CCS2 EV DC Charging Cable — Specification (125A–375A)

1) Product Overview

The CCS2 DC charging cable assembly is designed for high-power EV fast charging applications using the IEC 62196-3 CCS2 interface. It supports 125A to 375A current range and is suitable for DC fast chargers, fleet depots, and public charging networks. OEM/ODM customization is available for cable length, connector branding, and cooling type.

2) Electrical Specifications

• Connector Standard (Vehicle Side): CCS2 (IEC 62196-3)

• Charging Type: DC fast charging cable assembly

• Rated Current: 125A / 150A / 200A / 250A / 300A / 350A / 375A (selectable by model)

• Rated Voltage: Up to 1000 V DC

• Insulation Resistance: ≥ 1000 MΩ (typical)

• Withstanding Voltage (Hi-Pot): 2500–3000 V AC (typical; per design)

• Temperature Rise Control: Designed to meet DCFC thermal limits under rated load

3) Cable & Mechanical

• Standard Cable Length: 5 m (common industry spec)

• OEM Length Options: 3 m / 4 m / 6 m / 7 m / 10 m (custom available)

• Cable Structure: Power conductors + control/signal cores (CP/PP, interlock as required)

• Conductor Material: High-purity copper

• Outer Jacket: TPU (standard) / TPE (optional)

• Cable Color: Black (custom colors optional)

• Bending Radius: Designed for repeated flexing and public-use handling

• Typical Plug Insertion Cycles: ≥ 10,000 cycles (typical; depends on final connector spec)

4) Cooling Options (Choose One)

A) Air-Cooled (Standard)

• Recommended for 125A–250A continuous applications

• Lower cost, simpler maintenance

B) Liquid-Cooled (Optional)

• Recommended for 300A–375A high-duty or continuous applications

• Lower cable OD and improved ergonomics at high current

(Final current rating depends on cable cross-section, cooling method, and ambient temperature.)

5) Environmental & Protection

• Operating Temperature: -30°C to +50°C (typical; configurable)

• Ingress Protection: Plug typically IP54 / IP55 when mated (model-dependent)

• UV Resistance: Outdoor-grade jacket optional

• Flame Retardant: Available (market-dependent requirements)

6) Compliance & Quality

• Standards Reference:

• IEC 62196-3 (CCS2)

• IEC 61851 (charging system requirements)

• Factory Testing:

• Conductor continuity

• Insulation resistance

• Hi-pot test

• Connector function & locking check

7) OEM/ODM Customization

• Cable length, jacket material (TPU/TPE), labeling and logo

• Connector housing color & branding

• Liquid-cooling interface design (if liquid-cooled version)

• Packaging: retail box / bulk / branded carton

8) Typical Applications

• Public DC fast chargers (CPO networks)

• Fleet depot fast charging

• Highway service area DCFC

• Mobile DC fast charging / battery-integrated chargers

Tags: ev charge cable