DC charging allows the car to be charged significantly faster than AC charging. Currently, the most common charging stations are 50 kWh, but 150 kWh stations already appear, and 270 kWh and 350 kWh chargers are emerging, which is reflected in the constant need to develop more efficient connectors.

CCS - Type 1 and Type 2 (Combined Charging System)

CCS, or combined charging system, is a beautifully elegant solution for fast DC charging. These are the original plugs, either type 1 electric car charger or Type 2, to which two more pins are added at the bottom. In the case of DC charging, these two lower pins participate in the charging itself and from the upper part only the communication pin and the earth conductor, which provides the reference point for the protection systems, are used. These connectors can withstand power of up to 350 kW.

It is currently the most popular type of DC connector. Type 1 is common in the United States, while Type 2 CCS is used in Europe. The European Parliament's efforts to allow only CCS 2 and other plugs to be phased out of Europe have not been successful, but this standard is still winning, mainly because the car has only one socket. When using the CHAdeMO connector, the car must always have two sockets.

CCS are not compatible with CHAdeMO and GB / T charging stations because they use different communication protocolsa, so special adapters are needed and they are not easy to obtain.

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 Table of Content [Hide]

1. 1. Main requirements for EV cables for new energy vehicles

2. 2. Eight materials and standards commonly used in EV cables

As the main component of telex, EV cable is the carrier of power signal transmission, which plays a huge role in the charging process of electric vehicles. EV cables can be mainly divided into cable materials for charging pile stations and high-voltage cables in vehicles.

1. Main requirements for EV cables for new energy vehicles

EV cable is the main component of telex, which is mainly divided into charging pile/station cable materials and in-car high-voltage cable materials. Due to the high voltage, high current and harsh environment of use, the industry has put forward very high safety specifications and use requirements for cable materials.

2. Eight materials and standards commonly used in EV cables

At present, the eight materials commonly used in EV cables are XLPE, TPE, TPV, TPU, EPR, PVC/HNBR, silicone, and CPE/CR.

(1) Application of XLPE in EV cables

XLPE is mainly used for high-voltage cables in the car. The temperature resistance is good enough to burn red with an electric soldering iron, and it will remain on it for 10-20 seconds without damage. In 2017, the high-voltage cable in the car is mainly made of XLPE. Its standards in different application fields are as follows:

High voltage cable: ISO 6722, QC/T 1073, CQC1122/ DECRAK179 Charging cable: CQC1103 -1105, DECRA K175

(2) Application of TPE in EV cables

Compared with other cable materials, TPE has the advantages of adjustable softness, good touch, small specific gravity and high cost performance. Its standards in different application fields are as follows:

High voltage cable ISO 6722, QC/T 1073, CQC1122/ DECRA K179  Charging cable CQC1103 -1105, DECRA K175 EN50620, UL62

(3) Application of TPU in EV cables

TPU is mainly used in Europe, and some large cable factories in southern and central China want to develop TPU materials. Its standards in different application fields are as follows:

Charging cable CQC1103 -1105, DECRA, K175 EN50620, UL62

(4) Application of EPR in EV cables

EPR is used more in Europe, and is generally used in the core wire of charging piles. Its standards in different application fields are as follows:

High voltage cable ISO 6722, QC/T 1073, CQC1122/ DECRA K179 Charging cable CQC1103 -1105, DECRAK175, EN50620, UL62

(5) Application of silica gel in EV cables

Silicone has excellent heat resistance properties, up to 200 degrees. It also has a softness of 60-85A. Its standards in different application fields are as follows:

ISO 6722, QC/T 1073, CQC1122/ DECRA K179

(6) Application of PVC/HNBR in EV cables

This material is currently the most used in China because of its excellent feel and softness. However, due to the halogen content, environmental protection issues need to be resolved in the future. Its standards in different application fields are as follows:

Charging cable: CQC1103 -1105, DECRAK175, UL62

(7) Application of CPE/CR in EV cables

Compared with other cable materials, CPE/CR has better oil resistance and crack resistance. Its standards in different application fields are as follows:

Charging cable: CQC1103/CJS4522

(8) Application of TPV in EV cables

TPV appears less in the market, because the processing temperature is high, more than 200 degrees, if there is no suitable color masterbatch, it is easy to change color.

Its standards in different application fields are as follows:

Charging cable: CQC1103

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 Table of Content [Hide]

1. 1. What the SAE JI772 standard is

2. 2. The development history of SAE JI772

1. What the SAE JI772 standard is

SAE J1772, also known as IEC Type 1 (IEC 62196 Type 1) or J plug, is the electrical connector standard for electric vehicles in North America. It is maintained by the International Society of Automotive Engineers. The official name is SAE Surface Vehicle Recommended Practice J1772, SAE Electric Vehicle Conductive Charge Coupler. These include the physical characteristics, electronic characteristics, communication protocols and performance requirements of the electric vehicle conductive charging system and the vehicle-side coupler. Its purpose is to define a general electric vehicle conductive charging system architecture, including general requirements for vehicle sockets and mating connectors, performance requirements and size requirements.

