Professional cable manufacturer
IEC TS 62893-4-2:2021 · IEC 62196-3:2026 · UL 2251-2022 · GB/T 20234.3-2023
Liquid-Cooled Ultra-Fast EV Charging Cable 600A DC 1000V
Direct liquid-cooled DC charging cable assembly for 600 A / 1000 V DC ultra-fast chargers — integrated coolant circuit, IEC 62196-3 couplers and contact temperature monitoring for dynamic current control.
600 A
Rated DC Current
1000 V
Rated DC Voltage
600 kW
Max. Charging Power
90°C
Conductor Rating
↓ Download Datasheet (PDF)
Designed to IEC TS 62893-4-2:2021
IEC 62196-3 / UL 2251-2022 couplers
Sample orders available
Cut-to-length & pre-assembled
LIQUID-COOLED DC CHARGING
IEC TS 62893-4-2:2021DC charging cables with thermal management
IEC 62196-3:2026DC coupler dimensional compatibility
UL 2251-2022Up to 800 A / 1500 V DC, active cooling
GB/T 20234.3-2023Up to 800 A / 800 kW DC interface
90°CMax. conductor temperature, cable rating
Key Specifications
The essentials, at a glance
What a charger engineer checks first on a liquid-cooled cable — before reading the full specification below.
600 A
Continuous DC current
1000 V
Rated DC voltage
600 kW
600 A × 1000 V DC
Direct
Liquid cooling
2 × 2 AWG
Cooling-circuit conductors
IP67
Mated coupler
Product Overview
Cooling the copper is what makes 600 A possible
This is a direct liquid-cooled DC charging cable assembly for ultra-fast chargers, rated 600 A at 1000 V DC. It is designed to IEC TS 62893-4-2:2021, the part of the IEC 62893 charging-cable series written specifically for cables for DC charging according to mode 4 of IEC 61851-1 that are intended to be used with a thermal management system. The companion part, IEC 62893-4-1:2020, covers the same application without thermal management, which is the distinction that decides whether a project can push past roughly 500 A on a single cable.
The cooling is what changes the construction. Instead of one heavy power conductor, a 600 A assembly uses a mixed build: a pair of 2 AWG (≈ 33.6 mm²) conductors forms the cooled current path, alongside an auxiliary power core, a shielded signal pair and control cores — a named peer configuration for 600 A NACS is 2 × 2 AWG (cooling) + 1 × 13 AWG + (2 × 18 AWG) P2 + 4 × 18 AWG. That works out to a current density of roughly 17.9 A/mm² in the cooled conductors, against the 4–6 A/mm² that conventional air-cooled design practice assumes. The consequence is a cable that a driver can still lift and bend while it carries three to four times the current that copper of that size would otherwise allow.
Electrically, the assembly sits inside three different regional frameworks and it is worth keeping them apart. The cable itself follows IEC TS 62893-4-2:2021, which sets a maximum conductor temperature of 90 °C and assumes the charging cable is used with Class II equipment. The DC coupler follows IEC 62196-3:2026, which is a dimensional compatibility standard — the rated voltage and current values themselves come from IEC 62196-1:2025. In North America the connector standard is UL 2251-2022, which raised the scope to 800 A / 1000 V AC / 1500 V DC and was the first edition to write active cooling and dynamic current control into the body of the standard; it also requires that a cooled product state a non-cooled current rating as well. In China the DC interface is GB/T 20234.3-2023, which lifted the earlier 250 A ceiling to 800 A / 800 kW and added active cooling and temperature monitoring. NACS is no longer a proprietary outline: it is published as the SAE J3400 series.
On temperature we are deliberately narrow. The cable rating is 90 °C conductor temperature, per the IEC specification. Silicone insulation has a higher intrinsic material capability, but in an assembly with a TPU outer jacket the continuous rating is set by the jacket, so we quote the cable rating and confirm the assembly figure for the selected variant rather than publishing a single wide range. On the contact side, UL 2251-2022 judges at a contact temperature of no more than 100 °C at maximum rated current, while the vendor convention for terminal temperature rise is < 50 K; the two are different measurements and we state both with their conditions rather than blending them.
Coolant specification — fluid type, flow rate and inlet temperature — is agreed per project with the charger manufacturer rather than fixed on the data sheet, because it is the charger, not the cable, that owns the cooling circuit. For the AC side of the same site see our Type 2 32A IEC 62196 EV Charging Cable, and for the supply side of the charger, our Cu/XLPE/SWA/PVC 0.6/1 kV Power Cable.
More about the manufacturer: About SORIVO →
Key Features
Eight features that matter on an ultra-fast charger
Designed to IEC TS 62893-4-2:2021
The IEC part covering DC charging cables for mode 4 of IEC 61851-1 that are used with a thermal management system — the correct reference for a liquid-cooled cable, with a 90 °C conductor rating.
