Workersbee 800A CCS2 Liquid-Cooled DC Connector for Ultra-Fast Charging

The Challenge of Ultra-Fast Charging

As DC fast charging moves toward 500 kW and beyond, charging currents above 600 A push conventional air-cooled connectors to their thermal limits. Achieving higher current with air cooling requires larger conductor cross-sections — resulting in heavy, stiff cables that are difficult for users to handle.

How Liquid Cooling Works

The Workersbee 800A CCS2 connector uses an immersed liquid-cooling structure. Coolant circulates from the cooling unit through the charging cable, absorbs heat directly from the conductors and terminals, and returns to the cooling unit to be cooled before re-entering the circuit. This continuous heat exchange suppresses the temperature rise of both connector and cable, enabling sustained high-current transfer.

Engineered for Reliability

l Immersed cooling chamber: SUS316 housing with a dual-flow-channel structure, giving a large heat-dissipation area and low terminal temperature rise.

l Ultrasonic-welded power conductors: welded to SAE/USCAR38, with crimp resistance below 0.05 mΩ.

l Sealed, not just cooled: the connector interior is fully potted, so coolant never contacts internal conductors or terminals — removing the internal leak paths that are a common failure point in comparable liquid-cooled designs.

l Full-contact temperature monitoring: every DC power contact is individually monitored — thermal switch, PT1000 or NTC10K selectable — to prevent overheating.

lSealed protection: IP55 when mated, IP67 for the connector body.

Quality You Can Verify

Developed and manufactured under IATF 16949 and ISO 9001. Every connector undergoes 100% air-tightness and electrical performance testing before shipment.

Applications

l Liquid-cooled ultra-fast / HPC charging stations

l High-power charging pilots and 1 MW-class DC charging development

l Fleet and depot high-utilization charging

l Passenger EV and light commercial vehicle DC charging (CCS2)

800A Certified, 1000A Capable

TÜV-certified for 800A continuous charging. With a water-glycol dual cooling system, the same connector supports short-time charging up to 1000A.

Terminal Temperature Rise Below 20K at 800A

In internal thermal testing at 800A (ambient 25°C), DC terminal temperature rise measured 19.3K at DC+ and 19.6K at DC− — well below the 50K limit, and significantly lower than isolated liquid-cooled designs where cooling-tube overheating constrains sustained 800A operation.

1500V Platform Ready

Rated to 1500V DC. At 800A on a 1500V system that is up to 1.2 MW — the connector is ready for next-generation high-voltage platforms without derating.

Sealed and Verified Leak-Safe

The connector interior is fully potted so coolant never contacts internal conductors or terminals — and every unit passes 100% air-tightness testing before shipment. Design and production verification against the one risk that matters most in liquid cooling.

Built for High-Utilization Stations

Mechanical life exceeds 30,000 mating cycles (no load), verified by 1m drop testing (50 drops) and 5000N vehicle run-over resistance — engineered for the daily reality of public charging infrastructure.

Every Contact Monitored

Each DC power contact has independent temperature monitoring — thermal switch, PT1000 or NTC10K selectable — enabling real-time protection and current derating.