2. The development history of SAE JI772

The main force driving the development of SAE J1772 is from the California Air Resources Board (CARB). In the past, electric vehicles (such as General Motors EV1) were charged by inductive couplers. But later it was not recommended, and started to promote conductive car charging. Then, the California Air Resources Board also formulated the SAE J1772-2001 standard in June 2001 as the standard for electric vehicle charging in California.

The 2001 CARB regulations mandated that from 2006 onwards, the J1772-2001 specification must be introduced into the production of electric vehicles. CARB proposed a draft amendment to Title 13 section 1962.2 in 2008, compelling cars to be marketed from 2010 to use the chademo j1772 standard proposed later, and this amendment was passed in 2012.

Many electric vehicle depots after 2000 adopted the SAE J1772-2009 standard, such as the third generation of Chevrolet Volanda and Nissan Leaf, as well as earlier models. This connector has become a standard device in the U.S. market, mainly because there are many charging stations with this type of connector in the U.S. electric vehicle network (U.S. Economic Recovery and Reinvestment Act has subsidies for programs like ChargePoint America, which also has some help).

The European version of the vehicle is also equipped with SAE J1772-2009 connectors, until European car manufacturers decide to use IEC Type 2 "Mennekes" connectors as standard connectors, and all IEC connectors use the same SAE J1772 communication protocol, so car manufacturers can follow the market needs, and vehicles with SAE J1772-2009 connectors or IEC Type 2 connectors are sold. There are also converters for these two types of connectors on the market.

As a professional ev charging equipment manufacturer, AG Electrical's products are developed in accordance with SAE J1772, GB/T20234, IEC 62196 and other mainstream standards, and can be applied to different brands of electric vehicles and charging stations. We are striving to provide you with the latest standard electric vehicle charging equipment.

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 EV charging mode 1

In this mode, the EV is connected directly to a home socket. The maximum current of this mode is 16 A, and for single-phase systems the voltage should not exceed 250 V. For three-phase networks, the voltage should not exceed 480V.

The EV connects to the basic structure of a household socket.

Mode 1 is the simplest charging mode and does not support any communication between the EV charging cable and the charging point. This charging method is banned or restricted in many countries/regions.

EV charging mode 2

Household sockets do not always provide power according to actual standards. In addition, sockets and plugs designed specifically for home applications may not be able to withstand continuous current consumption at maximum ratings.

That's why connecting an EV charging cable to a socket without controls and safety features for an extended period of time increases the risk of electric shock. To solve this problem, the experts developed Charging Mode 2. Mode 2 ev charging uses a special EV charging cable. Such mode 2 ev charging cable is equipped with an in-cable control and protection device (IC-CPD). The safety features of this mode can detect and monitor protective grounding.

While Mode 2 EV charging can be used for private billing, its public use is restricted in many countries/regions.

EV charging mode 3

This mode utilizes dedicated EVSE and EV car chargers. An alternating current from the charging station is applied to the on-board circuit to charge the battery. Several control and protection functions are used to ensure public safety. This includes the verification of protective ground connections and connections between EVSE and EV.

In addition, this mode adjusts the charging current to the maximum current capacity of the cable assembly. The maximum current in this charging mode is 32A for 250 V 1-phase or 480 V 3-phase networks. It also supports a mode 2 compatible operating mode where the maximum current is limited to less than 32A in both phase 1 and phase 3.

EV charging mode 4

This is the only charging mode that combines a non-on-board charger with a DC output. DC current is sent directly to the battery and bypassed to the car charger. This mode provides A maximum current of 600V DC 400A. The high power levels involved in this mode require higher levels of communication and more stringent security features.

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 The IEC 62196 standard (European Electrotechnical Commission's conductive charging interface standard for electric vehicles) has a variety of EV charging systems, which clearly specifies various plug, type 2 EV charging socket, and connector products used in the household, EVSE and EV end entrance. IEC 62196-2-2022 applies to plugs, socket-outlets, vehicle connectors, and vehicle inlets with pins and contact-tubes of standardized configurations, herein referred to as accessories.

It can meet the requirements of AC charging-conductive charging connection of electric vehicles with a rated voltage not more than 480v, 50-60Hz, three-phase not more than 63A and single-phase not more than 70A. The standard products can be compatible in Europe, which greatly facilitates users and equipment manufacturers, and also reduces the waste of energy.

AG Electrical EV Charging Cable for Your Needs

AC Charging Cable (GB)

Reliable AC charging cables (GB standard) designed for efficient and safe power transfer, ensuring optimal performance for electric vehicles in regions using the GB

 GB/T EV Charging Cable (GB/T 20234)

 GB/T-GB/T Charging Mode3 Cable (GB/T 20234)

DC Charging Cable (GB)

High-performance DC charging cables (GB standard) engineered for rapid and secure charging, providing fast and reliable power delivery for electric vehicles in GB-standard

 GB/T EV DC Charging Cable (GB/T 20234)

 GB/T EV DC TPU Charging Cable (GB/T 20234)

AC Charging Cable (IEC)

Durable AC charging cables (IEC standard) offering efficient and safe power transfer, compatible with electric vehicles adhering to the IEC standard for global use.

