The latest and greatest high power connector for the Combined Charging System (CCS) is made by Phoenix Contact, for power of up to 500 kW!
The High Power Charging (HPC) is rated from 500A at up to 1,000 V, and provides backward compatibility to the current CCS standard.
The upgrade from 200A to 500A was possible using intelligent cooling of both the cable and the plug.
The Phoenix Contact HPC is to be available for both major regions - the North America market in the Type 1 version, and for Europe (and most of the rest of the world) in the Type 2 version.
The level of 500 kW is currently well beyond the needs of electric vehicles, which currently are only hinted at by manufacturers to use in the range of 150 kW and 350 kW.
So, is this a bit of overkill? Perhaps, but we welcome any advancements in the segment - totally necessary or not.
"Until now, the Combined Charging System (CCS) allowed for fast charging with currents of up to 200 A. Significantly higher currents are necessary, however, to achieve markedly short charging times. Conventional charging technology would result in dangerous overheating – or would require larger, cumbersome cable diameters.
Phoenix Contact's HPC technology is based on an active cooling system that makes charging currents of up to 500 A possible, without compromising on safety or manageability. They use an environmentally-sound and maintenance-friendly water-glycol mixture as the coolant. This cools both the charging cable and the DC power contacts in the vehicle connector. The contact carrier also acts as a heatsink, due to its outstanding thermal conductivity. Integrated temperature sensors measure the development of heat in real time. A controller evaluates this acquired data and regulates the cooling output accordingly. This reliably prevents overheating and, at the same time, increases the energy efficiency of the cooling system.
The HPC vehicle connector is based on the established Combined Charging System for Europe and North America and is therefore completely CCS-compatible. Furthermore, it is easy to maintain, because the mating face frame and the DC contacts can be easily exchanged, in the event of damage, without needing to drain the coolant. It is also especially safe thanks to integrated temperature and gas leak sensors. Even the flexible and easily managed HPC charging cable provides the user or operator with an early warning in the event of a safety risk, thanks to a wear indicator integrated in the cable sheath.
The HPC system by Phoenix Contact also includes several coordinated components in its delivery scope. These include a cooling unit coordinated with the charging station dimensions as well as a corresponding controller for the cooling system, in addition to the vehicle connector and charging cable. Moreover, a standardized interface is offered for guiding the charging cable into the charging station, with strain relief.
The HPC system is typically used in public or commercial charging parks, e.g. highway rest areas, where the driver of an electric vehicle has a limited amount of time. Cooling systems and controllers are usually centrally located in such charging parks, while separate, decentralized charging stations are supplied with coolant and only have individual heat exchangers. However, it is also possible to install the HPC system in independent charging stations, in which cooling systems and controllers have been integrated.
The HPC system's modular design provides a high degree of flexibility, meaning that nothing stands in the way of developing a modern, high-performance fast charging infrastructure nationwide. To realize individual HPC solutions, Phoenix Contact offers its customers professional and expert consulting."