CCS2 to CCS2 cable
The definitive solution for high-capacity DC fast-charging infrastructure. Our 400A CCS2 to CCS2 charging cable is engineered for the most demanding HPC (High Power Charging) environments. Capable of delivering up to 400kW of power, this cable features enhanced natural-cooling architecture and dual-channel temperature sensing to ensure safe, continuous operation at peak currents. Designed for public charging hubs and commercial fleet depots requiring maximum throughput.
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Standard: IEC 62196-3 (Combo 2) HPC
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Peak Current: 400A DC (Continuous) / 500A (Boost Mode)
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Voltage Rating: 1000V DC
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Thermal Safety: Dual PT1000 Temperature Sensors
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Cable Material: High-Flex, Flame-Retardant PUR/TPU
Engineering for the 400A Power Ceiling
Maximizing HPC Infrastructure Efficiency
As 800V vehicle architectures (such as the Porsche Taycan, Lucid Air, and Hyundai Ioniq 6) become the market standard, the demand for 400A+ current delivery has moved from “experimental” to “essential.” Our CCS2 to CCS2 cable provides the heavy-duty link required for ultra-fast charging stations. By utilizing high-purity oxygen-free copper with optimized cross-sections , we minimize voltage drop and heat generation even during prolonged 400kW sessions.
Engineering Authority & Safety
Handling 400A of Direct Current safely requires more than just thick wires. We integrate advanced safety protocols to ensure Trustworthiness and equipment longevity:
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Advanced Natural Cooling Technology: Through specialized internal spacing and heat-dissipative thermoplastic shells, our 400A connector manages thermal rise efficiently without the complexity of liquid cooling, reducing maintenance costs and weight for the operator.
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Dual-Channel Thermal Monitoring: Safety is non-negotiable. Each connector is equipped with dual PT1000 temperature sensors directly embedded in the DC+ and DC- power contacts. These sensors provide real-time feedback to the charger’s BMS, allowing for dynamic current throttling if temperatures approach critical thresholds.
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Silver-Plated Contact Precision: We utilize 5μ silver-plated copper alloy terminals. Silver’s superior conductivity ensures a contact resistance of ≤ 0.5mΩ, which is vital for preventing the “micro-arcing” and oxidation that lead to connector failure at high amperages.
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Unibody Ruggedized Design: The connector head features a seamless, screwless unibody design that meets IP67/IP69K standards. It has been tested to withstand a 2-ton vehicle drive-over and over 10,000 mating cycles, ensuring durability in high-traffic public stations.
Technical Specifications
| Feature | 400A High-Performance Spec |
| Maximum Current | 400A Continuous (530A Boost <15 min) |
| Rated Voltage | 1000V DC |
| Max Charging Power | 400kW |
| Temperature Sensors | 2x PT1000 (DC+ / DC-) |
| Terminal Temp Rise | 50K(Tested at 400A for 60 mins) |
| Cable Structure | 4x50mm²+6mm²+8×0.75mm²//4x60mm²+6mm²+(2×0.75mm² )(P2)+2x(2×0.75mm² ） |
| Bending Radius | 10 D (Approx. 380mm) |
| Protection Degree | IP67 (Body) / IP54 (Mated) |
| Flammability | UL94 V-0 |
🛠️ Expert Selection Guide: When to Choose the 400A Variant
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Public Highway Hubs: Essential for 350kW+ chargers to ensure every vehicle can pull its maximum supported current.
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Heavy-Duty Transit: The preferred choice for electric bus and truck depots where high-capacity batteries require rapid turnaround.
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Future-Proofing: Selecting a 400A-rated cable for a 250A charger reduces thermal stress on the hardware, significantly extending the cable’s service life and improving system reliability.
Frequently Asked Questions (FAQ)
Q: Does this cable require a liquid-cooling system?
A: No. Our 400A variant uses advanced natural-cooling technology and high-grade copper conductors to manage heat. This eliminates the need for expensive pumps, coolants, and maintenance associated with liquid-cooled cables up to 400A.
Q: Can I use this for a 150kW charger?
A: Yes. The cable is rated for up to 400A. Using it on a lower-powered charger is a “pro-tier” safety choice, as the oversized conductors will run exceptionally cool, maximizing efficiency and durability.
Q: Is it safe to use in extreme weather?
A: Absolutely. The cable is jacketed in flame-retardant PUR/TPU, which remains flexible at -40°C and is resistant to UV, ozone, and automotive oils. The IP67 rating ensures total protection against rain and dust.
