MAN project: All charging points permanently with 500 A and CCS charging cable – MCS in preparation

A total of four SEB-branded chargers have been installed at MAN in Munich, three units with 750 kW continuous power (880 A) and one with up to 1 MW peak power (up to 1250 V). The three 750kW units are installed at the test track at MAN in a separate concrete station and feed the electric trucks or electric buses via an imposing cantilever arm either via CCS plug, MCS plug, pantograph or hood. Currently, charging is installed via CCS plugs.

The power and current limit is currently 500 A due to the charging characteristics of the batteries in the truck or bus.

However, these 500 A already mean that the cable and contacts of the CCS charging cable must be liquid-cooled, because the normal air-cooled copper cable can handle max. 200 A. At higher currents, the cable and contacts quickly become too hot. At 400 A, the cable would already have a temperature of 90°C after a quarter of an hour. And only after stopping the charge and waiting another quarter of an hour would it have cooled down to 60°C again.

All the installations have shown that these 500 A are provided continuously without the cable or the contacts in the plug getting too hot. Both are temperature controlled. The special charging cable from Huber&Suhner is oil-cooled, i.e. the copper itself is surrounded by oil and cooled again via the recooling unit (heat exchanger). With the cable lengths used (7 m), 600 A could also be achieved permanently at 30°C outside temperature.

And soon there will be the new MCS plug from Huber&Suhner for the charging point in the test field. This has already arrived at SBRS and can already deliver 1500 A (!) permanently in its pre-series form. Of course, the batteries have to be able to do this first.