Kempower DC fast charging goes beyond specs. It delivers a system architecture that combines clean hardware with smart power management — the type of integration Munro readers expect from mature EV infrastructure.

During a Munro tour of Kempower’s Durham, North Carolina facility, the team explored modular cabinets, satellite dispensers, and advanced cable management. They also reviewed fleet-focused software. Together, these elements show where both public and depot charging are headed.

Modular power, scaled in 50 kW steps

At the heart of the line is a rectifier-dense power unit: 50 kW swappable modules rack in minutes; cabinets scale from a single-door 200 kW to a triple-door 600 kW configuration. That modularity matters for capex and utility latency; sites can launch at 150–200 kW, earn revenue, then add modules as the feed arrives. This staged path minimizes stranded assets and accelerates time to value — a practical win for fleets and CPOs balancing grid upgrades with demand growth.

Satellites and dynamic power sharing

One cabinet can feed up to eight satellite dispensers. Instead of hard-splitting power, the system detects each vehicle’s voltage and current needs, then routes amperage dynamically — giving a high-rate Kia the headroom it can use while a Bolt sips less, and then shifting power as states of charge change. For engineers, this is load-balancing at the edge; for operators, it’s higher utilization with fewer marooned kilowatts.

Cable management that actually works

Kempower’s dispensers use passive spring reels that keep heavy DC cables off the ground, extend reach, and eliminate pulley failures in cold climates. It’s a deceptively simple reliability play that reduces trip hazards, wear, and freeze-downs — the kind of field-learned fix that reduces OPEX without adding moving parts.

Serviceability by design

Munro-minded details show up everywhere. “Honeycomb” quick-connect backplanes let techs slide modules out with four bolts; every electrical connection is logged to a specific assembler and then validated on dedicated test benches. Filters are front-to-back service items; active air cooling manages heat from AC-to-DC conversion. Result: faster MTTR, fewer truck rolls, and a repair model that assumes parts will be replaced at the edge — not nursed along.

Footprint, variants, and payment flexibility

The satellite dispenser is compact — roughly a square-foot footprint — and can be configured single or dual, with CCS or NACS, and with or without on-pedestal UI. For public installs, tap-to-pay and RFID are available; for private lots, simple badge auth keeps sessions restricted. A QR code mirrors the local UI to a browser, giving users live power, voltage, and pin-temperature data without forcing another app download. The upshot for site design: more lanes per transformer, simpler traffic flow, and better UX without bespoke kiosks.

Liquid-cooled option: more amps, less copper

When current, length, or thermal limits become the bottleneck, Kempower’s liquid-cooled satellite raises continuous current capability (up to 500 A) while reducing copper mass in the cable; the hose stays manageable while the heat exchanger in the head takes the load. This isn’t free — the hardware is pricier — but for high-throughput sites chasing short dwell times, it enables higher average charge power without overwhelming the operator or the cable.

Control units for harsh, fleet-first environments

For depots and ports, stainless control heads ditch screens entirely in favor of a simple LED status bar. Mount them up high, drop the cable, and protect the head from forklifts and snowplows. Fewer surfaces to fail; fewer parts to vandalize. It’s the right level of UI for operators who value throughput and uptime over glossy kiosks.

ChargEye: software that keeps the electrons honest

Hardware only gets you so far. Kempower’s ChargEye software layer handles session visibility, fault reporting, and load management, including time-of-use constraints. For fleets, this means shifting energy to low-tariff windows; for public sites, it means orchestrating dynamic allocation as dwell times and vehicle mixes change throughout the day. Think of it as the energy brain that turns modular steel into revenue per circuit.

Packaging and sustainability that cut waste and cost

Returnable wood “coffins” ship cabinets and satellites without single-use hardware; they collapse and ship back on Kempower’s dime. Past the green optics, this reduces disposal costs, site clutter, and install friction. When coupled with plug-and-play module racking and pre-staged satellite hardware, it points to shorter install cycles and faster site commissioning.

Why this matters for engineers and investors

• Lean design reduces lifecycle cost. Swappable 50 kW bricks, documented connections, ESD-safe assembly, and 100% component testing move quality upstream and MTTR downstream — a hallmark of mature power electronics.
• Grid-constrained scaling is table stakes. Launch with the power you have; scale cabinets, satellites, and cables as utility capacity arrives. This de-risks cash flow while meeting real-world electrification timelines.
• UX and data transparency matter. Browser-mirrored UIs, RFID for private lots, and live charge curves reduce confusion and support faster turnover, especially as NACS/CCS transitions play out.
• Application-specific hardware wins. Liquid-cooled heads for high-amp lanes, rugged LED-only control units for depots, and compact satellites for garages let operators right-size capital to use case.

Takeaways for site designers and CPOs

1. Design for dynamic power, not static nameplates. Vehicle mix will always be uneven; dynamic load sharing protects utilization and revenue.
2. Shorten the maintenance loop. Specify architectures with front-service filters, documented connections, and slide-out modules; your uptime metrics will thank you.
3. Plan the expansion path on day one. Stub for eight dispensers even if you start with two; run conduits and pads now to avoid costly rework.
4. Match UI to environment. Public sites may need full payment stacks; depots often need nothing more than ID and status lights. Keep it simple where possible.

Keep Exploring with Munro

Want more expert teardown insight into chargers, connectors, and lean manufacturing choices shaping EV infrastructure? Subscribe to Munro Live or dive into Munro & Associates’ analyses and factory-floor walk-throughs to see what great engineering looks like — and what it costs — before you spec your next site.