What kind of charging cable do I need for an EV?

All About EV Charging Cables: Making the Right Choice

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Understanding the Type 2 Connector

Overview

The IEC Type 2 connector, commonly known as the Mennekes connector, is predominantly used in Europe for charging electric vehicles. As the standard set by the EU, it's designed based on the IEC three-phase industrial connectors. With a single size chosen for ease and compatibility, this connector relays power and communicates with the car via two additional communication pins.

This circular connector, with a flattened top edge, originally provided power outputs ranging between 3 kW and 50 kW using single-phase (230V) or three-phase (400V) AC. Practically, most vehicles see maximum power draws of 7.2 kW on single-phase AC and 22 kW on three-phase AC. The connector's sides are designed with openings to allow the locking mechanism, ensuring secure and uninterrupted charging.

Tesla, for its European Supercharger network, modified the Type 2 connector to output up to 150 kW using direct current (DC). With their Version 3 Superchargers, Tesla's transition to the CCS2 connector allowed for 250 kW outputs. All these advancements are supported by hardware upgrades and adapters in earlier Tesla models like Model S and X.

History of the Type 2 Connector

From Proposal to Standardization

Originally proposed by Mennekes, the Type 2 connector system was standardized by the German Association of the Automotive Industry (VDA) and later recommended by the European Automobile Manufacturers Association (ACEA). Officially adopted by the European Commission in January, this connector is favored in many countries, including New Zealand, reflecting its broad acceptance.

The parallel standard, IEC Type 1 (SAE J1772), is utilized for single-phase AC charging in the U.S., Canada, and South Korea, with a maximum output of 19.2 kW. North America supports three-phase AC charging via the same physical connector under the SAE J3068 standard, achieving up to 166 kW.

China's adaptation under the Guobiao standard GB/T specifies cables with Type 2-style connectors, though with reversed gender roles for vehicle and charging stations. The Combined Charging System (CCS) Combo 2, which incorporates Type 2 signalling and protective earth pins, allows for rapid charging up to 350 kW.

Comprehensive Description of EV Charging

Types and Regional Variations

The IEC Type 2 standard requires cars to have a male vehicle inlet while charging stations have a female socket outlet or a flexible cable with an attached connector. Connectors vary across regions, with the EU using IEC 62196 Type 2, while North America and China have their adaptations that cater to their respective power and signaling requirements.

Connector and Pin Allocation

The Type 2 connector comprises seven contact points. The top row has two pins for pre-insertion and post-insertion signaling, while the middle row consists of three power supply pins and an earthing pin. Depending on the charging mode, the power supply pins' allocation changes to support single-phase AC, three-phase AC, combined AC/DC, and various DC currents.

Guidelines for Choosing the Right EV Charging Cable

Selecting the appropriate electric vehicle charging cable can be straightforward with the right information. To achieve the best charging speed, durability, and user-friendliness, here's what you need to know:

Install a Home Charger

If you haven't already, consider installing a home charger. Available options include fixed cables or outlets, but you'll need a cable for charging away from home.

Opt for a Mode 3 Charging Cable

Mode 3 charging cables are the modern standard and can be used at any public charging point. Avoid Mode 1 as it is outdated, and use Mode 2 cables as an emergency backup. Mode 4 cables are specifically for fast chargers and are not loose but attached directly to the charger.

Select the Right Type

EV cables come with Type 1 or Type 2 vehicle-side plugs, corresponding to the inlet on your car. Type 2 is the current standard for new models, while older Asian car models may use Type 1.

Choose Appropriate Amp, kW, and Phase

Consider the onboard charger's capacity in your car when selecting amps and kW. The easiest choice is a cable with a kW rating equal to or higher than your onboard charger's capacity. Note that 3-phase cables can also work in 1-phase mode.

Consider Cable Length

EV charging cables come in different lengths, typically between 4 to 10 meters. A longer cable provides more flexibility but adds weight and cost. Choose a cable length that balances convenience and practicality.

Prioritize Quality

High-quality charging cables offer better durability, material strength, and protections against everyday use strains. These cables also remain flexible in extreme cold, reducing stiffness and making them easier to handle. Look for cables with caps that prevent water and dirt infiltration to avoid corrosion and poor connections.

Choose Recyclable Options

Opt for fully recyclable charging cables. Many cables use potting compounds that hinder recycling. Instead, select cables made with reusable materials.

Consider Accessories

Proper storage and transport accessories, like brackets, straps, or bags, ensure your cable remains tidy and protected. Lockable docking units can prevent theft and accidents.

Conclusion

In summary:

• Install a home charger if you haven't already.
• Opt for a Mode 3 charging cable with a Mode 2 as a backup.
• Check the inlet type on your vehicle, with Type 2 being standard for new models.
• Choose a cable with amp and kW ratings that match or exceed your onboard charger capacity. Consider your home charger’s capacity if used mainly at home.
• Select an appropriate cable length for flexibility.
• Invest in high-quality, durable cables.
• Choose environmentally-friendly, fully recyclable cables.
• Use protective accessories for safe storage and transportation.

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