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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.
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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Supports continuous high-current delivery with thermal and electrical stability for urban, highway, and intercity high-utilization charge points.
Handles repetitive high-load cycles in logistics and transit depots with extended duty cycles and precise temperature monitoring at connectors.
Enables high-amperage charging for electric trucks and buses using oversized conductors and reinforced insulation for mechanical and thermal endurance.
Interfaces directly with BESS DC output for controlled energy transfer, maintaining low voltage drop and EMI-free signal transmission.
Used in controlled lab environments to deliver stable, high-current DC with exact conductor resistance and communication line shielding properties.
Provides corrosion-resistant, weather-rated charging interfaces for electric boats and harbor equipment using CCS2 marine-rated configurations.
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.
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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.
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.
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.
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.
Frigate 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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10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ
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