Technology

Charging current flowing through half-open HPC vehicle connector

500,000 watts in one cooled vehicle connector

With HPC, we are revolutionizing fast charging technology. Learn more about how this technology works.

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

Our intelligent HPC technology is therefore based on an active cooling system that makes charging currents of up to 500 A possible – without compromising on safety or manageability.

The High Power Charging system at a glance

CCS type 1 and type 2 HPC vehicle connectors  

The HPC system can be used in North America and Europe

The modular HPC system from Phoenix Contact consists of several coordinated components:

  • Cooled DC vehicle connector
    (CCS type 1 for North America and CCS type 2 for Europe)
  • Cooled charging cable
  • Cable feed-through with specific interfaces for power, communication, and cooling
  • Controller for charging process and cooling
  • Cooling system customized for the installation space or heat exchanger from one of our technology partners

In addition, we offer many other components for your HPC charging stations, such as socket outlets, charging controllers, HMIs, power supplies, surge protection, and communication and connection technology.

How does the cooling system work for High Power Charging?

Temperature characteristic with and without cooling  

The cooling system ensures that the normative limit temperature ΔTmax is not exceeded.

According to the VDE-AR-E 2623-5-3 Guideline and the IEC TS 62196-3-1 standard, vehicle connectors and charging cables must not exceed a temperature that is 50 K higher than the ambient air temperature during the charging process (ΔTmax = 50 K).

In order to comply with this, multiple temperature sensors integrated in the HPC system measure the heat produced directly at the vehicle connector power contacts, and also in the charging cable in real time.

A controller evaluates the data acquired and regulates the cooling output accordingly. This reliably prevents overheating in compliance with standards and, at the same time, increases energy efficiency.

Technical data for the High Power Charging system

  • Max. charging power: 500,000 W
  • Max. rated current: 500 A
  • Max. rated voltage: 1000 V DC
  • 1 leakage sensor in the vehicle connector
  • 2 temperature sensors in the vehicle connector (1 sensor per DC contact)
  • 2 temperature sensors in the charging cable
  • CAN bus interface for controller connection and remote access
  • Digital output for signaling the system status
  • Compliant with VDE-AR-E 2623-5-3 and IEC TS 62196-3-1
  • Protection class: IP54 (plugged in)
  • Coolant: 50% water, 50% glycol*
  • Cooling capacity: 600 ... 1000 W*
  • Flow rate: 2 ... 4 l/min*
  • Operating pressure: approx. 1 ... 2 bar*
  • Flow temperature: approx. 20°C*
  • Operating temperature: -30°C … +65°C*

* Depends on the cooling system used and climatic ambient conditions

Direct access to our High Power Charging cables

Get all the commercial and technical data, drawings, and downloads for our High Power Charging cables and corresponding accessories, and order directly online.

Your individual High Power Charging solution

Are you a fast charging station manufacturer or charging station planner interested in our High Power Charging technology?

We will be happy to help you, and will create suitable components for your High Power Charging solution that are tailored to your application.

PHOENIX CONTACT (Israel) Ltd.

P.O.B. 1799 Industrial Park Hasharon
Quadima 60920
+972-9-8915700

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Faster than expected

You think charging an electric car takes hours? These times are over, thanks to HPC.


How does High Power Charging work?

Learn how the technology in the High Power Charging vehicle connector works.

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