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Liquid Charging Cable Cooling System 4.5kw 2.4kw 3.5kw for 600A 800A Connector of EV DC Charging Station
Cooling Unit for Oil Charging Cable
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Liquid Charging Cable Cooling System 4.5kw 2.4kw 3.5kw for 600A 800A Connector of EV DC Charging Station

The Charging Cable Cooling System delivers 4500W thermal management for high-power charging plugs with cable, operating with under 300W power consumption.​

  • Product name Charging cable cooling system
  • Product size(W*H*D) 240*534*330mm
  • Power dissipation <300W
  • Heat dissipation capacity 4500W@5L/min,1200m³/h,50℃Tamb
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Product Introduction

Developed specifically for liquid-cooled DC Charging Stations, the Charging Cable Cooling System achieves 4500W thermal management capacity through a highly efficient liquid cooling cycle. With a 5L/min flow rate and 1200m³/h of forced air cooling, it ensures stable temperature control even under high-power charging conditions. The system utilizes a modular architecture, integrating a 24V gear pump (150W) and multiple axial fans (55W each), keeping overall power consumption strictly under 300W, significantly reducing the charging station's operational energy consumption.

The system's engineered polymer tubing (PA12 material) is compatible with dimethyl silicone oil and other environmentally friendly cooling media. It incorporates high-precision PT1000 temperature sensing (±0.15°C) and 0-1MPa pressure monitoring, providing multiple protection mechanisms. An RS485 industrial bus supports real-time data transmission, facilitating remote monitoring of system status at charging stations.

Leveraging nine years of expertise in the new energy sector, we have incorporated patented thermodynamic design (see the flow channel optimization section in the Change History section) to ensure continuous operation within an ambient temperature range of -40°C to 50°C. Each system undergoes rigorous testing and provides cost-effective solutions with lifetime technical support to provide long-lasting and reliable heat dissipation for charging infrastructure.

Features

Excellent Heat Exchange Performance

● 4500W heat dissipation supports supercharging requirements

● Multi-stage fan system delivers 1200m³/h air volume

● Adjustable flow pump (0-5.5L/min) adapts to varying operating conditions

● Wide temperature range (-40°C to 100°C)

Detailed Energy Management

● Total power consumption is less than 300W

● 24V DC drive improves energy efficiency

● IP55 protection reduces environmental interference and loss

● Intelligent start-stop strategy optimizes operational efficiency

Cooling unit for two 600A ev charging Connector
Cooler unit for two 600A ev charging Connector

Military-grade durable design

● Pressure-resistant piping withstands 10 bar operating pressure

● Class A temperature sensor ensures measurement reliability

● Pressure element supports millions of cycles of testing

● Liquid level switch prevents cooling medium loss

Intelligent Integration Solution

● Compact design fits standard charging cabinets

● Industrial communication protocol enables device interconnection

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

● Module components support rapid maintenance and replacement

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Application

● Ultra-Fast Charging Equipment Cluster
In high-power charging stacks of 350kW and above, this system continuously dissipates heat accumulated in the charging connector cables, preventing power limitations caused by temperature rise and ensuring peak charging efficiency.

● Special Environment Charging Station
For charging stations in extremely cold permafrost zones or high-temperature desert areas, this system offers -40°C cold start characteristics and 50°C high-temperature heat dissipation capabilities, mitigating the risk of equipment downtime caused by extreme climates.

● Urban Bus Charging Hub
Meeting the continuous operation requirements of electric bus fleets, RS485 networking enables centralized monitoring of multiple cooling systems, significantly reducing the O&M intensity of high-density charging stations.

● Space-Conserving Charging Cabinets
Adaptable to compact cabinets with a depth of up to 330mm, this system achieves maximum heat dissipation efficiency within a limited space by optimizing the layout of the heat exchanger and fan.

Structure

Solution

Parameter

Comprehensive parameters

Product name Charging cable cooling system
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 4500W@5L/min,1200m³/h,50℃Tamb
Communication method RS485
Power dissipation <300W
Net weight 18kg
System volume 4L
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 Suction
Rated voltage 24V DC
Rated power 55W
Working temperature -40~125℃
Speed 2700RPM
Noise Max<60dB

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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