𐄀 Technology Connection to Future
Zhejiang Yonggui Electric Equipment Co., Ltd.
EN

DC Vehicle Connector GB HPC

With the development of new energy vehicles, range and charging time has become the two key factors restricting the development of new energy vehicles, and with the increase of range, battery capacity, charging time will be extended, in order to improve the practicability of new energy vehicles in society and convenience in daily use, high-power charging will be an effective way to shorten the charging time. This type of efficient charging connectors will be an appropriate choice.


Specifications of DC Vehicle Connector-GB HPC

GB Liquid (oil)- coold High-power DCCharging Connector Technical Specification
Technical parameters of the charging connector

Electrical parameters

Port definition

DC±

PE

CC1

CC2

Wiring specification (mm²)

30

6

1.5

0.5

0.5

0.5

Contact Terminal Diameter (mm)

Φ12

Φ6

Φ3

Φ3

Φ3

Φ3

Rated Operating Voltage (DC)

1000V

0—30V

0—30V

0—30V

0—30V

0—30V

rated current

100A(when the liquid cooling system is not working)

/

10A

2A

2A

2A

Maximum continuous working current

600A (line length and thermal management capacity)

outside diameter of cable

φ 30mm ± 0.6 (ground wire 6mm², auxiliary power supply 1.5mm²)

The weight of the connector

<1.1 Kg (without cable)

insulation resistance

2000 MΩ between DC positive and negative terminal and PE terminal (test voltage 1000V D C)

Pressure withstand (50Hz, AC)

Test after plug wiring:

① Resistance voltage between DC + and DC-4500 V DC 1min;

② DC +, DC-and PE, S +, S +, A +, A-resistance voltage 1500 V DC 1min; ③ PE, resistance voltage of 1500V D C 1min between S +, S-, A + and A-; ④ S +, S-, CC1, A +, A-two resistance voltage of 1500V D C 1min;

Note: The outer diameter and the core area of the cable can be designed and customized according to the actual needs of customers

Mechanical properties

Service life:

10000 times

Plug and pull force:

120N

Lock-in force:

200N

Environmental parameters

Level of protection before insertion:


IP54
Grade of protection after insertion:IP55
High-voltage electrical part:IP67

Ambient temperature:

-30℃ - - + 50℃
Flame retardant grade of insulation materials:UL94 V-0

Materials

Housing:

engineering plastics (temperature resistant PA66 or temperature resistant PC)
Terminal:copper, surface silver-plated

Seal parts:

silicone rubber

Appearance of the charging connector

wiring harness socket

custom wire harness assembly

Figure 1.1 Appearance of interface liquid (oil) cooled DC charging connector (GB / T 20234-2023)
Interface definition
The following figure shows the diagram of the power copper row interface, signal wire harness interface and cooling line interface between the connector line and the pile end. The following structure is generally customized design.

custom electrical cable assemblies

cable wire harness manufacturing

Liquid medium cooling unit (HPC cooling module assembly)
Technical parameters

Table 1: Technical parameters table

size

435×155×410(mm)

Heat dissipation power

3.0KW@4L/min .700m3/h

input voltage

DC12V

power

≤200W

cooling medium

Dimethyl silicone oil

Di-tert-butyl-p-methylphenol

TF8016 Fuchs Coolant

Shell E4

(-40~85℃)

Cooling flow

4L/min@450Kpa

Water supply pressure

0.6Mpa

working pressure

0~0.7MPa

working temperature

-40℃-50℃

Expansion pot volume

1.5 L

noise

≤60dB(A)

levels of protection

IP 68

weight

7Kg

communication mode

Based on the Modbus 485 /

232

control method

full-automation

life span

25000h

Definition of the wiring pin

Table 2 Definitions of the wiring pins

order number

name

Cross-sectional area of the

wire (mm²)

Terminal model

remarks

1

Signal ground

0.5

E0508

CI

2

A + (485

communication) /

485-A

0.5

E0508CI
3

A- (485

communication)

485-B

0.5E0508CI
4

Fan Enable +

0.5E0508

Fan power control

5

Fan enabling-

0.5E0508Fan power control
6

12V/24V+

1.0

TVS1.25-4

Controller power supply

7

GND

2.5

TVS2-4

Controller power supply
8

Pump enabling +

0.5E0508

Pump power control

9

Pump enabling-

0.5E0508Pump power control
10

Pump 12V / 24V +

1.0TVS2-4Pump power control
11

Fan: 12V / 24V +

1.0TVS2-4

Fan power supply

Safety precautions

This product takes the insulating liquid as the cooling medium, if unauthorized replacement may lead to the decline or damage of the sealing structure of the cooling module, or even cause the damage of the connector line.

