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CCS2 Charging Cable: Air-Cooled vs Liquid-Cooled Selection
Created on 11.03
CCS2 Charging Cable: Air-Cooled vs Liquid-Cooled Selection
Why CCS2 Charging Cable Selection Fails Before Installation Begins
Most procurement problems with a CCS2 charging cable do not start at the charger; they start at the specification sheet. A buyer compares a quoted cable against a charger’s rated output current, a vehicle inlet datasheet, and a site plan, and assumes the three numbers describe the same operating condition. In practice, the charger current is a maximum, the vehicle inlet rating is a component limit, and neither statement says anything about ambient temperature, cable length, or continuous duty. When those three inputs are mismatched, the first symptom is usually a warm connector body or a cable jacket that softens in summer heat, not an immediate failure. Engineers then discover that the cable was dimensioned for a short bench test rather than a long, repeated charging cycle. This article sets out how to compare air-cooled and liquid-cooled designs so that the cable you order matches the charger, the vehicle, and the environment it will live in.
The second common failure is treating cable length as a commercial detail rather than an electrical one. A longer CCS2 charging cable adds conductor resistance, which converts energy into heat along the run and reduces the voltage actually reaching the vehicle. On a DC fast-charging circuit this shows up as derating, thermal protection trips, or a charger that never reaches its advertised current. On an AC charging circuit the effect is smaller per metre but still measurable across a long parking-bay installation. Buyers who specify length only to reach the vehicle comfortably often end up with a cable that is electrically longer than the charger can support. The practical answer is to give the supplier both the electrical requirement and the mechanical reach, then let the conductor cross-section and cooling method be confirmed together.
How a CCS2 Charging Cable Combines Type 2 AC Contacts with DC Pins
The Combined Charging System Type 2 connector is described in IEC 62196-3, which defines the mechanical and electrical interface for DC charging couplers. A CCS2 charging cable carries the seven Type 2 contacts used for AC charging, namely line, neutral, protective earth, control pilot and proximity pilot, and adds two larger DC power pins below them. The AC contacts handle the on-board charger path at modest current, while the two DC pins carry the full fast-charging current directly to the battery. Because both paths share one housing and one cable assembly, the thermal behaviour of the DC pins dominates the design of a high-power CCS2 charging cable. The control pilot and proximity pilot conductors are signal-level wires, but their insulation and shielding still matter for communication reliability around high-current conductors. Understanding this split is the first step in reading a supplier datasheet critically instead of comparing current figures alone.
Conductor size, insulation material, and the cooling method together decide how much continuous current an assembly can carry at a given ambient temperature. Copper cross-section sets the base resistance, and resistance sets the heat generated per metre at a given current. Insulation and jacket compounds set how much of that heat can escape and how the material behaves when it does get warm; IEC 62893 series cables are commonly referenced for EV charging cable construction. Terminal design at the connector also matters, because IEC 62196-1 defines permissible temperature rise at the contact interface, and a well-made crimp can matter as much as an extra square millimetre of copper. This is why two CCS2 charging cable assemblies with the same nominal current rating can behave very differently on a hot day at a busy site. The honest comparison is not a single amperage figure but a rating curve tied to ambient temperature and duty cycle.
Air-Cooled Designs
Air-cooled CCS2 charging cable assemblies rely on conductor cross-section and surface area to dissipate heat into the surrounding air. They are the simplest, lightest, and most flexible option, and they suit AC charging and moderate DC power levels where the current is carried intermittently. Because there is no coolant path, the cable has no pump, no fittings, and no maintenance routine for the cooling circuit. The trade-off is that the current a given cross-section can carry falls as ambient temperature rises, so a cable that performs well in a mild climate may need derating in a hot enclosure or a sun-exposed bay. Air-cooled designs also tend to be stiffer as conductor size grows, which affects handling for drivers and cable management hardware for operators. For sites with moderate power and reasonable airflow, they are usually the first option an engineer considers.
