What is a Cooling Unit?

Precision Thermal Management for Ultra-Fast EV Charging Stations

A cooling unit in electric vehicle (EV) charging systems is a critical component designed to manage heat generated during high-power charging (500–800A). Traditional air-cooled systems struggle with thermal buildup at these currents, risking cable degradation and safety hazards. Fiver's HPC Cooling Unit solves this with an intelligent liquid cooling system that maintains CCS temperatures within a 50K safety margin from ambient conditions, even in extreme environments (-40°C to 50°C).

Working Principle of the Liquid Cooling System

The High-Power Charging (HPC) CCS is capable of transmitting charging currents exceeding 500A, but traditional charging methods often rely on heavy cables, which can lead to overheating issues. To address this, Fiver’s intelligent HPC charging technology utilizes an advanced liquid-cooled system. This system employs environment-friendly cooling media to provide a consistent cold source for the CCS, ensuring easy maintenance and optimal performance. The cooling medium efficiently cools both the charging cable and the DC power terminal of the charging connector, while the terminal itself acts as a radiator due to its excellent thermal conductivity. A closed-loop system is established by connecting the liquid inlet and outlet pipes of the HPC Cooling Unit with those of the CCS. A circulating pump drives the cooling medium through the system, absorbing heat generated during charging and transferring it to a radiator, which dissipates the heat using an electronic fan. Real-time temperature sensors at the inlet and outlet allow the system to adjust the pump and fan speeds dynamically, ensuring precise heat dissipation and keeping the CCS within its optimal operating range. This intelligent thermal management ensures the safe and stable operation of the HPC charging pile, even under the most demanding conditions

Parameters of Fiver's Liquid Cooling Unit for CCS High Power Charging.

Product Features of Fiver’s Cooling System for CCS High-Power Charging?

1. Optimized Heat Dissipation

   • Radiating Power: 3000W at 4L/min, ensuring efficient cooling even during high-power charging.
   • Supports charging currents of up to 800A, enabling faster charging times.

2. Intelligent Temperature Control

   • Maintains system temperature rise ≤50K relative to ambient temperature, preventing overheating and ensuring safety.
   • Real-time adjustment of fan and pump speeds for precise thermal management.

3. Compact and Durable Design

   • Dimensions: 435×155×410mm, Weight: 7KG—ideal for space-saving installations.
   • IP68 Protection: Ensures durability and reliability in harsh environments.

4. Eco-Friendly Cooling Medium

   • Uses dimethyl silicone oil, a non-conductive and environmentally friendly coolant, for safe and efficient operation.

5. Seamless Integration

• MODBUS RTU Communication: Enables easy integration with smart charging networks for real-time monitoring and control
• Adopt quick plug to pagoda connector and a single ear hose clamp, enables easy operation with rapid connection and disconnection, This pairing ensures a reliable connection with good sealing performance and strong tightening force, preventing fluid leakage and hose detachment

Applications of the Liquid Cooling System

Our Cooling System is perfect for:

Related Products:

   700A CCS2 HPC Cable                                            600A CCS2 Charging Cables