CHARX connect – DC charging cables for fast charging stations

DC charging cables for fast charging stations

The CHARX connect DC charging cables are used for fast DC electric vehicle charging. In addition to type 1 and type 2 CCS (Combined Charging System) charging cables, we also provide the GB/T standard for China. Charging powers of up to 500 kW are achieved with the aid of cooled High Power Charging charging connectors. This allows vehicle batteries to be charged at an HPC charging station within a matter of minutes to quickly top up the travel range.

More information

Your advantages

  • Complete product range for CCS type 1, CCS type 2, and GB/T
  • The right charging cable for every application, from the carport to the charging park
  • Convenient handling due to the ergonomic design
  • On request with your logo – for consistent branding of your charging station
  • Safe against overheating with temperature measurement at every DC power contact
  • Developed and produced in accordance with the IATF 16949 automotive standard and ISO 9001

New products

Type 1 CCS charging cables for High Power Charging – liquid-cooled fast charging with up to 500 kW
Type 1 CCS charging cables for High Power Charging
Liquid-cooled fast charging with up to 500 kW

CHARX connect DC charging cables for High Power Charging are now also available for the type 1 CCS charging standard. With liquid-cooled charging connectors, they can charge electric vehicles in a just a few minutes. A passive cooling unit, cable handle for convenient handling, and repair kits for easy maintenance complete the portfolio.

These are the main features

  • Ultra-fast HPC charging with a charging power of up to 500 kW, efficient cooling, and safe temperature and leakage monitoring
  • Fast and safe installation with optional panel feed-through
  • Easy to maintain and environmentally friendly thanks to a replaceable mating face and semi-open cooling circuit based on a water-glycol mixture
  • Convenient handling with a flexible charging cable, rubberized handle component, and optional cable handle

These are the advantages

  • DC rated current: 500 A
  • DC rated voltage: 1,000 V
  • CAN bus interface and status output
  • Temperature and leakage sensors
  • Cooling medium: water-glycol mixture
  • Degree of protection: IP54 (when plugged in)
  • Cable length: 5 m (additional lengths on request)

Presentation by our Product Manager

Presentation of the CHARX connect DC charging cables
Presentation of the CHARX connect DC charging cables MovingImage
Diagram of fast DC charging in accordance with mode 4

Fast DC charging in accordance with mode 4 What exactly does that mean?

With DC fast charging, the charging power is generally very high. Charging processes are therefore completed within a very short amount of time.

A DC charging cable in accordance with charging mode 4 has a vehicle charging connector and an open cable end. This connects it directly to the charging station that houses an AC/DC converter, also called power electronics. This converts the AC line current into DC current, which can be used to charge the battery of the electric car.

Cooled CCS charging cables for High Power Charging Discover our HPC charging cables

A man charges his electric car with High Power Charging at a charging station
Electric car is charged with a High Power Charging cable, progress is viewed on a smartphone
Cooled High Power Charging connector
Graph of the High Power Charging temperature curve during a charging process
High Power Charging charging station with electric car
Dirk Moseke, Robert Ewendt, and Michael Heinemann from Phoenix Contact with Dr. Wladimir Klitschko and DDW General Manager Michael Oelmann (Photo: Uwe Erensmann/@uepress)
A man charges his electric car with High Power Charging at a charging station

Our CCS charging cables with our proprietary High Power Charging Technology (HPC) are used in fast charging stations and fast charging parks. With HPC, long charging times are a thing of the past: Electric car batteries can be charged for a driving range of 100 kilometers in just three to five minutes.

With this technology, Phoenix Contact is setting a milestone for the future of electromobility, because HPC makes the charging of electric cars practical.

Electric car is charged with a High Power Charging cable, progress is viewed on a smartphone

With High Power Charging, fast charging for significant distances will become comparable to filling a combustion engine vehicle. This advanced charging technology makes it possible to charge electric car batteries with a charging power of 500,000 watts (half a megawatt) during a coffee break.

Our HPC charging connectors follow the CCS standard and are therefore also backward-compatible for electric cars that do not yet support the high HPC charging power.

Cooled High Power Charging connector

Until now, permanent charging currents of only up to 200 kW were technically possible with the Combined Charging System (CCS). Significantly higher currents are necessary to achieve very short charging times. Conventional charging technology would result in dangerous overheating or would require larger, cumbersome cable diameters.