Liquid-Cooled Designs
Liquid-cooled CCS2 charging cable assemblies circulate coolant through channels inside the cable or through a jacket around the conductors, removing heat from the conductor surface instead of waiting for it to escape through insulation. That allows a smaller conductor cross-section to carry a higher continuous current, which keeps the cable lighter and easier to handle at high power. The cost lands on complexity: coolant hoses, a pump, a reservoir, connectors and seals that must be leak-tested, and a maintenance schedule the site operator has to follow. Liquid cooling is typically considered for high-power DC charging where sustained current is the design driver and cable weight is a genuine ergonomic constraint. It is also worth remembering that liquid cooling does not remove the need for thermal protection at the connector interface. A liquid-cooled CCS2 charging cable still depends on correct terminal crimping and a clean mating interface to meet the requirements of IEC 62196-1.
Selection Points for a CCS2 Charging Cable Order
Current Rating and Duty Cycle
Start with the charger’s continuous output current rather than its peak claim, then state the duty cycle the site will actually run. A cable rated for a short burst is not the same product as one rated for repeated back-to-back sessions at a busy corridor site. Ask the supplier for the rating basis, including the reference ambient temperature and the standard the rating is declared against. If the site operates in high ambient temperatures or in direct sun, request the derating information before confirming the order. Duty cycle also drives connector wear, so a high-cycle site may need better strain relief and a more robust coupling nut rather than more copper. Recording these two numbers early avoids re-specifying the cable after the first commissioning test.
Cable Length and Voltage Drop
Length should be specified in metres of finished assembly, measured along the cable path rather than across the parking bay. Buyers should give the supplier the required reach plus the maximum acceptable voltage drop, so that conductor size and length are optimised together. For DC charging, a long run can push the assembly beyond the thermal envelope of the chosen cooling method. For AC charging, a long run increases earth conductor impedance, which matters for protection coordination. Where the length is not yet fixed, ask for the voltage drop per metre at the target current and calculate from there. Comparing cable options through thePRODUCTSlisting is a practical way to see how different lengths and current ratings are presented.
Connector Standard and Vehicle Compatibility
Confirm that the vehicle inlet complies with the CCS2 interface as defined in IEC 62196-3 and that the latch geometry matches the coupler you intend to order. Compatible standards do not always mean identical mechanical tolerances, and a latch that is too tight or too loose becomes a warranty issue at the site. Buyers importing into markets with their own regulatory overlay should confirm that the assembly is accepted by the local approval framework. Providing the supplier with the vehicle model list or inlet drawing shortens the confirmation cycle considerably. It is also worth checking that the same cable configuration will not be used interchangeably across incompatible charger brands.
Environmental Protection and Mechanical Durability
Outdoor charging bays expose a CCS2 charging cable to UV, rain, dust, salt, and vehicle traffic, so the IP rating alone is not a complete description of fitness. Ask how the coupling, the cable gland, and the strain relief are sealed, and whether the assembly has been tested after repeated mating cycles. Cold-climate buyers should also check jacket flexibility at low temperature, because a stiff jacket becomes a handling complaint in winter. Mechanical durability includes resistance to being driven over, so cable management and strain relief design belong in the purchasing decision. These details are usually visible in a factory drawing, so request one before the order is finalised.
Certification Documents
Request the test reports and certificates that apply to the exact configuration being ordered, not to a similar model. Relevant references include IEC 62196 for the connector interface, IEC 62893 for the charging cable, and CE marking documentation where the product is placed on the EU market. Where a supplier claims TUV or another third-party approval, ask for the certificate number and the scope it covers. Documents should name the model, the current rating, and the length range that was tested. A file that lists a different configuration is not evidence for your order, however impressive the cover page looks.
Matching the Cable to Charger Power and Site Conditions
The final selection step is to compare the cable against the charger’s power stage and the site’s cooling reality. A charger that can sustain full output in a closed cabinet will stress the cable differently from one that derates in heat. Site conditions also include cable management hardware, because a heavy liquid-cooled assembly needs a support system rated for its weight and bend radius. Operators running mixed fleets should confirm that one cable specification can serve the whole site rather than creating a stock of incompatible spares. Reviewing the manufacturing and testing workflow described on theR&D page helps buyers judge which design questions a supplier can actually answer.
Supply Details from ANHUI BONWAY IMP. & EXP. CO., LTD.