Direct Liquid Cooling
The coolant circuit is integrated with the conductor path rather than wrapped around a conventional core, which is how the assembly reaches 600 A at a manageable outer diameter.
600 A / 1000 V DC
600 kW of charging power at the rated point. Higher current and 1500 V DC variants follow the UL 2251-2022 and GB/T 20234.3-2023 envelopes and are quoted on request.
IEC 62196-3:2026 Couplers
CCS1 and CCS2 DC couplers to the dimensional-compatibility standard, with the rated voltage and current values taken from IEC 62196-1:2025 as the standard requires.
Contact Temperature Monitoring
DC power contact temperature sensing brought out to the charger, so the dispenser can run dynamic current control instead of a fixed current limit.
UL 2251-2022 Scope
Covered up to 800 A and 1500 V DC. The 2022 edition also fixes the contact judgement at ≤ 100 °C at maximum rated current and expects a declared non-cooled current rating.
GB/T 20234.3-2023 Interface
The Chinese DC interface as revised in 2023 — up to 800 A and 800 kW, with active cooling and temperature monitoring added to the requirements.
Assembled and Tested
Cable, coolant path and coupler are supplied as one assembly, with dielectric, insulation-resistance and continuity checks recorded before shipment.
Applications
Where liquid cooling is the only way to reach the current
The applications below are the ones where 500 A class air-cooled cable stops being practical — either because of current, or because of the weight and stiffness that come with it.
01
Highway Ultra-Fast Corridors
600 kW-class charging plazas on long-distance routes, where each bay has to add range in the shortest possible stop.
02
Fleet and Depot Charging
Van, taxi and light-commercial depots running multiple high-power sessions per vehicle per day, where cable weight affects driver handling.
03
Urban Charging Hubs
Multi-bay city hubs with liquid-cooled dispensers, where a thin, flexible cable also means a smaller cable management system.
04
Bus and Truck Depots
Opportunity charging for heavy vehicles, where high current and short turnaround times come together.
05
Cold-Climate Sites
Northern corridors and mountain routes, where a cable that stays flexible matters as much as the current it carries.
06
Coastal and High-Humidity Sites
IP67 mated couplers and a sealed coolant circuit for installations exposed to salt air and heavy rain.
07
Retrofit of Air-Cooled HPC
Replacing an air-cooled high-power cable assembly on an existing dispenser to raise the delivered current without changing the cabinet.
08
Charger OEM Builds
Volume supply to charger manufacturers who need the cable assembly as a released component with its own documentation set.
Technical Specifications
Full specification sheet
The complete parameter set — the same data our engineers quote from.
Table 1 Construction of a 600 A liquid-cooled DC cable
| Element | Conductor | Function | |
|---|---|---|---|
| Cooled current path | 2 × 2 AWG (≈ 2 × 33.6 mm²) | Carries the DC current and forms the liquid-cooled circuit | |
| Auxiliary power core | 1 × 13 AWG (≈ 2.6 mm²) | Auxiliary supply within the assembly | |
| Shielded signal pair | (2 × 18 AWG) P2 | Data / communication pair with shield | |
| Control and signal cores | 4 × 18 AWG (≈ 0.75 mm²) | Control, proximity and sensing conductors |
The configuration above is the published construction of a named peer 600 A liquid-cooled assembly, used here because it is the clearest available illustration of how a cooled DC cable is actually built — it is not a measurement of our own product. The exact construction of the assembly we quote is confirmed against the selected variant and the charger-side interface before the order is released. Current density in the cooled conductors is approximately 17.9 A/mm² at 600 A, against 4–6 A/mm² assumed in conventional air-cooled design practice.