The lid of the expansion pot is filled with cooling medium and opened when necessary. In other cases, the lid is in a tight state to prevent dust, small particles, water and other substances from entering, so as to avoid blockage or safety accidents.

It is forbidden to touch the hand in the product work to prevent the fan from injuring the hand. Do not touch the radiator during the product work to prevent scalding.

Cleaning and maintenance

Clean up only when the product is not energized.

Clean the electrical parts and the remaining parts with a dry cloth.

Do not use detergent, water connector, steam connector with corrosive effect for cleaning.

Most of the product parts are thermoplastic plastic, do not make the product is impacted by external force, so as not to affect the use.secret

During the use of the product, the expansion pot liquid level should be checked regularly to avoid the failure of the liquid level sensor

Product damage and safety accidents caused by the alarm. The recommended inspection period is once a quarter.

Check the product regularly for leakage.



GB Liquid (water)- coold High-power DC Charging Connector Technical Specification

Technical parameters of the charging connector

Electrical parameters

Port definition

DC±

PE

CC1

CC2

Wiring specification (mm²)

48

6

1.5

0.5

0.5

0.5

Contact Terminal Diameter (mm)

Φ12

Φ6

Φ3

Φ3

Φ3

Φ3

Rated Operating Voltage (DC)

1000V

0—30V

0—30V

0—30V

0—30V

0—30V

Rated current

125A (when the liquid cooling system is not working)

/

10A

2A

2A

2A

Maximum continuous working current

500A (line length and thermal management capacity)

outside diameter of cable

φ28mm±0.6

The weight of the connector

<1.1 Kg (without cable)

insulation resistance

2000 MΩ between DC positive and negative terminal and PE terminal (test voltage 1000V AC)

Pressure withstand (50Hz, AC)

Test after plug wiring:

① Resistance voltage between DC + and DC-4500 V DC 1min;

② DC +, DC-and PE, S +, S +, A +, A-resistance voltage 1500V AC 1min;

③ PE, resistance voltage of 1500V AC 1min between S +, S-, A + and A-;

④ S +, S-, CC1, A +, A-two resistance voltage of 1500V AC 1min;

Note: The outer diameter and the core area of the cable can be designed and customized according to the actual needs of customers

Mechanical performance

Service life:

10000 times
Plug and pull force:120N
Lock-in force:200N

Enviromental parameter

Level of protection before insertion:

IP54

Grade of protection after insertion:

IP55
High-voltage electrical part:IP67
Ambient temperature:-30℃ - - + 50℃
Flame retardant grade of insulation materials:UL94 V-0

Material

Housing:

Engineering plastics (temperature resistant PA66 or temperature resistant PC)
Terminal:copper, surface silver-plated
Seal parts:silicone rubber

Interface definition

The following figure shows the diagram of the power copper row interface, signal wire harness interface and cooling pipeline interface between the connector wire and the pile end. The following structure is generally customized design.

replace turn signal wiring harness

Figure 2. Diagram of connector line inlet pile interface (for reference)

Liquid medium cooling unit (HPC cooling module assembly)

Technical parameters

Table 1. Technical parameters table

size

306×136×358(mm)

Change the heat

1.6KW(50℃)

input voltage

DC12V/24V

power

≤160W

current

Fan (12V)

Max 9A

Pump (12V)

Max 7A

cooling medium

Antifreeze solution (water +

ethylene glycol)

Cooling flow


0-2.5L/min Adjustable

Water supply

pressure

6bar

working pressure

0-6bar

working temperature

-30℃-50℃

Expansion pot volume

1.5 L

noise

≤60dB(A)

levels of protection

IP 68

weight

3.5Kg

communication mode

Based on the Modbus 485 /

232

Definition of the wiring pin

Table 2. Definition table of wiring pins

No.

