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Product

power connection cable series1000–1500 V DC · 500–850 AIEC 62893-4-2 / UL 2263Water-Glycol / Dielectric Cooled

Liquid-Cooled High-Power DC Charging Cable1000–1500 V DC 500–850 A liquid-cooled HPC / MCS fast-charging cable

Q: Why is active liquid cooling mandatory above 300–350 A on public EV fast-charging cables?

To carry 500–650 A DC with passive air cooling while keeping the outer jacket touch temperature below +50 °C (IEC 61851-23), each DC+ and DC− conductor would need 150–185 mm² of copper—resulting in a stiff > 48 mm diameter cable weighing over 4.5 kg/m that is impossible for consumers to bend in winter. Active liquid cooling removes 200+ W/m of heat directly from the copper, allowing a 2×50 mm² cable (1.75 kg/m, 30.8 mm OD) to carry 500 A continuously.

Liquid-Cooled High-Power DC Charging Cable (HPC / MCS) engineered per IEC 62893-4-2 and UL 2263 for 350 kW to 1+ MW electric vehicle dispensers—integrating two internally cooled DC+ and DC− fine-stranded copper conductors (35–95 mm².

55 % Lighter Hand-Flex

Active Liquid Cooling Loop

Drive-Over & Oil Resistant

IEC 62893-4-2 / UL 2263

HPC cable rating

Order designation: HPC-LC 2×50+25+CP (500A)
Outer Ø: 30.8 mm
Dry weight: 1.75 kg/m
Continuous DC: 500 A
Coolant flow: 2.2 L/min

All sizes (4)

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Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum

Standards: IEC 62893-4-2
DC voltage: 1,000 / 1,500 V
Continuous current: 500 to 850 A DC
DC conductor: 2 × 35–95 mm²
Coolant media: Water-Glycol/Oil
Outer diameter: 28.5 to 36.0 mm

Typical values for this cable type, based on IEC 62893-4-2 / UL 2263 / EN 50620 — confirmed in the datasheet and quotation for your order.

Application fit

Is Liquid-Cooled High-Power DC Charging Cable right for your machine?

Enables 350 kW, 500 kW and 1 MW (MCS) DC ultra-fast charging with a slim, lightweight 29–35 mm cable that any driver can handle effortlessly—by actively removing I²R heat directly from the DC+ and DC− copper cores.

Self-supporting pendant & push-button drop

Suitable

Suspended from HPC dispenser cable-management retractors at motorway CCS1, CCS2, NACS (SAE J3400) and ChaoJi stations.

Trailing & towing

Suitable

Extruded E-TPU (Polyether Polyurethane) outer jacket withstands asphalt dragging, vehicle wheel drive-over and -40 °C winter frost.

Immersion & wet locations

Suitable

Internal FEP/PA12/silicone micro-cooling tubes circulate 50/50 water-glycol or synthetic dielectric fluid at 1.5–4.0 L/min.

Fixed installation

Not suitable

Flexible dispenser-to-vehicle charging tether; for fixed underground supply to the charger cabinet use ConnectEV SWA or N2XH.

Use ConnectEV SWA

Typical machines350–600 kW Passenger EV HPC Stations (CCS / NACS)1+ MW Heavy-Truck Megawatt Charging (MCS)Electric Bus, Mining Haul Truck & Port AGV DepotsElectric Marine Ferry & eVTOL Fast TurnaroundHigh-Current Battery Test Bench Load Tethers

Construction

Layer by layer

Liquid-Cooled High-Power DC Charging Cable showing 2 × hollow/tube-cooled Class 6 copper DC+ / DC− power cores, coolant supply/return channels, PE ground core, shielded CP/PP/PLC communication pairs, PT1000 temperature-monitoring leads, and wear-indicator E-TPU outer sheath.

