CCS DC Charging Cords

Name: Rapid-Charge CCS DC Charging Cords | Combined Charging System EV Cable - Frigate
Price: 249.00 USD
Availability: InStock

CCS DC Charging Cords is engineered to withstand continuous current ratings up to 500A without thermal degradation. The conductor is constructed using high-strand-count, oxygen-free copper with a low skin effect, paired with insulation rated for 125°C continuous operation. The cord maintains stable thermal profiles even in constrained enclosures, preventing insulation creep and connector thermal runaway during sustained fast charging cycles.

Conductor Material

High-strand oxygen-free copper (Class 6)

Conductor Cross-Section Area

35 mm² to 120 mm²

Continuous Current Rating

Up to 500A (air-cooled); ≥600A (liquid-cooled variant)

Operating Voltage

Up to 1000V DC

Insulation Material

XLPE / TPE, 125°C continuous temperature rating

Product Description

CCS DC Charging Cord features low-resistance core geometry with conductor cross-sections up to 120 mm², reducing DC resistive losses across long cable lengths. Voltage drop is minimized to within ±2% under full-load conditions, ensuring stable DC bus voltage and preventing charge controller undervoltage lockouts. This allows reliable integration in public charging stations with extended cord lengths.

Dielectric Strength

>10 kV/mm (across insulation layer)

Shielding Type

100% aluminum foil + >85% tinned copper braid

Signal Pair Impedance

100 ±10 ohms (twisted pair for CAN/PLC communication)

Temperature Sensor Support

Integrated NTC/PTC sensors near contact terminals

Bending Radius

≤6 × OD (tested with Class 6 conductor)

EMI Attenuation

≥40 dB from 150 kHz to 30 MHz

Jacket Material

UV-resistant, halogen-free flame-retardant TPU or TPE

Insulation Resistance

≥1000 MΩ·km @ 500V DC, 25°C

Thermal Cycling Endurance

>500 cycles from -40°C to +125°C

IEC 62196-3, IEC 62893, ISO 15118, DIN 70121

Technical Advantages

CCS DC Charging Cords is designed for repeated flexing and movement, with Class 6 fine-wire copper stranding and low-friction jacket materials such as TPU and TPE. The minimum bending radius is optimized for high-current applications while preserving conductor integrity under torsion. The cord supports high duty-cycle robotic applications, cold-start flexibility, and tangle-free manual use in constrained urban installations.

CCS DC Charging Cords integrates dual-layer shielding (100% aluminum foil and >85% copper braid coverage) around twisted-pair signal lines. This structure isolates CAN, PLC, and pilot signals from DC power harmonics and external EMI sources. Shield continuity and impedance control meet ISO 15118 and DIN 70121 communication protocols for secure vehicle-charger interoperability.

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Industry Applications

Public DC Fast Charging Stations

Supports continuous high-current delivery with thermal and electrical stability for urban, highway, and intercity high-utilization charge points.

Fleet Depot Charging Infrastructure

Handles repetitive high-load cycles in logistics and transit depots with extended duty cycles and precise temperature monitoring at connectors.

Heavy-Duty Electric Vehicle Charging

Enables high-amperage charging for electric trucks and buses using oversized conductors and reinforced insulation for mechanical and thermal endurance.

Battery Energy Storage System Integration

Interfaces directly with BESS DC output for controlled energy transfer, maintaining low voltage drop and EMI-free signal transmission.

Electric Vehicle Test Benches

Used in controlled lab environments to deliver stable, high-current DC with exact conductor resistance and communication line shielding properties.

DC Fast Charging for Marine EVs

Provides corrosion-resistant, weather-rated charging interfaces for electric boats and harbor equipment using CCS2 marine-rated configurations.

Interoperability Across CCS Platforms

CCS DC Charging Cords conforms to IEC 62196-3 dimensional and material standards, ensuring compatibility with both CCS1 and CCS2 interfaces. The cord supports embedded NTC or PTC sensors for real-time temperature monitoring at the terminal interface. This allows charger firmware to adjust current dynamically, protecting hardware and ensuring protocol-compliant charge sessions.

CCS DC Charging Cords can be tailored to application-specific parameters including conductor gauge, signal pinout, jacket compound, and overmold geometry. Factory testing includes HiPot, contact resistance (R<sub>dc</sub>), and shield continuity. This reduces on-site commissioning time and ensures direct integration into modular EVSE platforms or retrofit kits.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure conductor uniformity in CCS DC Charging Cord during high-current operation?

Frigate uses precision-drawn, oxygen-free copper with tightly controlled strand lay length to ensure low-resistance current flow. Each batch is tested for conductor circularity and strand compaction. This improves ampacity and reduces hot spots under 400–500A continuous loads. Uniform geometry also supports consistent thermal dissipation across the cable.

What insulation systems does Frigate use in CCS DC Charging Cord for thermal and electrical stability?

Frigate selects cross-linked polyethylene (XLPE) or thermoplastic elastomer (TPE) insulation rated up to 125°C continuous and 150°C peak. These materials offer high dielectric strength and low dielectric loss at DC voltages. Insulation passes partial discharge and tracking resistance tests per IEC 60245. This ensures long-term performance under elevated temperatures and voltages.

How does Frigate test CCS DC Charging Cords for high-voltage and insulation reliability?

Each CCS DC Charging Cords undergoes HiPot testing at 3kV DC for insulation verification between conductor and shield. Insulation resistance is measured at 500V DC to ensure >1000 MΩ at 25°C. Frigate also performs leakage current and withstand voltage tests based on IEC 62893 standards. These tests confirm safe operation in high-voltage DC environments.

How are the shielded communication lines in Frigate’s CCS DC Charging Cord constructed?

Frigate uses twisted-pair signal wires with 100% aluminum foil and over 85% copper braid shielding. The cable impedance is tuned to 100 ±10 ohms for CAN and PLC compatibility. Signal lines are physically separated from power cores to reduce crosstalk. This design supports error-free communication in noisy charging environments.

Can Frigate customize CCS DC Charging Cord for temperature sensing and connector-side integration?

Fregatte offers embedded NTC or PTC thermistors near the plug interface with wiring integrated into the signal bundle. These sensors allow real-time thermal feedback to the EVSE controller. Custom overmold designs support precise sensor placement and strain relief. This enables active thermal management for safety during high-rate charging.

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LOCATIONS

Sitz

10-A, First Floor, V. V Komplex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, Indien.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti Coimbatore-641035, Tamil Nadu, Indien. ㅤ

CCS DC Charging Cords

Conductor Material

Conductor Cross-Section Area

Continuous Current Rating

Operating Voltage

Insulation Material

Product Description

Dielectric Strength

Shielding Type

Signal Pair Impedance

Temperature Sensor Support

Bending Radius

EMI Attenuation

Jacket Material

Insulation Resistance

Thermal Cycling Endurance

IEC 62196-3, IEC 62893, ISO 15118, DIN 70121

Technical Advantages

Let's Get Started

Industry Applications

Interoperability Across CCS Platforms

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CCS DC Charging Cords

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