Full-load Test: Operated at rated power for ≥ 8 hours to verify system efficiency stays ≥ 94% without thermal derating.
• Outdoor Adaptation Test: Simulated -30 °C to +55 °C temperature cycling, dust, and heavy rain to ensure IP54 structural integrity and electrical insulation.

04 Logistics and Execution

Equipment was secured in export-grade, moisture-proof, and shock-resistant packaging to withstand long-haul transport. RW Energy managed the entire logistics chain to ensure all components, including the 480 kW rectifier and 6 dispensers, arrived at the Shijiazhuang site on schedule.

05 Field Installation and Operational Summary

5.1 Installation and Implementation

• Executed site surveys, concrete foundation verification, and cabling path planning, combined with foundation reinforcement, grounding system construction, and protective site measures for outdoor conditions.

• Conducted the hoisting and positioning of the rectifier cabinet, terminal installation, and high/low-voltage cable wiring.
• Strictly followed drawings for high-voltage circuits, DC output circuits, control circuits, and grounding systems, with a specific focus on implementing standardized cable inlet fire-stop sealing and verifying wiring tightness and insulation reliability.
• Performed on-site power-on commissioning, power allocation logic verification, and fault simulation testing to validate protection, communication, and platform connectivity before grid integration.
• Provided specialized training for the station O&M team, covering equipment operation, troubleshooting, platform monitoring, routine maintenance, and fire-stop sealing inspection standards.

5.2 Operational Feedback 

Since its official commissioning, the 480 kW split-type DC fast charging system has delivered exceptional performance:

• High-Reliability Continuous Operation: The system has withstood multiple cycles of extreme cold, intense heat, and sandstorms in Shijiazhuang with zero unplanned downtime, maintaining a power supply availability rate of over 99.99%.
• High-Concurrency Efficient Operation: With 12 charging terminals operating in parallel at full load, average charging time for users has been reduced by 40%, while the station's daily charging volume has increased by 50%.
• Comprehensive Safety and Control: The synergy between standardized fire-stop sealing and multi-layer electrical protection has completely eliminated cable fire risks and electrical hazards, ensuring zero safety accidents since deployment.
• Intelligent Cost Reduction and Efficiency: Remote monitoring and automated alerts enable proactive fault detection and resolution, reducing manual inspection frequency by 60% and significantly lowering overall O&M costs.

This project fully demonstrates RW Energy's core strengths in high-power DC fast charging equipment R&D, integrated station solutions, and engineering delivery. As a flagship demonstration for public fast-charging infrastructure in North China, it provides a mature and replicable blueprint for charging stations in high-concurrency and extreme outdoor environments.

06 Life-cycle Managed O&M Services

RW Energy provides integrated life-cycle O&M services for the Shijiazhuang station, covering installation, monitoring, periodic inspection, and health assessments. We specifically focus on fire-stop integrity, protection grade verification, and power module health. This closed-loop management ensures long-term stability and a low total cost of ownership (TCO) for the Jing-Jin-Ji region's EV infrastructure.

The technologies of this project are fully compatible with mainstream international standards and possess robust capabilities for rapid localization and deployment. Having undergone rigorous operational validation across multiple countries, we offer mature and proven EV charging solutions for the global market！

Please feel free to contact us at any time for further information!