Name

Cross-sectional area of the

wire (mm²)

Terminal model

remarks

1

Signal ground

0.5

E0508

CI

2

A + (485

communication) /

485-A

0.5E0508CI
3

A- (485

communication)

485-B

0.5E0508CI
4

Fan Enable +

0.5E0508

Fan power control

5

Fan enabling-

0.5E0508Fan power control
6

12V/24V+

1.0

TVS1.25-4

Controller power supply

7

GND

2.5

TVS2-4

Controller power supply
8

Pump enabling +

0.5E0508

Pump power control

9

Pump enabling-

0.5E0508Pump power control
10

Pump 12V / 24V +

1.0

TVS2-4

Pump power control
11

Fan: 12V / 24V +

1.0TVS2-4

Fan power supply


Matters Needing Attention of DC Vehicle Connector GB HPC

GB Liquid (oil)- coold High-power DC Charging Connector Technical Specification


  • Liquid medium cooling unit (HPC cooling module assembly)


1. Overview

The HPC cooling module assembly (HPC-CU) is used for intelligent high-power charging (HPC) technology. The heat dissipation power of 3.0KW can bring the charging current up to 600A, while ensuring the safe and stable operation of the combined charging connection system (CCS). The core technology of this product is to provide coolant with appropriate temperature and flow to CCS under full working conditions, so as to ensure that the temperature of CCS relative to the ambient temperature is not more than 50K (ΔTmax = 50K) during charging.


2. Principle

HPC CCS Charging can transport more than 600A charging current, the use of conventional charging technology requires the use of heavy cables or often lead to CCS overheating, in order to facilitate charging operation, intelligent HPC charging technology adopts liquid cooling system, the system HPC cooling module assembly uses environmental protection cooling medium to provide cooled source to CCS, easy to maintain. The cooling medium can simultaneously cool the cable and the DC power terminal of the charging connector.

Charging connector terminal has excellent thermal conductivity, so it can also act as a radiator in the charging process.

A closed loop connecting the HPC cooling module assembly inlet and outlet tube to the CCS outlet tube and inlet tube, The cooling medium is driven by the circulating pump, CCS Transfer of the generated heat to the circulating cooling medium, The cooling medium then transfers the heat to the radiator, The radiator then achieves continuous heat dissipation through an electronic fan blower, In this process, The module collects real-time inlet and outlet liquid temperature through the sensor, Adjust the rotational speed of the pump and fan according to the collected temperature, Realize the real-time adjustment of the heat dissipation power, Put the CCS within a suitable working range, So as to ensure the safety and stability of HPC charging pile.

cable wire harness manufacturing

Figure 1. Schematic diagram of the high-power charging and cooling system


3. Product diagram of high-power charging liquid cooling system (W)

industrial wire harness

Figure 2. Product diagram of the liquid-cooling system


4. Functional features
  1. Vehicle standard grade products
    Design and development, component selection, experimental verification, manufacturing process and quality control are all developed in accordance with the vehicle specification level IATF16949 system.
  2. IP68 protection
    Fully prevent dust from entering the internal core components, in not more than 1 m deep water immersion, clean can work normally.
  3. Miniaturization
    Lightweight, integrated, and small in size.
  4. Energy-saving
    According to the charging condition, the output power of the fan and water pump is automatically adjusted to achieve energy saving.
  5. Automation

    Automatic control program (standby mode, automatic mode, sleep mode, fault mode, etc.), can prolong the life and save energy.


5. Installation dimensions

railway wiring harness

Figure 3. Installation dimensions of bottom plate (optional)

custom wiring harness for engine swap

Figure 4. Installation dimensions of the bottom plate (customizable)


6. Block diagram of electrical control principle

custom engine wiring harness

Figure 5. Schematic block diagram of electrical control


The functions of the controller include: collecting the sensor information, collecting the abnormal fault information, communicating with the charging pile end, and adjusting the pump and fan speed.

1) Collect the sensor information

The temperature and pressure of the inlet fluid and the temperature of the return fluid.

2) Collect the abnormal fault information

Collect fan fault, pump fault, temperature sensor fault, temperature and pressure sensor fault, high temperature, high pressure, low pressure, high level and low level.

3) Charging pile terminal communication

The controller sends the collected normal information and the abnormal information.

For example, receive information about "whether to be charging", "whether to limit current charging", "whether debugging and maintenance", and the temperature value of charging pile collection, etc.