Table 2 Construction and performance parameters
| General Information | |
| Product Name | Liquid-Cooled Ultra-Fast EV Charging Cable 600A DC 1000V |
| Product Type | Liquid-cooled DC charging cable assembly with integrated coolant circuit |
| Cable Standard | Designed to IEC TS 62893-4-2:2021 — charging cables for electric vehicles up to 0.6/1 kV, Part 4-2: DC charging cables intended to be used with a thermal management system |
| Comparison Reference | IEC 62893-4-1:2020 — the same DC charging application without a thermal management system |
| Coupler Standards | IEC 62196-3:2026 (dimensional compatibility) with ratings to IEC 62196-1:2025; UL 2251-2022 (North America); GB/T 20234.3-2023 (China); SAE J3400 series for NACS |
| Equipment Class | Class II equipment, as assumed for charging cables specified in the IEC 62893 series |
| Cooling Method | Direct liquid cooling with an integrated coolant channel and circulation circuit |
| Coolant Specification | Agreed per project with the charger manufacturer — fluid type, flow rate and inlet temperature are properties of the charging system, not fixed on this data sheet |
| Electrical Ratings | |
| Rated Current (DC) | 600 A continuous |
| Current Steps | 250 A / 300 A / 350 A / 600 A classes are the common liquid-cooled tiers; the 600 A class is the rating of this page |
| Non-Cooled Rating | Declared separately, as UL 2251-2022 requires for actively cooled equipment — confirmed for the selected assembly |
| Rated Voltage (DC) | 1000 V DC; 1500 V DC available on request, within the UL 2251-2022 envelope |
| Max. Charging Power | 600 kW at 600 A × 1000 V DC; 800 kW class available on request |
| Insulation Resistance | ≥ 2000 MΩ at DC 1000 V |
| Withstand Voltage | 3200 V AC |
| Contact Resistance | ≤ 0.5 mΩ |
| Contact Temperature | ≤ 100 °C at maximum rated current (UL 2251-2022 judgement) |
| Terminal Temperature Rise | < 50 K at rated current, at the test ambient temperature declared by the manufacturer |
| Temperature Monitoring | DC power contact temperature monitoring with sensing leads brought out for dynamic current control |
| Dynamic Current Control | Supported, per the temperature feedback path required by UL 2251-2022 |
| Construction | |
| Conductor Material | Flexible annealed copper; silver-plated copper available |
| Cooled Conductor | 2 AWG class (≈ 33.6 mm² per conductor) in the named peer 600 A construction |
| Current Density | ≈ 17.9 A/mm² in the cooled conductors at 600 A |
| Control and Signal Cores | Shielded signal pair plus control cores in the 18 AWG class, in the named peer construction |
| Insulation | Silicone — selected for the temperature and dielectric requirements of a liquid-cooled assembly |
| Outer Sheath | TPU — oil-resistant and abrasion-resistant; the continuous rating of the finished assembly is limited by the jacket |
| Cable OD | Confirmed against the selected assembly; a 600 A cooled construction stays well below the diameter of an air-cooled equivalent |
| Coupler Housing | Thermoplastic, UL 94 V-0; UL 2251-2022 additionally requires a flammability rating of at least HB and a thermal index of at least 100 °C |
| Contact Plating | Copper alloy with silver plating; UL 2251-2022 recommends a silver or silver-alloy layer of at least 5 µm |
| Mechanical and Environmental | |
| Cable Conductor Temperature | +90 °C maximum, per IEC TS 62893-4-2:2021 |
| Insulation Material Capability | Silicone insulation has a higher intrinsic temperature capability than the cable rating; it is the jacket that limits the finished assembly |
| Connector Ambient Range | −30 °C to +50 °C |
| Component Thermal Cycling | −40 °C to +125 °C over 10 cycles, per UL 2251-2022, with a temperature-rise variation within ±5 °C |
| Ingress Protection | IP67 mated at the coupler / IP55 at the charger-side back housing |
| Mechanical Life | > 10,000 no-load mating cycles |
| Flame Performance | UL 94 V-0 on plastics; IEC 60332-1-2 vertical flame propagation, which is the test method referenced by IEC TS 62893-4-2:2021 |
| Coolant Circuit | Sealed, with leak testing recorded for the assembly before shipment |
| Configuration & Logistics | |
| Cable Length | 3 m / 5 m / 7 m standard; other lengths to order |
| Coupler Options | CCS1, CCS2, GB/T (20234.3-2023), CHAdeMO, NACS (SAE J3400 series) |
| Housing and Colour | Standard black; housing colour and branding to order |
| Packaging | Individual carton with foam protection; custom packaging per request |
| MOQ | 100 units; sample orders negotiable |
| Lead Time | 15–25 working days; stocked configurations may be available sooner |
| Customization | Cable length, coupler type, housing colour, logo and packaging |
Final selection depends on the charger’s cooling circuit, the delivered current profile, the ambient conditions at the site and the regional coupler standard. The coolant specification and the non-cooled current rating are agreed with the charger manufacturer against the selected assembly, and our engineers confirm the construction and documentation scope for your project before release. Certification scope should always be confirmed against the certificate for the selected configuration.
Certificates & Standards
Verify before you buy — we make it easy
IEC TS 62893-4-2:2021
The IEC technical specification for DC charging cables used with a thermal management system. It is a Technical Specification, so we describe the assembly as designed to it rather than certified to it, and we state its 90 °C conductor rating.
Request document set →IEC 62196-3 / IEC 62196-1
The DC and AC/DC coupler dimensional-compatibility standard and the general standard that carries the rated voltage and current values. Coupler test documentation is provided with the quotation.
Request test report →UL 2251-2022 / GB/T 20234.3-2023
The North American coupler safety standard covering active cooling and dynamic current control, and the Chinese DC interface standard as revised in 2023. Scope and edition are confirmed per configuration.
