1000V 500A Liquid Cooled Electric Vehicle Charging Cables for CCS1 Ultra-fast Charging

The global shift toward electric mobility has intensified the demand for charging infrastructure that prioritizes speed, reliability, and safety. Addressing these challenges head-on, Fiver New Energy introduces its 1000V 600A Liquid Cooled CCS1 Charging Cable—a groundbreaking advancement in ultra-fast DC charging technology. Designed to support 500KW+ power delivery, this high-performance cable combines a 1000V voltage rating with a 500A continuous (600A peak) current capacity, enabling rapid replenishment of next-generation EVs equipped with 800V+ battery systems. Engineered for commercial fleets, public charging networks, and cutting-edge electric vehicles, the cable leverages advanced liquid cooling to maintain optimal thermal efficiency under extreme loads, ensuring consistent performance without compromising safety. Its robust construction, featuring abrasion-resistant TPU shielding and IP55-rated connectors, guarantees long-term durability in high-traffic environments. By seamlessly integrating power density, intelligent thermal management, and compliance with global standards, Fiver’s solution not only meets the urgent needs of today’s EV ecosystem but also lays the foundation for scalable, future-ready charging infrastructure.

Parameters of Fiver's 500A/600A Liquid Cooled EV Charging Cable

Product Features for Fiver's High-power Charging Cable for Electric Vehicles:

Fiver's proprietary liquid cooling system provides superior thermal regulation, even under the most demanding charging scenarios:

1. Optimized Coolant Selection:

Silicone Oil: Chosen for its non-conductive properties, high flash point (>200°C), and chemical stability, ensuring safe and reliable operation.

Efficient Flow Rate: A flow rate of 3–6 liters per minute (LPM) at a maximum pressure of 0.7MPa ensures rapid and effective heat extraction.

Precise Temperature Control: Integrated PT1000 sensors continuously monitor the cable temperature, automatically reducing power or initiating a shutdown if temperatures exceed 90°C, enhancing safety and preventing damage.

2. Integrated Leak Detection & Enhanced Safety:

Built-in sensors provide immediate detection of any coolant leaks, triggering emergency stops to eliminate potential electrical hazards.

A robust dual-layer tubing design provides an extra layer of protection, ensuring coolant containment even under high pressure.

3. Engineered for Durability and Performance

Long-Lasting Connections: Tested to withstand over 10,000 insertion cycles, meeting the rigorous IEC 62196-3 standards for heavy-duty applications.

Robust Cable Construction:

Outer Jacket: Constructed from Thermoplastic Polyurethane (TPU) for exceptional resistance to abrasion, oil, and UV exposure, ensuring longevity in harsh environments.

Compact Design: With a diameter of just Ø33.5mm, the cable offers a space-saving design, crucial for installations in urban charging hubs and other space-constrained locations.

Lightweight  Advantage: Weighing only 1.5kg/m, it's 30% lighter than comparable high-power cables, reducing strain and improving handling.

Connector Reliability: Rated IP55 for protection against dust and water ingress, ensuring dependable performance in various weather conditions.

4. Multi-Layer Safety Protection Mechanisms

Advanced Thermal Management: Real-time temperature monitoring via integrated PT1000 sensors. Automatic shutdown protocols are activated immediately if coolant flow is interrupted or if temperatures exceed the critical 90°C threshold

Superior Electrical Safety: Withstands a 3500V AC insulation test (exceeding IEC 62893 standards), guaranteeing a high level of electrical safety,  Reinforced shielding effectively minimizes electromagnetic interference (EMI), ensuring reliable operation.

Robust Mechanical Safety: Stainless-steel coolant fittings provide exceptional resistance to corrosion and vibration, ensuring long-term reliability. An easily accessible emergency stop button allows for immediate manual intervention in the event of any detected faults

Application Scenarios of Fiver's 500A/600A CCS1 Charging Cables

Empowering Commercial EV Fleets

• Electric Buses & Trucks: Significantly reduce downtime for logistics and public transportation. A 600A charge can replenish an 80% charge on a 400kWh truck battery in under 45 minutes, maximizing operational efficiency.
• Taxis & Ride-Sharing Services: Enable rapid turnaround times, maximizing daily revenue potential for ride-sharing and taxi fleets.

Building the Future of Ultra-Fast Charging Hubs

• 500kW+ Charging Stations: Future-proof infrastructure investments by deploying stations capable of supporting the next generation of high-power EVs.
• Strategic Highway Corridors: Directly address the requirements of programs like the NEVI program in the U.S. and AFIR mandates in the EU for establishing robust interstate charging networks.

Supporting Industrial and Heavy-Duty Electrification

• Mining & Construction Equipment: Facilitate the electrification of heavy-duty machinery like excavators and haulers operating in demanding environments.
• Port & Logistics Operations: Enable continuous 24/7 operation for electric cranes and terminal trucks, increasing efficiency and reducing emissions.

The Working Principle of the Liquid Cooled High Power Charging