4) Control the fan and the pump

The controller compares the collected current temperature with the set upper temperature limit (such as 90℃) (e.g., the current inlet liquid temperature and the current inlet liquid temperature upper limit), uses the control algorithm to obtain the target speed of the fan and pump, and then adjusts the pump speed and fan speed.

custom made engine wiring harness

Figure 6. Definition diagram of the wiring pin


7. Matters needing attention

A. Product supplementary description

  1. The above test data do not represent the temperature rise data of all models of liquid-cooled charging connectors, but should be comprehensively considered according to the wire diameter, cable length, the power of the radiator matched by the system and the pump (the flow of coolant circulation) (our company will provide full technical support);

  2. The product conforms to GB / T 20234.1-2023;

  3. Liquid-cooled cable is customized cable, no standard cable, its performance (such as mechanical strength, etc.) can refer to the relevant provisions of GB / T 33594-2017, IEC 62893-4-1 / 2, but temporarily cannot pass the certification;

B. Notes for use

  1. Charging connector coolant is recommended to choose insulating liquid such as Shell E4 and TF8016 Foss coolant;

  2. Unfixed accessories model of the heating management system (such as oil pump, radiator, etc.), conduct comprehensive analysis and experiment for power matching of the accessories according to the customer's current carrying requirements, charging curve, charging connector line length and other requirements;

  3. It is recommended to use the connector line manufacturer to specify the thermal management system (pump, radiator, temperature sensor, control program, etc., integration), and also to provide the cooling system matching and selection support;

  4. The rated working pressure of the connector line is 5Bar, meeting the minimum flow rate of thermal management is 4L / min;

  5. Other cooling medium other than the coolant specified by the manufacturer is prohibited, and the mixing of the cooling medium is prohibited.


GB Liquid (water)- coold High-power DC Charging Connector Technical Specification


  • National standard liquid (water) cooled DC charging connector


1. Product model and interface standard:

The internal model of the product is YGC1352A-EV-P9P-500XL1, and the interface standard of liquid (water) cooled DC charging connector meets the requirements of GB / T 20234.3-2023 standard.


2. Introduction of product advantages

And the product relative to the conventional national standard dc charging connector rated voltage (1000V), the current larger (depending on specific charging strategy, through the 500A, 30 minutes current test), charging power, charging efficiency is higher, can truly solve the new energy vehicles users charging anxiety, the test data 3-5 minutes can supplement the new energy vehicles driving 100 Km electricity.


3. Appearance of the charging connector

custom engine harness

custom automotive wiring harness

Figure 1. Appearance of Yonggui National Standard (GB / T 20234-2015) interface liquid (water) cooled DC charging connector


  • Liquid medium cooling unit (HPC cooling module assembly)


1. Product Introduction

HPC cooling module assembly (HPC-CU) is used for intelligent high-power charging (HPC) technology. The heat dissipation power is 1.6KW, which enables the charging current to reach 500A, and ensures the safe and stable operation of GB DC charging connector line assembly (referred to as DC charging connector line). The core technology of this product is to provide coolant with appropriate temperature and flow to the DC charging connector under full working conditions, so as to ensure that the temperature of the DC charging connector does not rise more than 50K (ΔTmax = 50K).


2. Principle

HPC DC charging connector line can transfer more than 500A when charging current. Using conventional charging technology needs to use heavy cable or often lead to overheating of DC charging connector line. In order to facilitate charging, intelligent HPC charging technology adopts liquid cooling system. HPC cooling module assembly in this system uses environmentally friendly cooling medium to provide cooled source for DC charging connector line and is easy to maintain.

The cooling medium can simultaneously cool the cable and the DC power terminal of the charging connector. Charging connector terminal has excellent thermal conductivity, so it can also act as a radiator in the charging process. The closed loop is formed by connecting the incoming and outlet pipes with the HPC cooling module assembly and the inlet pipe of the DC charging connector line, The cooling medium is driven by the circulating pump, The DC charging connector line transfers the generated heat to the circulating cooling medium, The cooling medium then transfers the heat to the radiator, The radiator then achieves continuous heat dissipation through an electronic fan blower, In this process, The module collects real-time inlet and outlet liquid temperature through the sensor, Adjust the rotational speed of the pump and fan according to the collected temperature, Realize the real-time adjustment of the heat dissipation power, So that the DC charging connector line is in a suitable working range, So as to ensure the safety and stability of   HPC charging pile.

custom automotive wire harness manufacturers

Figure 2. Schematic diagram of the high-power charging and cooling system


3. Product diagram of high-power charging liquid cooling system (W)

turn signal switch wiring harness

Figure 3. Product diagram of the water-cooling system


4. Functional features

⑴ Car standard grade products

Design and development, component selection, experimental verification,  manufacturing process and quality control are all developed in accordance with the vehicle specification level IATF16949 system.

⑵ IP68 protection

Fully prevent dust from entering the internal core components, in not more than 1 m deep water immersion, clean can work normally.

⑶ Miniaturization

Lightweight, integrated, and small in size.

