EV Charging Connector

EV Charging Connectors & Cables

For the past 50 years, KST has literally stamped its reputation as a leading global manufacturer of electrical terminals and automotive connectors.  In 2012, leveraging decades of stamping and injection mold experience,  KST expanded its portfolio to include EV Charging Connectors and cable assemblies.

Today, through research & development, KST has an innovative range of AC/DC charging solutions for residential, industrial, and commercial charging station (EVSE) scenarios and EV applications.

Figure 1. KST EV charging connector types by region and AC/DC inlet capabilities, for residential, workplace and charging station scenarios.

AC EV Charging Connectors & Cables

SAE J1772 (Type 1) - UL 2251 / US & Canada | IEC 62196-2 / Europe, India, Thailand
Figure 1. KST EV charging connector types by region and AC/DC inlet capabilities, for residential, workplace and charging station scenarios.

The Society of Automotive Engineering (SAE) defines the general physical, electrical, communication, and performance requirements for EV charging systems used in North America, as part of the SAE J1772 standard. Below are the current charging levels that are practiced in the North American market.

SAE J1772 (Type 1) is a single-phase connector and is a standard for EVs in North America and Japan. It allows you to charge your car at a rate of up to 19.2 kW. Of course, this is contingent on the compacity of your car’s onboard charger, voltage, and amperage grid capability.

Charging “levels” are specific to SAE J1772 and are used to categorize the rated power, voltage, and current of the charging system. The evolving standard currently has 2 different EV charging levels for AC Charging.

  • AC Level 1: Residential charging from a standard 120V outlet with a maximum current of 12 or 16A. This delivers a maximum power of 1.44kW or 1.92kW. In this configuration, the EV’s onboard charger converts AC to DC.
  • AC Level 2: Residential, Workplace charging from a standard 240V outlet or from a dedicated EV charge point (EVSE). In this scenerio, 240V AC, with a maximum current of 80A provides for a maximum power of 19.2KW. In this configuration, the EV’s on-board charger converts AC to DC.

AC EV Charging Connectors & Cables

IEC 62196 (Type 2) - Europe, India, Thailand
Figure 1. KST EV charging connector types by region and AC/DC inlet capabilities, for residential, workplace and charging station scenarios.

IEC 62196 Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive charging of electric vehicles is a series of international standards that define requirements and tests for plugs, socket-outlets, vehicle connectors and vehicle inlets for conductive charging of electric vehicles. (“IEC 62196 – Wikipedia”)

IEC 62196 (Type 2) connectors have three additional wires allowing for triple-phase power and current providing for higher charging rates when compared to single-phase SAE J1772 Type 1 connectors. For residential charging, the highest charging rate is 19.2 kW, while charging stations can achieve charging rates of up to 43 kW. Again, this is  dependant on the compacity of your car’s on-board charger, as well as the your scenarios voltage and amperage grid capability.

AC EV Charging Connectors & Cables

GB/T 20234 - China
Figure 1. KST EV charging connector types by region and AC/DC inlet capabilities, for residential, workplace and charging station scenarios.

GB/T 20234 Plugs, socket-outlets, vehicle connectors, and vehicle inlets – Conductive charging of electric vehicles is a series of international standards that define requirements and tests for plugs, socket-outlets, vehicle connectors, and vehicle inlets for conductive charging of electric vehicles.

The AC standard (GB/T 20234.2) EV connector and inlet use the same interface connector as the European IEC 62196-2 Type 2 connectors but the gender of the GB/T 20234.2 connector and inlet has been reversed.  GB/T 20234.2 specifies a male connector and female vehicle inlet.  Like IEC 62196-2 Type 2 EVSE Outlets and Plugs,  GB/T 20234.2 also specifies a female Charging Station Outlet and a male Charging Station plug.  Furthermore, GB/T 20234.2 uses CC/CP (charging confirmation and control pilot) signals. IEC 62196-2 specifies PP/CP (proximity pilot and control pilot) signaling.

It allows mode 2 (250 V) or mode 3 (440 V) single-phase AC charging at up to 8 or 27.7 kW, respectively. In Mode 2, power is supplied with a current of 10/16/32A and a voltage of 250V. In Mode 3, power is supplied with a current of 16/32/63A and a voltage of 440V.  Although the seven-pin interface does support three-phase AC power,  KST’s current product offering only supports single-phase power.

In general, charging speeds are also limited by the vehicle’s onboard charger, which is usually less than 10 kW. The onboard charger converts the AC input power to DC.

AC/DC Combination EV Charging Connectors & Cables

CCS1 - United States & Canada | CCS2 - Europe, India & Thailand

The Combined Charging System (CCS) is a standard for charging electric vehicles, which uses Combo 1 and Combo 2 AC/DC inlets which can be used with both AC and DC connectors to provide power at up to 400kW. These connectors, both inlets and plugs are an extenstion of the SAE J1772 (Type 1) and IEC 62196 (Type 2) connectors. These connectors have two additional direct current (DC) contacts to support high-power DC fast charging. CCS plugs support DC charging only.

AC/DC Combination EV Charging Connectors & Cables

CCS1 | United States & Canada
https://ksterminals.com/wp-content/uploads/CCS1-Charging-connector-1-160x160.jpg

The CCS1 connector is an enhanced version of the Type 1 connector, with two additional DC power contacts for the purpose of fast charging. CCS1 EV Charging Inlets support AC and DC charging.

AC/DC Combination EV Charging Connectors & Cables

CCS2 | Europe, India, and Thailand
https://ksterminals.com/wp-content/uploads/CCS2-Charging-connector-1-160x160.jpg

The CCS2 connector is an enhanced version of the Type 2 connector, with two additional DC power contacts for the purpose of fast charging. CCS2 EV Charging Inlets support AC and DC charging.

Charging “levels” are used to categorize the rated power, voltage, and current of the charging system. The standard currently has 2 different EV charging levels for DC charging.

  • DC Level 1: EVSE DC charging ranging from 50 to 1000V, with a maximum current of 80A and a maximum power of 80kW.
  • DC Level 2: EVSE DC charging ranging from 50 to 1000V, with a maximum current of 400A and a maximum power of 400kW.

DC EV Charging Connectors & Cables

GB/T 20234.3 | China
DC EV Charging Connector - GB

The DC charging standard (GB/T 20234.3) uses a different charging interface than in North American and European markets.  Instead, the GB/T20234.3 standard specifies a larger connector that supports charging at up to 250 kW and supports current of 80/125/200/250A and voltage of 750-1000V.  

There are four pins for signaling: two to provide charging confirmation (CC1 / CC2) and two for communication via CAN bus (S+ / S-). 

EV Charging Connector Terminology

EV Charging Connector Terminology

EV Charging Connectors

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