Comprehensive Guide to Type 2 EV Charging Cables: Innovations and Tips for 2024
After more than 9,500 views of our original guide to EV charging cables, we thought it was high time we revisited this topic and updated it with the information our customers want. With advancements in cable technology over the past year, we've brought this guide up to date for 2024. So, here we go!
Welcome to our comprehensive guide on EV Type 2 charging cables. By the end of this blog update, you'll have all the information you need about these essential components, including the latest innovations and materials used in their construction. We'll cover the differences between male and female plugs, the IEC 62196 standard, the pin layout, the history of the Type 2 plug, and much more.
Introduction to EV Charging Cables
Electric vehicle (EV) charging cables have evolved significantly since the inception of EVs. There are different modes of charging cables: Mode 1, Mode 2, Mode 3, and Mode 4.
Mode 1: Mode 1 charging involves connecting the EV directly to a standard AC socket without any communication between the EV and the power supply. Due to safety concerns and lack of control, Mode 1 is largely deprecated and rarely used today.
Mode 2: Mode 2 charging is now the norm for slower, home-based charging. It uses a standard AC socket but includes an in-cable control and protection device (IC-CPD) that enhances safety by providing communication between the EV and the power source. This mode is suitable for overnight charging at home.
Mode 3: Mode 3 charging involves a dedicated EV supply equipment (EVSE) or charging station, which communicates directly with the EV to provide controlled, safe, and efficient charging. This mode is typically used for faster AC charging in public and semi-public locations, such as workplaces and commercial properties.
Mode 4: Mode 4 charging is for DC fast charging and uses an off-board charger to supply DC power directly to the vehicle’s battery. This mode allows for rapid charging at public charging stations, significantly reducing the charging time compared to AC charging modes.
Among these, the Type 2 charging cable, adhering to the IEC 62196 standard, has become the dominant standard in Europe and is gaining popularity worldwide.
Type 2 EV Charging Cables: The Standard in Europe
Type 2 EV charging cables, also known as Mennekes connectors, are the most common charging cables used in Europe. These cables connect an EV to a charging station or wall box, allowing the vehicle's battery to be charged efficiently and safely. They are used by many major EV manufacturers, including Audi, BMW, Mercedes-Benz, and Volkswagen.
Charging Standards in Other Continents:
- In North America, the standard is the Type 1 (SAE J1772) connector, commonly known as the J-plug. Some older UK models may also adopt this connector type.
- In Asia, particularly Japan, the CHAdeMO and GB/T standards are prevalent for fast charging, while Type 1 is also used for AC charging.
- In China, the GB/T standard is the dominant charging protocol for both AC and DC charging.
Male and Female Plugs (Connectors)
Type 2 charging cables feature male and female plugs. The male plug is located on the charging station or wall box, while the female plug, larger in size, is found on the charging cable. Both connectors have seven pins: CP, PP, N, PE, L1, L2, and L3. Single-phase systems (7.2 kW) use five pins (excluding L2 & L3), while three-phase systems (22 kW) utilize all seven pins.
Pin Layout and Application
The pin layout of Type 2 connectors is as follows:
- CP (Control Pilot): Communicates between the EV and the charging station.
- PP (Proximity Pilot): Detects the presence of the charging cable.
- N (Neutral): Serves as a return path for the current.
- PE (Protective Earth): Ensures safety by grounding the system.
- L1, L2, L3: Represent the three phases of AC power. L1 is used in single-phase systems, while all three are used in three-phase systems.
IEC 62196 Standard
The IEC 62196 standard defines the Type 2 charging cable and connector system for AC charging. This international standard specifies dimensions, performance requirements, and testing methods, ensuring all Type 2 connectors are compatible across different charging stations and EVs.
Evolution of the Type 2 Plug
The Type 2 plug has evolved significantly since its introduction. Initially developed with five pins, the current seven-pin version was standardised in 2013, allowing for higher charging speeds and enhanced safety. Today, these cables are widely used by major automotive manufacturers and are commonly found at public charging stations, homes, and businesses.