⑷ Energy saving

According to the charging condition, the output power of the fan and water pump is automatically adjusted to achieve energy saving.

⑸ Automatization

Automatic control program (standby mode, automatic mode, sleep mode, fault mode, etc.), can prolong the life and save energy.


5. Installation dimensions

custom auto wiring harness

Figure 4. Installation dimensions diagram


6. Block diagram of electrical control principle

turn signal wiring harness

Figure 5. Block diagram of electrical control principle


The functions of the controller include: collecting the sensor information, collecting the abnormal fault information, communicating with the charging pile end, and adjusting the pump and fan speed.

⑴ Collect the sensor information

The temperature and pressure of the inlet fluid and the temperature of the return fluid.

⑵ Collect abnormal fault information

Collect fan fault, pump fault, temperature sensor fault, temperature and pressure sensor fault, high temperature, high pressure, low pressure, high level and low level.

⑶ Charging pile terminal communication

The controller sends the collected normal information and the abnormal information.

For example, receive information about "whether to be charging", "whether to limit current charging",  "whether  debugging  and  maintenance",  and  the  temperature  value  of  charging  pile collection, etc.

⑷Control the fan, and the pump

The controller compares the collected current temperature with the set upper temperature limit (such as 90℃) (e. g., the current inlet liquid temperature and the current inlet liquid temperature upper limit), uses the control algorithm to obtain the target speed of the fan and pump, and then adjusts the pump speed and fan speed.


7. Definition of the wiring pin

turn signal harness

Figure 6. Definition diagram of the wiring pin


8. Matters needing attention

8.1. Product supplementary description

⑴ High-power liquid-cooled charging connector has no corresponding national and industry standards, so it cannot pass the strong inspection certification;

⑵ Liquid-cooled cable is customized cable, no standard cable, its performance (such as mechanical strength, etc.) can refer to the relevant provisions of GB / T 33594-2017, IEC 62893-4-1 / 2, but can not pass the certification;

⑶ Because there is a cooling pipeline inside the liquid-cooled connector line, the connection fixed structure with the pile end cannot directly follow the cable tightening structure of the conventional DC charging connector line. According to the different shape of the charging pile and the internal electrical design, the connection structure of the connector line and the pile needs to customize the design.

8.2. Notes for use

⑴ Charging  connector  coolant  must  be  selected  vehicle  coolant  (can  be  50%  ethylene  glycol aqueous solution, but need to use deionized water), it is recommended to purchase through regular channels, prohibit self-blending;

⑵ It is strongly recommended to use the liquid medium cooling device (HPC cooling module assembly) designated by the connector line manufacturer. After selecting the cooling device, the pressure and flow rate should be matched and adjusted. The rated working pressure of the connector line is <1Bar, which can meet the minimum flow rate of 1L / min of thermal management;

⑶ No cooling medium other than the coolant specified by the manufacturer, the mixing of cooling medium, and the cooling system filled with cooling medium such as dimethyl silicone oil.

⑷ Expansion pot lid in the filling cooling medium and open when necessary, the rest of the situation to ensure that in the tight state, to prevent dust, small particles, water and other substances from entering, so as to avoid blockage or safety accidents.

⑸ It is forbidden to touch the product work, to prevent the fan injured hand.

⑹ Do not touch the radiator during the product work to prevent scald.

⑺ Can only when the product is not powered up, use dry cloth to clean electrical parts and other parts, do not use corrosive detergent, water connector, steam connector for cleaning.

⑻ Most of the product parts are thermoplastic, do not make the product is impacted by external forces, so as not to affect the use.


Contact Yonggui Electric for Connectors
Contact Yonggui Electric for Connectors
We Can Provide
  • Customized Solutions

    Tailoring connectors to your unique needs.

  • Expert Technical Support

    Provide systemic solutions

  • Quick Response

    Respond to needs within 12 hours

Blog & News
New Beginnings, New Journey | Grand Opening of Yonggui Thailand Factory
On November 22, 2024, the grand opening ceremony of Yonggui's Thailand factory took place in the Rayong Industrial Zone, Thailand. Chairman Mr. Fan Jijun, along with senior leaders of the group, B...
Read More
Yonggui Electric Signs Distributor Agreement with Alfatec GmbH & Co. KG, Expanding Global Reach in Electronic Components
We are pleased to announce that Yonggui Electric has officially entered into a distributor partnership with Alfatec GmbH & Co. KG, marking a significant milestone in our expansion strategy. At an ...
Read More