 AC EV Charging Cable TYPE2 (IEC 62196-2)

 TYPE2-TYPE2 Charging Mode3 (IEC 62196-2)

DC Charging Cable (IEC)

Robust DC charging cables (IEC standard) designed for fast and secure charging, ensuring quick power delivery for electric vehicles worldwide using the IEC standard.

 Combo2 Charging Systems(CCS2) (IEC 62196-3)

 Combo2 Charging Systems (CCS2 Low Current) (IEC 62196-3)

AC Charging Cable (SAE)

Efficient AC charging cables (SAE standard) providing safe and reliable power transfer, tailored for electric vehicles in regions following the SAE standard.

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 As it is reported by Electrek, on April 24, CHAdeMO Association and China Electricity Council have jointly released the new version of the CHAdeMO fast-charging standard-CHAdeMO 3.0.

The CHAdeMO 3.0 charger is smaller and its cable size will be reduced. It uses the same plug as the chademo GBT charging protocol, and also adopts liquid cooling technology to cool the charger.

The DC charging power of the vehicles using CHAdeMO 3.0 standard can exceed 500 KW (the maximum current is 600 A). The CHAdeMO 3.0 is also compatible with the previous CHAdeMO version, GBT charging, CCS and other fast-charging systems of different standards. In addition, the CHAdeMO standard also supports bidirectional charge and discharge from the beginning. This feature is not available in the current mainstream CCS fast charge standard.

Currently, China and Japan are cooperating on the new fast-charging standard, and India is also expected to become a new partner. According to CHAdeMO, South Korea and some other Southeast Asian countries have also shown strong interest in such charging technology.

The biggest difference between CHAdeMO and the current mainstream CCS standard is that the CHAdeMO standard is designed with a core function of two-way charging-discharge from the beginning, which can not only charge electric vehicles, but also recycle the power and sell it back to the grid.

Once China and Japan have reached an agreement on the fast-charging standard, CCS will lose its leading position.

It is said that the CHAdeMO 3.0 standard test requirements will be released within a year.

In the past, the CCS standard has always prevailed in the industry; however, with the release of the CHAdeMO 3.0 standard, the war of global fast-charging standard will start again. Though the CHAdeMO 3.0 charger is smaller, it is capable of charging up to 500 kW, thereby making itself very competitive.

In addition, as China, the largest consumer market for electric vehicles, will also adopt the CHAdeMO 3.0 standard, CCS may lose its leading position in the field of fast-charging standards.

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Dive Deeper into Our AC EV Charging Portable Charger (IEC) Solutions

EV Portable Charger TYPE2 Mode 2

Excellent protection performance, protection grade of IC-CPD achieved IP66 and achieved IP55 of plug (working condition) High security. It has passed all tests of TUV. There are all kinds of protective measures to ensure the safety for every user.

EV Portable IEC Charger Type 2 Mode 2 Features

Conform to the provisions and requirements of IEC62752. High compatibility. It can charge all EV with Type 2 inlets, correctly and effectively.

Using riveting pressure process with none screw, have a beautiful appearance. Hand-held design conform to the ergonomic principle, plug conveniently.

The control box panel adopts display function, the current and voltage, the charging state and the temperature of the circuit board in real time.

Excellent protection performance, protection grade of IC-CPD achieved IP66 and achieved IP55 of plug (working condition) High security. It has passed all tests of TUV. There are all kinds of protective measures to ensure the safety for every user.

Adopted double color coating technology, custom color accepted (regular color orange, blue, green, grey, white).

Easy operation. Simply connect the plug with the EV inlet, then the charger will automatically detect the connection status and handshaking protocol automatically, and starts charging.

Switchable currents. Customers can choose an appropriate charging current according to the demand.

Containing the intelligent chip. It can automatically repair minor charging problems while charging. When a fault occurs, the lights will blink in different ways to indicate different problems.

Application of IEC Type 2 Portable EV Charger

Apply to Vehicle

For Tesla Model3, for Tesla Model S, for Tesla Model X, for BAIC EU-Series, for BYD Yuan/S2 EV, for BYD e5, for Chevrolet Volt, for Mia, for Mia Electric Van, for Mitsubishi OUTLANDER PHEV, for Nissan NV200 SE Van, for Nissan leaf, for SAIC Baojun E-Series, for SAIC Roewe Ei5 EV, for BMW 530e/Le, for Renault Zoe, for Hyundai Kona EV, for BMW i3, for BYD Tang PHEV, for Chery eQ EV, for Toyota Prius PHEV, for Volkswagen e-Golf, for Geely Emgrand EV, for Great Wall Ora R1 EV.

Application in Area

Commercial EV Charging/Workplace EV Charging, Hotels EV Charging, Home/Residential EV Charging, Public EV Charging.

AG ELECTRICAL EV Portable Charge acquires all safety and production certificates in electrical filed, ISO9001, ISO 14001, OHSAS 18001, TUV(Rheinland)/IEC EN 62196&EN50620.

IEC Type 2 Portable EV Charger Parameter

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