Inside the Handset: Material and Component Innovations
At EVSTOR, our handsets are constructed using advanced materials and components. The housing is made from C/PA66+GF30%, a composite material comprising nylon 66 reinforced with 30% glass fiber. This provides exceptional strength, heat resistance, and dimensional stability, ensuring the durability and reliability of the handset.
The exterior of the handset is coated with PC (Polycarbonate) and TPE (Thermoplastic Elastomer). PC offers high impact resistance and transparency, while TPE adds flexibility and a comfortable grip. Together, they ensure durability and ease of use. This new innovation is being phased in during Autumn 2024. Users should check individual listings for changes.
Furthermore, this 3rd generation handset has been designed from the ground up with no external fixings, thereby eliminating potential entry points for water ingress. This design feature enhances the overall IP rating, offering superior protection against environmental factors.
Our TPU (Thermoplastic Polyurethane) cables offer excellent flexibility, chemical resistance, and durability, making them ideal for both indoor and outdoor use. They remain pliable in cold temperatures and resist abrasion, ensuring a long service life.
Single-Phase vs. Three-Phase Charging Cables: What to Consider
When purchasing an EV charging cable, it’s essential to consider whether you need a single-phase or three-phase cable. Most modern EVs support an AC charge rate of 11 kW or 22 kW, meaning they are capable of three-phase charging.
Single-Phase Charging: Typically supports charging up to 7.4 kW. This is sufficient for overnight home charging and smaller applications.
Three-Phase Charging: Supports charging up to 22 kW, making it ideal for faster charging at public stations. Three-phase cables are backward compatible with single-phase supplies, meaning you can use them in both single-phase and three-phase situations.
Why Choose Three-Phase?
- Future-Proofing: While three-phase cables are slightly more expensive, they future-proof your investment. As public charging infrastructure continues to improve, having a three-phase cable ensures you can take advantage of higher power supplies.
- Flexibility: If you frequently charge away from residential properties, a three-phase cable allows you to benefit from the increasing availability of faster public charging stations.
- Compatibility: Using a three-phase cable with a single-phase supply works seamlessly, providing flexibility regardless of the charging situation.
Always check your EV’s owner manual to confirm support for three-phase charging to make the most of your investment.
Latest Innovations at EVSTOR
We are excited to introduce several new innovations at EVSTOR:
Automated Manufacturing: We now make use of an automated manufacturing process, significantly enhancing the consistency and quality of our EV cables. This technology reduces human error, ensures precise assembly, and speeds up production, resulting in superior products at competitive prices.
New Handset Covers: Launching in Autumn 2024, our new handset covers feature a "gravity-assisted drainage design." This unique feature prevents water from accumulating inside the cover, thereby protecting the charging pins from corrosion. Made from TPE and attached with a durable nylon cord, these covers are more robust than their silicone predecessors and represent the first of their kind in the market.
Range of Cable Lengths and Their Uses
We offer a variety of Type 2 EV cables to suit different needs:
- 3 Metre Type 2 EV Cables: Ideal for home use where the charging station is close to the vehicle.
- 5 Metre Type 2 EV Cables: Offers more flexibility for home and public charging stations.
- 7.5 Metre Type 2 EV Cables: Provides additional reach, useful in larger garages or public charging with limited parking space.
- 10 Metre Type 2 EV Cables: Great for situations where the charging station is farther from the vehicle, such as in parking lots.
- 15 Metre Type 2 EV Cables: Offers maximum reach, useful for commercial settings or large properties.
Conclusion
Understanding the components and innovations in Type 2 charging cables is crucial for EV owners. With our comprehensive range and cutting-edge manufacturing processes, EVSTOR is at the forefront of providing reliable and efficient EV charging solutions. Keep an eye out for our new products and continue to enjoy the benefits of electric driving!