Schematic, not to scale — generated from the layer data

#	Layer	Material & reference
1	2 × Liquid-cooled Class 6 copper DC+ & DC− cores + PE	2 × 35, 50, 70 or 95 mm² Class 6 extra-fine bare/tinned copper stranded around/within flexible coolant micro-ducts + 16–25 mm² PE earth conductorDirect fluid-to-copper heat transfer achieves 10–14 A/mm² current density
2	Closed-loop coolant supply & return tubing	Kink-resistant fluoropolymer (FEP/PFA), cross-linked PE or peroxide-cured elastomer coolant conduits (working pressure 2–5 bar, burst ≥ 15 bar)Compatible with water/propanediol-glycol or dielectric ester coolant
3	1,000–1,500 V DC TPE-E / EPR power core insulation	High-dielectric halogen-free elastomer/TPE insulation on DC+, DC− and PE coresTested to 5,000 V AC / 7,500 V DC dielectric withstand
4	Shielded CP / PP / PLC control + PT1000 sensor pairs	4 to 8 × 0.50–0.75 mm² tinned copper control & temperature-interlock cores with tinned copper braid shield (≥ 85 %)Isolates ISO 15118 PLC / PWM pilot signals from 800 A DC ripple
5	Dual-layer wear-indicating E-TPU (PUR) outer sheath	Co-extruded Matte Black outer / Coloured inner wear-indicator Polyether Polyurethane (E-TPU) jacketVisually alerts operator if asphalt abrasion breaches outer skin

HPC-LC-500A (2×35 / 2×50 mm² · 1000 V DC)

Slim 29.5–31.5 mm OD water-glycol or oil-cooled cable for 350–500 kW CCS1 / CCS2 / NACS passenger EV chargers

HPC-LC-650A (2×70 mm² · 1200 V DC)

650 A continuous (800 A boost) liquid-cooled charging cable for high-utilization highway fleet plazas

MCS-LC-850A (2×95 mm² · 1500 V DC Megawatt)

850 A continuous (1,000+ A peak) 1,500 V DC liquid-cooled cable for commercial truck Megawatt Charging System (MCS)

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on IEC 62893-4-2 / UL 2263 / EN 50620. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated DC power voltage: 1,000 V DC / 1,500 V DC (control cores: 30–60 V DC)
Continuous DC current: 500 A (2×50 mm²) · 650 A (2×70 mm²) · 850 A (2×95 mm² @ 2.5 L/min)
Dielectric test voltage: 3,500–5,000 V AC on DC power cores · 1,000 V AC on control cores
Pilot / PLC impedance: Shielded twisted pair supports HomePlug GreenPHY (ISO 15118)

Thermal

Ambient operating temp.: -40 °C to +60 °C (surface touch temp kept ≤ +50 °C per IEC 61851)
Max. conductor / coolant temp.: +90 °C max core temp (monitored by dual PT1000 / NTC loops)
Heat dissipation capacity: Removes 150 to 320 W/m of I²R Joule heating via 2–4 L/min chiller

Mechanical

Nominal outer diameter: 29.5 mm (500 A) · 32.8 mm (650 A) · 35.8 mm (850 A MCS)
Min. bend radius: 5 × OD to 6 × OD (without coolant flow restriction < 90 %)
Flexing & torsion life: ≥ 50,000 bending cycles & ±180°/m torsion per IEC 62893-4-2

Resistance

Vehicle wheel crush test: Passes 5,000 N / 11,000 N vehicle drive-over without tube leak
Coolant burst pressure: Working pressure 2–5 bar · Burst pressure ≥ 15 bar @ +85 °C
Weather, oil & halogen-free: UV, gasoline, diesel, de-icing salt resistant & IEC 60754-1 LSZH

Reference standards

Liquid-cooled EV cable std: IEC 62893-4-2 & UL 2263 (EV Cable with Thermal Management)
System safety standard: IEC 61851-23 & SAE J1772 / J3400 / CharIN MCS
RoHS & REACH: 2011/65/EU & EC 1907/2006 compliant

Identification

Outer sheath: Matte Black E-TPU with contrasting Orange/Blue inner wear-indicator layer
Customs tariff (HS): 8544.4993
Core identification: DC+ (Red/Brown), DC− (Black/Blue), PE (GNYE) + colour-coded pilot/sensor

Sizes

4 standard Liquid-Cooled High-Power DC Charging Cable configurations

DC copper cross-section, continuous cooled ampacity, outer diameter, weight and coolant flow rate.

