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3.5kW 4.5kW 2.4kW Liquid Cooling System for Dual Gun 800A 600A Charging Cable of DC EV Charging Station
Cooling Unit for Oil Charging Cable
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3.5kW 4.5kW 2.4kW Liquid Cooling System for Dual Gun 800A 600A Charging Cable of DC EV Charging Station

The Charging Cable Cooling System delivers 3.5kW thermal management for high-current charging applications using integrated liquid-air cooling technology.​

  • Product name Charging cable cooling system
  • Heat dissipation capacity 3500W@5L/min,1200m³/h,50℃Tamb
  • Product size(W*H*D) 393*412*130mm
  • Power dissipation <300W
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Product Introduction

The Charging Cable Cooling System provides targeted thermal management for high-current charging operations, specifically engineered for 800A single-gun or 600A dual-gun applications. Its 3,500W heat dissipation capacity operates at 5L/min coolant flow and 1,200m³/h airflow, maintaining component stability during continuous charging cycles. The compact design (393mm W × 412mm H × 130mm D) integrates a gear pump (150W), axial fan (144W), and precision sensors, with total system power consumption below 300W.

Constructed with PA12 polymer coolant lines, the system supports dielectric fluids and features RS485 communication for real-time monitoring. Critical safeguards include PT1000 temperature sensors (±0.15°C accuracy), 0-1MPa pressure sensors, and low-coolant alarms triggered at 30% reservoir capacity. Operational resilience spans -40°C to 50°C ambient temperatures, ensuring reliability in diverse climates.

Leveraging nine years of EV charging expertise, our patented thermal solutions (referencing control box optimizations in revision A/1) undergo rigorous validation. We deliver cost-efficient performance with dedicated lifecycle support, minimizing downtime through modular serviceability.

Features

High-precision thermal conductivity

● 3,500W heat dissipation load supports 800A charging

● PT1000 sensor achieves ±0.15°C monitoring

● Flow sensor covers a range of 0.1-25.5L/min

● Dual-mode adaptability for single- and dual-pump applications

Energy-saving system architecture

● Total power consumption <300W

● 24V DC drive reduces energy consumption

● Adjustable pump speed (500-3,500rpm) to meet demand

● IP55 protection reduces environmental impact

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Multiple reliability guarantees

● PA12 piping withstands 10 bar pressure

● Pressure sensor supports 10⁶ cycles

● -40°C cold start ensures operation in extreme conditions

● Liquid level switch prevents loss of medium

Compact and intelligent integration

● 130mm depth fits into narrow spaces

● RS485 protocol enables remote diagnostics

● Full-size interfaces (φ4-8mm) simplify connections

● Modular components speed up maintenance

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Application

● High-Current Dual-Charger Charging Station
The 600A dual-charger configuration continuously dissipates heat, preventing power limitations caused by cable overheating and ensuring continuous operation and stability.

● Charging Terminal for Cold Regions
With a -40°C cold start feature and antifreeze coolant, this charging station ensures all-weather operational reliability in extremely cold regions.

● Bus Fast Charging Depot
Meets the needs of clustered electric bus charging. RS485 networking enables centralized multi-system monitoring and optimizes O&M efficiency.

● Space-Constrained Charging Cabinet
For compact cabinets with a depth of ≤130mm, this system achieves efficient space utilization through optimized heat exchanger layout.

Structure

Solution

Parameter

Comprehensive parameters

Product name Charging cable cooling system
Application Single Gun 800A/Single Gun 600A
Product size (W) 240 * (H)534 * (D)330mm
Heat exchanger size (W) 230 * (H)460 * (D)85mm
Coolant 10CST silicone oil or Degradable dielectric coolant
Heat dissipation capacity 3500W@5L/min,1200m³/h,50℃Tamb
Communication method RS485
Power dissipation <300W
Net weight 18kg
System volume 3L
Material of cooling pipeline PA12
Interface specifications φ4*6/5*7/6*8/8*10mm

Environmental conditions

Ambient temperature -40℃~50℃
Storage temperature -40℃~85℃
Inlet temperature <85℃
Application environment Charging Internal
Altitude ≦2000m

Circulating pump

Pump type Gear pump
Rated voltage 24V DC
Rated power 150W
Speed 500~3500 rpm
Working pressure 0~10bar
Flow 0~5.5L/min(Adjustable)
Coolant temperature -40~100℃
Operation temperature -40~80℃
Protection grade IP55

Fan

Fan type Axial flow fan
Air volume 1000m³/h
Wind direction Blow
Rated voltage 24V DC
Rated power 144W
Working temperature -40~125℃
Speed 3600RPM
Noise Max<65dB

Flow sensor

Operating voltage 4.5~60VDC
Working temperature -40~100℃
Maximum frequency 34Hz
Flow range 0.1~25.5L/min
Starting flow 0.35L/min
Maximum pressure 1Mpa

Pressure sensor

Working pressure 0~1MPa
Medium temperature -30~105℃
Output Type 4~20mA
Accuracy 0.5%FS
Supply voltage 12~30VDC
Service life 10⁶ Pressure cycle

Temperature sensor

Sensor Type PT1000
Range -50~150℃
Insulation resistance 500VDC,100MΩ
Measurement accuracy Class A,±0.15℃

Level switch

Switch Type Normally closed
Alarm point Remaining quantity of oil tank
Working pressure 0~1MPa
Working temperature -40~100℃
Pole length 160mm

Quality Control

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Packaging

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