Compact CCS cable offering Level 2 fast DC charging

2023-10-19 09:58:47

We need convenient, reliable charging to eliminate the "range anxiety" of electric vehicles (EVs). To support these demands, designers of electric vehicle service equipment (EVSE) infrastructure need to provide multiple charging options, including medium-power Level 2 direct current (DC) fast chargers in residential, commercial, and retail environments, delivering up to 80 amps. Current (A); high-power Level 3 ultra-fast chargers delivering up to 500 A DC; low-power Level 1 alternating current (AC) charging for overnight charging and emergency charging.

However, DC charging of EVs is complicated. EVSE requires continuous monitoring of connector lock, system isolation, charging voltage, charging current, and connector temperature. If any of these parameters exceed its set limits, the EVSE should shut down. Additionally, it is challenging to design and assemble compact cables and connectors for Level 2 DC chargers while ensuring their long-term mechanical and electrical integrity. This cable includes 5 conductors: +DC, -DC, Communication, Lockout Monitor, and Protective Earth. One end of these wires must be securely connected to the EVSE and the other end to the Compact Charging System (CCS) connector. If there are any issues with these connections, the EVSE may require costly and time-consuming rework to ensure reliable operation.

To address assembly issues around CCS connectors and cables for Level 2 EV installations, designers can use pre-assembled compact CCS connectors with connecting cables. These cable and connector assemblies are intended for use in Level 2 charging facilities that do not require Level 3 charging, but are faster than Level 1. These cables are suitable for Type 1 installations in North America and Type 2 installations in Europe, where Type 1 meets the requirements of UL2251.


The CCS connectors for Level 2 and Level 3 DC charging (up to 250 kW) are similar in size and can be used in common vehicle sockets. The main difference is that the 250 kW rated units have approximately 50% more cable diameter to carry the higher power levels, with a corresponding increase in cable weight. Due to the much smaller cables, Class 2 connectors and cable assemblies rated up to 80 kW are significantly lighter and easier to handle. DC charging up to 500 kW or more requires liquid cooling in the vehicle socket and requires larger connectors and cables

A locking mechanism is incorporated into the CCS DC charging connector system to keep users safe and ensure proper operation of the EVSE. These locking mechanisms are designed to withstand high pull-out forces, making it nearly impossible to disconnect the connector while the EV is charging. The locking mechanism for Type 1 connectors is a manual clip, as shown in Figure 2. In Type 2 connectors, the locking is done with a solenoid-operated metal stud. In both cases, the locking mechanism is monitored and its status communicated to the EVSE via a dedicated connection.

Integrated temperature sensing is required in the CCS2 DC charging connector. With precise temperature monitoring directly at the power contacts, the charging process can be stopped or slowed in the event of overheating to prevent user injury and protect the EVSE from damage. These connectors include two PT1000 sensors, one on each contact (Figure 3). The resistance of these sensors increases linearly with temperature, simplifying temperature monitoring. The temperature is communicated to the EVSE via signal wires in the cable.

Class 2 DC Connector Solutions

When charging currents up to 80A~250A are required, EVSE designers can turn to Sailtran Contact's lightweight CCS 2 DC charging connectors and cable assemblies. They are available in various lengths of cable for Type 1 and Type 2 applications. Compliant with all CCS standards, these ergonomic connectors have a low profile for quick connection and disconnection and can be used in a range of power charging applications. If required, products with company logos can be provided to enhance EVSE's branding. Despite their small size, they offer high performance, including:

CCS2 plug

· Silver-plated contacts for optimum performance and reliability

Integrated sensor according to CCS standard for monitoring the temperature of the power contacts and integrated locking mechanism

· According to DIN EN 50620, equipped with extruded insulation and sheath with rated voltage up to 1000 V, suitable for connecting EVSE and electric vehicles in harsh environments.

Compliant with IATF 16949 Automotive Standard and ISO 9001 Standard Requirements

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