Current rating, dimensions & cooling
Order designation	DC power + PE + control	Outer Ø mm	Dry weight kg/m	Cont. DC A	Coolant flow L/min
1000–1500 V DC Liquid-Cooled EV Fast-Charging Cables
HPC-LC 2×35+16+CP (400A)	2×35 mm² DC + 16PE + 6×0.5C · 1000V	28.8	1.42	400	1.8
HPC-LC 2×50+25+CP (500A)	2×50 mm² DC + 25PE + 6×0.5C · 1000V	30.8	1.75	500	2.2
HPC-LC 2×70+25+CP (650A)	2×70 mm² DC + 25PE + 8×0.5C · 1200V	33.2	2.15	650	2.8
MCS-LC 2×95+35+CP (850A)	2×95 mm² DC + 35PE + 8×0.75C · 1500V	35.8	2.68	850	3.5

Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
Continuous DC current ratings assume +25 °C coolant inlet temperature and +40 °C ambient air per IEC 62893-4-2.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

ConductorClass 5 stranding
Spark test100 % in-line
Lay-upCores, earth, fillers
SheathingInner, braid / screen, outer
Electrical testsAC voltage, resistance
DimensionsOD, wall thickness
Inspection documents & dispatchDrum & dispatch

Testing & inspection	Test value / reference	Frequency
Routine tests
100 % 5.0 kV AC dielectric, DC resistance & 10 bar hydraulic pressure test	Zero electrical breakdown and zero coolant tube pressure drop over 30 min	Every manufactured cable length
Sample tests
50,000-cycle flex + ±180°/m torsion under internal coolant pressure	No copper strand break, < 10 % flow restriction and zero leakage	Type qualification
Vehicle drive-over crush (11 kN) & -40 °C cold impact test	Zero tube rupture or insulation short after tire crush	Type qualification

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

IEC 62893-4-2 CompliantUL 2263 EV ChargingRoHS 2 & REACH Compliant

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX LIQUID-COOLED HPC DC CHARGING CABLE 1000V/1500V IEC 62893-4-2

Delivery form: Fumigated wooden drums or steel export reels
Standard lengths: 500 m · 1000 m (or custom cut lengths)
MOQ: 100 m (standard) · 500 m (custom)
Lead time: 2–4 weeks ex-works
Incoterms: EXW, FOB, CIF, DAP

Technical documents

Downloads

PDFLiquid-Cooled High-Power DC Charging Cable – technical datasheet4 sizes · construction, technical data, approvals XLSXLiquid-Cooled High-Power DC Charging Cable spec data (Excel)All 4 sizes with dimensions and data, for your BOM or quotation

Revision: 2026-10-20
Updated: 2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

Why is active liquid cooling mandatory above 300–350 A on public EV fast-charging cables?

To carry 500–650 A DC with passive air cooling while keeping the outer jacket touch temperature below +50 °C (IEC 61851-23), each DC+ and DC− conductor would need 150–185 mm² of copper—resulting in a stiff > 48 mm diameter cable weighing over 4.5 kg/m that is impossible for consumers to bend in winter. Active liquid cooling removes 200+ W/m of heat directly from the copper, allowing a 2×50 mm² cable (1.75 kg/m, 30.8 mm OD) to carry 500 A continuously.

What is the difference between water-glycol cooling and synthetic dielectric oil cooling inside the cable?

In water-glycol systems, the conductive 50/50 water-glycol mixture flows inside an electrically insulating fluoropolymer/elastomer tube while copper strands are arranged around or coaxially with the tube (or hollow copper sits inside a return tube), keeping water isolated from HV potential. In dielectric oil/ester systems, non-conductive fluid flows directly through the interstitial spaces of the stranded copper conductor itself.

How does the dual-layer wear-indicating E-TPU outer sheath enhance station safety?

The outer Matte Black E-TPU jacket is co-extruded over a bright Orange or Blue inner polyurethane layer. During routine station inspections, if dragging across concrete abrades through the outer black skin, the bright inner colour becomes immediately visible long before the coolant tubes or HV insulation are exposed.

Which cable should we use for the fixed underground supply between the substation and the EV charging posts?

Use ConnectEV SWA (armoured power + Cat5e), ConnectEV, or EV ProInstall Cat6A for single/three-phase AC chargers, and N2XH or MV-90/105 for high-power DC charger cabinet feeds.

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Datasheet Request a quote

Liquid-Cooled High-Power DC Charging Cable1000–1500 V DC 500–850 A liquid-cooled HPC / MCS fast-charging cable

Self-supporting pendant & push-button drop

Trailing & towing

Immersion & wet locations

Fixed installation

HPC-LC-500A (2×35 / 2×50 mm² · 1000 V DC)

HPC-LC-650A (2×70 mm² · 1200 V DC)

MCS-LC-850A (2×95 mm² · 1500 V DC Megawatt)

Electrical

Thermal

Mechanical

Resistance

Reference standards

Identification

Inspection certificate

Product approvals

Company certificates

01Selected sizes

02Reel & motion

03Message for our engineers

EV ProInstall Cat6A

ConnectEV SWA

ConnectEV

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