AC AND DC CHARGING

PARTS OF EV CHARGER
1) AC/DC converter
2) Charging port, cable and connector
3) BMS and charge controller
On-board charger/ AC charging: Maximum power 1.9-22 kW
o Size restrictions
o Weight restrictions
Off-board charger/ DC charging: Maximum power 50-350 kW

 CONNECTOR TYPE & POWER LEVEL

AC charging types: -
• The EV industry has not agreed on one specific AC connector, so depending on the
car brand and country, the connector varies in shape, size and pin configuration. One
of the main reasons is the difference in AC voltage and frequency.
• For e.g. In US 120V, 60Hz single phase AC or 240V,60Hz dual phase AC is used on
the other hand in Europe 230V, 50Hz single phase AC or 400V,50Hz three phase AC
is used.

• 4 types of AC connectors are used worldwide.

o The Type 1 connector, which is mostly used in USA & Japan.

o The Type 2 connector, which is mostly used in Europe, including those of Tesla cars.

o The Type 3 connector, used in Europe but is being increasingly phased out by Type 2
connectors.

o The proprietary connector used by Tesla for its cars in the USA

o China has its own standard for AC charging, which is similar to Type 2 connectors.
 Fig: TYPE-1 Fig: TYPE-2

Fig: Proprietary charger in US

Type1
• L1 and L2 for single phase AC
• Two AC pins, one earth and 2 signal pins
• Voltage and current ratings: voltage 120V or 240V; current up to 80A
Type2
• Both single and three phase AC charging
• Two signal pins and five power pins
 • Voltage and current ratings: 1 phase 230V, up to 80A;
3 phase 400V, up to 63A
Tesla US connector
• USA -proprietary connector, Europe- Type2
• Same connector for AC and DC
• Maximum AC power of 17.2kW when connected to 240V AC

Control and Proximity pilot

• The Type 1 and Type 2 connectors have 2 common communication pins: the Control
Pilot (CP) and the Proximity Pilot (PP).
• The Proximity Pilot (PP) checks if the vehicle connector is connected properly to the
vehicle inlet. If the connection is not properly established, the Proximity Pilot will
detect it, and the entire process will be disabled for safety.
• The second special pin is the control pilot (CP), and it is used for controlling the
charging current. The control pilot continuously sends a pulse width modulated or
PWM signal to the car. In this way, it tells the car the maximum current that can be
drawn from the charging station, Imax. The car then can draw the desired current Iac,
as long as this value is smaller than the maximum current Imax.

DC charging types:
There are five types of DC charging connectors used globally
o The CCS-combo 1, which is mainly used in the US,
o The CCS-combo 2, which is mainly used in Europe,
o The Chademo connector, used globally for cars built by Japanese automakers.
o The Tesla DC connector, which is used for AC charging as well
o And finally, China has their own DC connector, based on the Chinese GB/T standard.
 Fig: Combo-1

Fig: Combo-2

CCS combo 1 and 2

• CCS means combined charging system
• CCS are integrated connectors for both AC and DC charging
• combo-1 is shown on left side and vehicle inlet is shown on right side
• CCS combo-1 is derived from AC type-1 connector
• vehicle inlet for both AC and DC charging
• max current 350A
• voltage range 200-1000V
• max power 350kW
CHADEMO
• 3 power pins
• 7 signal pins
• CHAdeMO v1.2: 50-500V, up to 400A up to 200 kW

Fig: CHAdeMO

China GB/T standard

• 5 power pins- 2 for DC power, 2 for low voltage auxiliary power & 1 for ground
• 4 signal pins- 2 for proximity pilot and 2 for control area network communication.
• Nominal voltage 750V to 1000V
• Maximum current 250A
DISADVANTAGES OF FAST CHARGING

• Higher charging current leads to higher overall losses both in the charger and in the
battery. As the charging currents increases, the effective capacity of the battery
decreases as well.
• The battery C-rate increases with fast charging and this reduces the battery lifetime
due to the heat produced and increased degradation due to the higher temperature.
• When fast charging a battery, the SOC of the battery can only be reached till 70-80%.
This is because fast-charging creates a lag between the voltage and state-of-charge
and this phenomenon increases as the battery is being charged faster. Hence, fast
charging is typically done in the constant current or CC region of the battery charging
and after that, the charging power is reduced in the constant voltage or CV charging.
• For any EV charger, it is important that the cable is flexible and lightweight for
people to use and connect it to the car. With higher charging power, thicker cables are
needed to allow more charging current, else it will heat up due to the losses.