ANHUI BONWAY IMP. & EXP. CO., LTD. operates as an export house working with audited partner factories rather than as a single manufacturing site. That structure lets buyers combine several cable and instrument items in one shipment while each production run stays with a partner that specialises in it. Minimum order quantity and lead time are confirmed per cable configuration, because a standard air-cooled assembly and a liquid-cooled high-power assembly do not share a production schedule. Buyers receive a datasheet, available test reports and certificates where applicable, and a packing list with the shipment. For projects with specific marking or packaging requirements, the process can be discussed through theCustomized service page. General company and product background is summarised on the ABOUT US page.
Next Step: Confirm Your CCS2 Charging Cable Specification
Send three inputs and the specification work becomes straightforward: the charger’s continuous current rating, the finished cable length you need, and the vehicle connector standard or inlet drawing. Add the site’s ambient temperature range and duty cycle if they are known, because those two details decide whether an air-cooled or liquid-cooled CCS2 charging cable is the sensible starting point. We will match those inputs against available configurations, confirm the configuration-specific MOQ and lead time, and return the suitable option together with the quotation. If the project needs private labelling or a specific packing format, say so in the same message so it can be priced in one round. Starting from theHOME page gives an overview of the categories available for combined orders. A short, complete brief at the start saves a full revision cycle later.
Frequently Asked Questions (FAQ)
How do I choose the current rating for a CCS2 charging cable?
Start from the charger’s continuous output current, then add the site’s duty cycle and maximum ambient temperature. A CCS2 charging cable rating declared at a moderate ambient temperature may need derating in a hot, sun-exposed bay. Ask the supplier for the rating basis and the standard it is declared against before confirming the order.
When should I choose a liquid-cooled CCS2 charging cable instead of an air-cooled one?
Liquid cooling is typically considered where sustained high DC current is the design driver and cable weight or handling is a genuine constraint. It allows a smaller conductor cross-section to carry continuous current but adds a coolant circuit, seals, and a maintenance routine. Air-cooled assemblies remain the first option for AC charging and moderate DC power levels.
Does cable length affect the performance of a CCS2 charging cable?
Yes. A longer CCS2 charging cable adds conductor resistance, which generates heat along the run and reduces the voltage reaching the vehicle. On DC fast-charging circuits this can lead to derating or thermal protection trips. Specify the finished length and the acceptable voltage drop together so conductor size and cooling method can be confirmed as one decision.
Which standards apply to a CCS2 charging cable?
IEC 62196-3 defines the DC charging coupler interface, while IEC 62196-1 covers general requirements including permissible temperature rise at the contacts. IEC 62893 series standards are commonly referenced for EV charging cable construction. Buyers placing product on the EU market should also request the applicable CE marking documentation.
Is a CCS2 charging cable compatible with my vehicle?
Vehicle compatibility depends on the inlet complying with the CCS2 interface and on the latch geometry matching the coupler. Compatible standards do not guarantee identical tolerances, so provide the vehicle model list or inlet drawing to the supplier. This shortens confirmation and avoids warranty issues at the site.
What documents should arrive with a CCS2 charging cable shipment?
Expect a datasheet for the exact configuration, test reports and certificates where applicable, and a packing list. Where a third-party approval such as TUV is claimed, ask for the certificate number and the scope it covers. Documents should name the model, the current rating, and the tested length range.
What is the minimum order quantity for a CCS2 charging cable order?
MOQ is confirmed per cable configuration rather than as a single company-wide figure. A standard air-cooled assembly and a liquid-cooled high-power assembly do not share a production schedule, so quantities and lead times differ. Send the full specification in the first enquiry so both can be confirmed together.
How is an export house different from a manufacturer for CCS2 charging cable sourcing?
An export house works with audited partner factories, so each production run stays with a partner that specialises in that item. This structure also allows several cable and instrument items to be combined in one shipment. Buyers should still request configuration-specific test reports and certificates for every order.
Can a CCS2 charging cable be customised for private labelling or packing?
Customisation options such as labelling and packing format can be discussed together with the technical specification. Include the requirement in the initial enquiry so it can be quoted in the same round as the cable. Confirming these details late usually adds a revision cycle to the lead time.
What information should I send for a CCS2 charging cable quotation?
Send the charger’s continuous current rating, the finished cable length you require, and the vehicle connector standard or inlet drawing. Adding ambient temperature range and duty cycle helps decide between air-cooled and liquid-cooled options. We will confirm the suitable configuration with the quotation.
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