Request certificate copy →
Transparency note: certification status and exact scope should always be confirmed against the certificate for the selected product configuration. We provide the certificate and test reports with every quotation — no blank promises.
Quality & Factory
Assembled, leak-tested and electrically checked before it ships
Every liquid-cooled assembly is built to order, so the release checks happen on the finished cable rather than on the drum alone.
- 1Incoming material control — copper conductors, silicone insulation, hose and coupler components are checked against specification before assembly starts.
- 2Coolant circuit assembly — the coolant channel is built and sealed, then pressure and leak tested as a sub-assembly.
- 3Electrical routine tests — insulation resistance, withstand voltage and continuity are measured on the finished assembly and recorded.
- 4Assembly documentation — test records, coupler standard and temperature-monitoring wiring are documented per unit for the charger manufacturer’s file.
19+
countries served
60+
EV & energy projects
100%
routine test before shipment
How to Order
From inquiry to loaded carton in 5 steps
Send Inquiry
Tell us the charger model, the coupler standard and the delivered current you need.
Confirm Configuration
We confirm connector variants, cable construction and quotation within one working day.
Sample Evaluation
Sample for qualification — stocked configurations within a few working days.
Bulk Production
15–25 working days with assembly-level test documentation.
Delivery & Support
Carton packing, shipping documents and support through charger integration and field commissioning.
FAQ
Questions buyers ask before ordering
It changes the conductor. A 600 A assembly does not carry its current through one large power core — a named peer 600 A construction uses a pair of 2 AWG (≈ 33.6 mm²) cooled conductors, giving a current density of roughly 17.9 A/mm² against the 4–6 A/mm² that conventional air-cooled design assumes. That is why a 600 A cable can stay flexible enough for a driver to handle, instead of being a heavy, stiff assembly.
Yes, but the precise designation matters: it is IEC TS 62893-4-2:2021, a Technical Specification rather than a full IEC or EN standard. Its title is “Cables for DC charging according to mode 4 of IEC 61851-1 — Cables intended to be used with a thermal management system”. The non-cooled counterpart is IEC 62893-4-1:2020, and the difference between the two is exactly the thermal management system.
The coolant specification is a property of the charging system, not of the cable, so it is agreed per project with the charger manufacturer — fluid type, flow rate, inlet temperature and the associated materials in the circuit. We do not publish a fixed coolant or a universal compatibility claim on the data sheet; tell us the system you are building and we will confirm the assembly against it.
No, and the distinction matters. UL 2251-2022 requires actively cooled charging equipment to declare a non-cooled current rating alongside the cooled one, because the current the assembly can carry falls sharply if the coolant loop stops. We state the cooled rating of 600 A and confirm the non-cooled figure for your selected assembly, so the charger can set a safe fallback current.
They are different measurements and both are useful. UL 2251-2022 judges at an absolute contact temperature of no more than 100 °C at maximum rated current. Terminal temperature rise < 50 K is the vendor convention, and it only means something with the test ambient temperature stated — a 50 K rise from a 40 °C ambient lands at 90 °C. We quote both with their conditions rather than presenting them as one number.
It follows the market the charger is going into. CCS2 in Europe and most of the world outside North America and China, CCS1 in North America, GB/T 20234.3 in China, and NACS — now published as the SAE J3400 series — for the North American Tesla-compatible network. The cable assembly is built around the coupler, so the coupler standard is fixed at the quotation stage rather than changed later.
The standards envelope allows it: UL 2251-2022 covers up to 800 A and 1500 V DC, and GB/T 20234.3-2023 raised the Chinese DC interface to 800 A / 800 kW. What we will not do is quote a higher rating as if it were a catalogue item — above 600 A it is a project-specific assembly, confirmed against your charger and cooling circuit. For the AC side of the same installation, our Type 2 32A IEC 62196 EV Charging Cable covers Mode 3 AC charging.
Yes. Because the assembly is built to order, samples are quoted as a specific configuration — coupler type, length and current class. Documentation including routine electrical test records and the coupler standard referenced for your configuration is provided with the quotation and the shipment, and the exact certification scope is always confirmed against the certificate for the item supplied.
Need a 600 A liquid-cooled assembly for a charger project?
Tell us the coupler standard, cable length and delivered current — we reply within one working day.
Get a Free Quote
Send your liquid-cooled charging cable requirement
The more detail you give, the faster and more accurate our quotation. Our engineers reply within one working day.
- Coupler standard and vehicle side: CCS1 / CCS2 / GB/T / CHAdeMO / NACS
- Delivered current and voltage: 600 A at 1000 V DC, or a different class
- Charger model and coolant circuit: fluid type, flow rate and inlet temperature if known
- Cable length and quantity (units per year, and first order)
- Destination market, for the certification and marking scope
- Whether a sample assembly is needed for charger qualification
Inquiry received
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