The HPC500 can withstand continuous charging at up to 500 A (500 kW at 1,000 V) even at +50°C temperature.

HUBER+SUHNER, one of the top suppliers of liquid-cooled charging cable systems for EV fast chargers, announced the introduction of a new model, the RADOX HPC500, which is the world's first capable of withstanding continuous charging at 500 Amperes even in high-temperature environments (up to 50°C).

The RADOX HPC500 is envisioned for 150-500 kW chargers. The maximum power output depends on the voltage and current of the charger and battery system in a vehicle:

  • at 400 V and 500 A it's 200 kW
  • at 800 V and 500 A it's 400 kW
  • at 1,000 V and 500 A it's 500 kW

This new HPC500 cable and connector builds on the "proven performance and design of the HPC400" (good for 400 A at 1,000 V and used for example by Electrify America) and offers several improvements:

  • enhancements include continuous 500 A charging for up to 500 kW in temperature range from -35°C to +50°C
  • IP67 connector protection rating
  • the option of a ready-to-use metering system
  • replaceable contacts for longer service life
  • new plug and play 24V DC cooling unit prefilled with coolant to reduces installation time and increased cooling capacity
  • 20% lower connector weight and improved cable flexibility
HUBER+SUHNER RADOX HPC500
HUBER+SUHNER RADOX HPC500

One of the most important improvements is the new 24V DC cooling unit, which is installed in the chargers to keep the cable cool even at such high power transfer.

"Alongside the cooled cable system, HUBER+SUHNER has also developed a new 24 V cooling unit to increase cooling capacity and reduce operational temperatures of the power lines, enabling continuous 500 A charging at environmental temperatures of up to 50oC.

The new plug-and-play cooling unit, which is pre-filled with coolant, fits into existing charging stations, significantly reducing installation time. The speed of both the ventilators on the heat exchanger and the coolant pump is automatically adjusted to achieve the most efficient performance, with normal operating levels requiring lower speed, significantly reducing noise level."

The HPC500 is available in both CCS1 and CCS2 versions:

  • CCS1 (see pdf here):
    Weight of the connector is 0.9 kg,
    Weight of outer cable (including coolant) is 1.6 kg/m
    Cable diameter is 34.5 mm
  • CCS2 (see pdf here):
    Weight of the connector is 0.9 kg,
    Weight of outer cable (including coolant) is 1.3 kg/m (almost 19% lighter than CC1 as the cable are thinner)
    Cable diameter is 31.5 mm
HUBER+SUHNER RADOX HPC500
HUBER+SUHNER RADOX HPC500

Having parts like this, manufacturers of chargers will be able to provide 350-500 kW chargers on the market so the next-generation high-end EVs (or simply heavy-duty vehicles) will be able to charge at higher power.

Gallery: HUBER+SUHNER charging solutions

Source: HUBER+SUHNER
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HUBER+SUHNER enables continuous electric vehicle charging at 500 A

HUBER+SUHNER, a leading global supplier of electrical and optical connectivity solutions, has today launched the RADOX® HPC500; a new addition to the RADOX® high power charging portfolio. It is the world’s first cooled charging cable system that allows continuous charging at 500 Amperes even in high-temperature environments.

The HPC500 cable and connector builds on the proven performance and design of the HPC400 family, as well as the extensive field experience and continuous innovation in cooled cable solutions for EV charging stations. Several improvements and new features make the system ready for existing and future requirements. These enhancements include continuous 500 A charging, an IP67 connector protection rating, the option of a ready-to-use metering system and replaceable contacts for longer service life.

Alongside the cooled cable system, HUBER+SUHNER has also developed a new 24 V cooling unit to increase cooling capacity and reduce operational temperatures of the power lines, enabling continuous 500 A charging at environmental temperatures of up to 50oC.

The new plug-and-play cooling unit, which is pre-filled with coolant, fits into existing charging stations, significantly reducing installation time. The speed of both the ventilators on the heat exchanger and the coolant pump is automatically adjusted to achieve the most efficient performance, with normal operating levels requiring lower speed, significantly reducing noise level.

The features and cost-effective quality of the HPC500 make it a convenient, future-proof solution for operators. The 20% reduction in the connector weight and improved cable flexibility, compared to the previous model of the HPC system, offers easier handling for end-users.

“The improvements we have made to the complete HPC system make this a truly ground-breaking product which enables continuous charging at 500 A for the first time,” said Max Göldi, Market Manager Industry at HUBER+SUHNER. “This helps charging station operators prepare for the future with an improved return on investment.”

With HUBER+SUHNER being an important supplier of Electrify America, its HPCs are currently installed across the States, and the company is also part of EV roll out initiatives across Europe. Having established itself as a key player in the history of HPC innovation – with its previous model enabling a charging time below 15 minutes while maintaining safe and easy handling – HUBER+SUHNER has continued to uphold its industry lead with the launch of its latest product.