Mastering Thermal Efficiency: The Science Behind Fiver’s Liquid-Cooled EV Charging Systems

Introduction: The Thermal Challenge in High-Power EV Charging

As electric vehicles (EVs) demand faster charging speeds, high-power systems like CCS (Combined Charging System) face a critical hurdle: heat management. Conventional air-cooled solutions struggle to handle currents exceeding 500A, risking overheating, energy waste, and hardware degradation. Fiver New Energy Co., Ltd. addresses these challenges head-on with its liquid-cooled EV charging technology, engineered to deliver precision, reliability, and sustainability.

This blog unpacks the science behind Fiver’s cutting-edge liquid-cooled CCS charging cable and high-performance cooling unit, revealing how they work synergistically to redefine efficiency for high-power EV charging.

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Key Features of Fiver’s Liquid-Cooled EV Charging Ecosystem

1. High-Performance Heat Dissipation

• 3000W Radiating Power: At a flow rate of 4L/min, Fiver’s cooling unit efficiently dissipates heat even during 800A ultra-fast charging.
• Temperature Control: Limits temperature rise to <50K above ambient, preventing overheating in both cables and connectors.

2. Intelligent Thermal Management

• Real-Time Monitoring: Sensors track inlet/outlet temperatures in the cooling unit and power pins of cables, enabling dynamic adjustments to pump/fan speeds.
• Energy Efficiency: Automated power adjustments reduce energy consumption by up to 30% during partial-load conditions.

3. Liquid-Cooled Charging Cables: Engineering Excellence

• 500-800A Current Support: TPU-jacketed cables with liquid cooling enable lightweight, flexible designs (50% lighter than conventional cables).
• Advanced Safety: IP55-rated connectors, IP54-rated pumps/fans, and UL 94-V0 flame-resistant materials ensure compliance with IEC 62196-3 and global safety standards.
• Low Noise Operation: The Cooling unit quiet performance (≤58dB) for residential and commercial use.

4. Compact & Durable Design

• Cooling Unit: Compact dimensions (435×155×410mm) and lightweight (7kg) for easy installation.
• Cables: Reduced bulk and TPU insulation enhance portability and durability.
• IP68 Protection: Resists dust, water, and harsh environments across the entire system.

5. Eco-Friendly Cooling Medium

• Dimethyl Silicone Oil: Non-conductive, biodegradable coolant ensures zero environmental harm and safe operation in cables and cooling units.

6. Energy-Saving Automation

• Smart Modes: Standby, automatic, and sleep modes optimize energy use and extend component lifespan.
• Customizable Speed Control: PWM and voltage signals adjust fan/pump speeds for peak efficiency.

7. Advanced Communication & Safety

• MODBUS RTU Integration: RS485-based communication enables seamless compatibility with existing infrastructure.
• Fault Detection: Monitors coolant levels, leaks, and component health in real time.

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Key Components & Their Roles in Thermal Efficiency

Component	Function
Liquid-Cooled Cables	TPU-jacketed cables with silicone oil circulation enable 800A charging while dissipating heat.
Radiator	Dissipates heat via electronic fans, maintaining stable temperatures even at 3000W loads.
Circulating Pump	Drives coolant at 4L/min through closed-loop pipes and cables.
Electronic Fan	Adjustable airflow for continuous cooling; ≤58dB noise levels.
Temperature Sensors	Monitor cable power pins and cooling unit temps for AI-driven adjustments.
Control Controller	Processes data to optimize cooling power, reducing energy waste.

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Why Fiver’s System Outperforms Conventional Solutions

1. Synergy Between Cables & Cooling Unit

Traditional air-cooled systems rely on passive heat dissipation, leading to energy loss and component stress. Fiver’s closed-loop liquid cooling actively circulates coolant through both cables and the liquid cooling unit, achieving:

• 50% faster cooling compared to air-cooled alternatives.
• Zero cable degradation even after 10,000+ charging cycles.

2. Adaptive Intelligence for Peak Performance

By analyzing real-time temperature data from cable power pins and cooling unit sensors, Fiver’s system automatically:

• Adjusts pump speed to maintain optimal flow rates.
• Modulates fan RPM to balance noise and cooling power.

3. Sustainability Without Compromise

• Biodegradable Coolant: Unlike traditional ethylene glycol, dimethyl silicone oil poses no environmental risk.
• Recyclable Components: Cables, radiators, and pumps are designed for easy disassembly and recycling.

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Applications of Fiver’s Liquid-Cooled CCS High Power Systems

• High-Power Charging Stations: 800A support for buses, trucks, and next-gen EVs.
• Fleet Charging Hubs: Durable, compact design suits high-traffic depots.
• Extreme Climates: IP68 protection ensures reliability in deserts, coastal areas, and sub-zero temperatures.

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Conclusion: The Future of EV Charging is Cooler

Fiver New Energy’s liquid-cooled CCS charging systems and cables eliminate the trade-offs between speed, safety, and sustainability. By combining intelligent automation, eco-friendly materials, and military-grade durability, this technology sets a new benchmark for high-power EV charging.

Ready to upgrade your charging infrastructure? Contact Fiver New Energy to explore custom solutions tailored to your needs.