That is why our intelligent HPC technology is based on active liquid cooling that allows charging currents of up to 500 kW without compromising safety or manageability. With it, we are revolutionizing fast charging technology.

Graph of the High Power Charging temperature curve during a charging process

And what do the standards require? To determine the rated current, the charging connector and cable may be a maximum of 50 K warmer than the ambient air (ΔTmax = 50 K) in accordance with the directive VDE-AR-E 2623-5-3 and the standard IEC TS 62196-3-1. Thus, a maximum temperature of +90°C is allowed to occur during the charging process.

To ensure this, a total of five temperature sensors in the HPC charging connector measure the heat development in real time. A controller evaluates the data acquired and regulates the cooling output accordingly. The environmentally friendly coolant efficiently dissipates the heat via integrated cooling ducts. This prevents overheating safely and in compliance with standards.

High Power Charging charging station with electric car

During the development of High Power Charging, the focus was not only on high charging power but also on making installation as easy as possible.

Therefore, our HPC charging cables are optionally available with a panel feed-through, which enables a quick, safe and convenient installation of the charging cable at the charging station. It contains defined interfaces for power transmission, communication, and the cooling circuit.

Dirk Moseke, Robert Ewendt, and Michael Heinemann from Phoenix Contact with Dr. Wladimir Klitschko and DDW General Manager Michael Oelmann (Photo: Uwe Erensmann/@uepress)

Phoenix Contact was named Innovator of the Year 2019 for its High Power Charging Technology. Honorary award winner Dr. Wladimir Klitschko presented the German Business Award (DDW) to Michael Heinemann (CEO of Phoenix Contact E-Mobility GmbH), Robert Ewendt (Project Manager HPC) and Dirk Moseke (Developer HPC) at the ceremony in Düsseldorf.

A total of 20 companies received awards. Only three of them also received the People's Choice Award, which was decided by a vote among the readership.

Product video

CCS charging cables for High Power Charging – CHARX connect
CCS charging cables for High Power Charging – CHARX connect YouTube
Research project
High Power Charging in practice
In the research project FastCharge, we demonstrated together with Allego, BMW, Porsche, and Siemens that ultra-fast charging technology can be put to real-world use. Our cooled HPC charging cables played a key role in this project.
Find out more now
A High Power Charging (HPC) connector is plugged into the electric car

The HPC charging connector in detail Smart technology for a fast and safe charging process

Interactive image map: Interior view of the High Power Charging connector
Microprocessor and sensor technology
Integrated sensor technology provides information on the overall status of the charging connector, its usage and wear, and further analysis data. A microprocessor processes and stores all of the information and transmits it via CAN bus interface to the charging controller in real time.
Coolant
We use an environmentally sound and maintenance-friendly mixture of water and glycol as the coolant. It cools both the charging cable and the power contacts.
Contact carrier
The contact carrier also acts as a heatsink due to its excellent thermal conductivity. It works together with the coolant to remove heat as effectively as possible.
Replaceable power contacts with temperature sensors
The silver-plated DC power contacts can be easily replaced during maintenance without having to drain off the coolant. Integrated temperature sensors measure the heat produced in real time, delivering energy-efficient cooling performance in accordance with requirements.
Replaceable mating face frame
If it becomes damaged, the mating face frame can be replaced by simply removing five screws – no further steps are necessary.
Leakage sensor
The leakage sensor offers an especially high level of safety: If coolant escapes from inside the charging connector, a signal is immediately sent to the controller to stop the charging process.
3D product view
Experience all details in 3D
Take a look at the liquid cooled CCS type 1 HPC charging connector in the greatest level of detail. The product can be viewed from any angle using free zoom and rotate functions.
To the 3D product view
3D product view of the CCS type 1 HPC charging connector

Compact CCS charging cables for low powers Discover our CCS C-Line product family

A man charges an electric car at home with a home charger
Compact charging cables for CCS type 1 and CCS type 2
A CCS charging connector is plugged into an electric car
CCS charging connector in outdoor use in the rain
Diagram: CCS charging cable for vehicle-to-grid and vehicle-to-home applications
A man charges an electric car at home with a home charger

In contrast to conventional AC charging, DC charging saves on expensive electronics in the electric car, and is also faster and more efficient.

