CCS1 EV DC Charging Cable — Specification (80A–250A)

1) Product Overview

The CCS1 DC charging cable assembly is designed for DC fast charging systems using the CCS1 interface (SAE J1772 Combo 1). It supports 80A to 250A (model-dependent) and is suitable for public DC fast chargers, fleet depots, and mobile DC charging equipment. OEM/ODM customization is available for cable length, labeling, and branding.

2) Electrical Specifications

• Connector Standard (Vehicle Side): CCS1 (SAE J1772 Combo 1 / IEC 62196-3 Combo 1)

• Charging Type: DC fast charging cable assembly

• Rated Current Range: 80A–250A (select by model)

• Common ratings: 80A / 100A / 125A / 150A / 200A / 250A

• Rated Voltage: Up to 1000 V DC (typical for DCFC; configurable by design)

• Signal/Control Cores: Integrated control/signal wiring (CP/PP and interlock as required)

• Insulation Resistance: ≥ 1000 MΩ (typical)

• Withstanding Voltage (Hi-Pot): 2500–3000 V AC (typical; per design)

3) Cable & Mechanical

• Standard Cable Length: 5 m (industry common)

• OEM Length Options: 3 m / 4 m / 6 m / 7 m / 10 m (custom available)

• Conductor Material: High-purity copper

• Outer Jacket Material: TPU (standard) / TPE (optional)

• Cable Color: Black (custom colors optional)

• Strain Relief: Reinforced anti-bend design for high-duty usage

• Typical Plug Insertion Cycles: ≥ 10,000 cycles (typical; depends on final connector spec)

4) Cooling

• Cooling Method: Air-cooled (standard)
  (For this 80A–250A range, air-cooled is typically sufficient. Liquid-cooling is usually reserved for higher current classes.)

5) Environmental & Protection

• Operating Temperature: -30°C to +50°C (typical; configurable)

• Ingress Protection: Plug typically IP54/IP55 when mated (model-dependent)

• UV Resistance: Outdoor-grade jacket option available

• Flame Retardant: Available (market requirement dependent)

6) Compliance & Quality Control

• Standards Reference:

• SAE J1772 (Combo 1 / CCS1 interface)

• IEC 62196-3 (application dependent)

• IEC 61851 (charging system requirements, application dependent)

• Factory Tests (Typical):

• Continuity test

• Insulation resistance test

• Hi-pot test

• Connector function & lock verification

7) OEM/ODM Customization

• Current rating selection (80A–250A)

• Cable length, jacket material (TPU/TPE), cable print marking

• Connector housing color & logo branding

• Packaging: bulk / branded carton / retail box

8) Typical Applications

• Public CCS1 DC fast chargers

• Fleet depot DC charging (vans/light trucks)

• Mobile DC chargers / battery-integrated fast chargers

• Service and maintenance DC charging equipment

Tags: ev charge cable