Therefore, the advantages of this charging technology will also be used in the home in the future. The same is true in front of restaurants, supermarkets, and car dealerships, where customers spend 30 minutes to a few hours.

Charging power in the lower range, from 20 to 80 kilowatts, is enough to charge the battery of the electric car during this time frame. Our compact DC charging cables from the CCS C-Line family are the ideal and economic solution here.

Compact charging cables for CCS type 1 and CCS type 2

The CCS charging connectors with their sophisticated design and their compact dimensions are consistently designed for modern DC home chargers in garages and carports as well as for small DC charging stations in the public and commercial sector.

The charging cables are available for the established charging standards CCS type 1 and CCS type 2, making them suitable for use almost anywhere in the world.

A CCS charging connector is plugged into an electric car

The design of the charging connector features a contemporary style and is also functionally well-developed. The ergonomic shape of the gripping zone ensures easy handling and a comfortable feel.

CCS charging connector in outdoor use in the rain

The clever sealing concept ensures continuous longitudinal water tightness, which prevents moisture from penetrating the charging connector or the cable. High-quality materials ensure the necessary robustness. Therefore, there is nothing preventing constant outdoor use.

Diagram: CCS charging cable for vehicle-to-grid and vehicle-to-home applications

Due to bidirectional converter technology, the DC home chargers of the near future will be able to perform vehicle-to-grid and vehicle-to-home power feed-ins. Here, the electricity can flow under control from the vehicle battery via the charging station into the power grid or the user's own home.

For these V2G and V2H applications, our compact CCS charging cables are the ideal solution.

What makes the CCS C-Line so special

Presentation of the compact CCS C-Line CCS charging cable
Presentation of the compact CCS C-Line CCS charging cable MovingImage

The CCS charging connector in detail Perfectly tailored to DC home chargers and smaller DC charging stations

Interactive image map: Compact CCS charging connector for DC charging power up to 80 kW
Silver-plated contacts
The silver-plated surfaces of the power and signal contacts ensure efficient power transmission, optimum corrosion protection and a long service life.
Clever sealing concept
Our sophisticated sealing concept ensures continuous longitudinal water tightness, which prevents moisture from penetrating the charging connector or the cable.
Compact design with ergonomic handle
The ergonomic shape of the gripping zone guarantees easy handling and ensures a comfortable feel. In addition, the compact design ensures a harmonious overall appearance between the charging station and charging connector.
Cable in accordance with DIN EN 50620
The particularly robust, VDE-certified charging cable has been specially designed for use in e-mobility applications with regard to insulation thickness, material flexibility, and other properties.
Your individual logo
As an alternative to the Phoenix Contact logo, we are also happy to manufacture the charging connectors with your logo on request, printed on a UV- and weather-resistant plastic label.
Integrated temperature sensor technology
With precise temperature measurement directly at the power contacts, the charging process can be interrupted in the event of overheating to protect the user from danger and the charging station from damage.
3D product view
Experience all details in 3D
Take a look at the compact CCS type 2 charging connector in the greatest level of detail. The product can be viewed from any angle using free zoom and rotate functions.
To the 3D product view
CCS C-Line charging connector in 3D product view

Overview of DC charging cables

Our portfolio at a glance:

Lower power range – CCS C-Line

Medium power range

Upper power range – High Power Charging (HPC)

Application
Scope Private to semi-public Semi-public to public Public
Typical examples Private carports, company, restaurant and retail parking lots, public parking garages Company, restaurant and retail parking lots, public parking lots, and gas stations HPC fast charging parks, service stations, and rest areas on freeways and expressways
Technology and features
Charging standards CCS type 1, CCS type 2 CCS type 1, CCS type 2, GB/T CCS type 1, CCS type 2
Charging power (nominal operation) 40 kW … 80 kW 80 kW … 250 kW 400 kW … 500 kW
Maximum charging power (Boost Mode) ¹ - 500 KW -
Replaceable mating face ²
Liquid cooling
Optional panel feed-through
Compatible accessories
Charging connector holder ³
Cable glands
Repair kits ²
Cable handle
Passive cooling unit
Directly to product (example) Directly to product (example) Directly to product (example)

¹ Allows higher charging power for a short time. The possible time span depends on numerous ambient conditions. Details can be found in the packing slip of the respective item.
² Currently not valid for GB/T.
³ Currently not valid for HPC CCS type 2.