What is an EV Charging Connector?

Meet the Connector: EV Charging Connectors

EV charging connectors are used to charge electric vehicles. They connect the vehicle to charging infrastructure, whether that be a “pump” type charger or a suitable high-voltage outlet in a building. The plug end (or male connector) delivers power from an electricity source to the port end/inlet (or female connector) on the vehicle. EV charging connectors (or charging plugs) are available for AC or DC.

As of 2024, several types of EV charging connectors exist, each with specific characteristics. The type of connector used varies by geographic region or vehicle manufacturer. However, beginning in 2024 or 2025, most U.S. and European manufacturers will move to a single standard, the NACS (North American Charging Standard) connector, standardized as SAE J3400. This interface was developed by Tesla as part of its Supercharger network. This five-pin connector AC single and three phase charging, as well as high-speed DC charging. Tesla’s latest chargers can deliver up to 250 kW to suitably equipped vehicles.

Previous generations of vehicles will continue to use a variety of interfaces, and connector adapters will enable them to access a charge at NACS-equipped charge points.

AC Charging Plugs are either Type 1 or Type 2. Type 1 is a single-phase plug that is common in American vehicles. It has a charging speed of up to 7.4 kW. Type 2 is standard in European and Asian vehicles manufactured in 2018 and beyond. It is a triple-phase plug and can charge up to 43 kW.

The SAE J1772 (also known as a J plug) is an IEC 62196 Type 1 connector and is a North American standard that covers the physical, electrical, and communication protocol, as well as performance requirements for the EV conductive charge system and coupler. The standard defines a common EV conductive charging system architecture that includes operational requirements and the functions and dimensions required for the vehicle inlet and mating connector.

SAE J1772 AC Charging Coupler from BizLink is an industry-standard vehicle connector for convenient EV and EVSE (Electric Vehicles Supply Equipment) charging. Contact assemblies are sealed against moisture and corrosion and are UL 2251 recognized, resistant to common automotive fluids.

The IEC 62196 Type 2 connector (also known as Mennekes for the company that created the design in 2009). It is a circular connector with a flattened top edge, used mainly in Europe and was selected by the European Commission as the official charging plug of the European Union in 2013. In North America, it was released under the name SAE J3068, a three-phase AC connector, and in the China as the Guobiao standard GB/T 20234.2-2015 for AC-charging.

DC Charging Plugs are either CHAdeMO or CCS. CHAdeMO is used in Asian vehicles for high charging capacities and bidirectional charging. Bidirectional charging allows fully charged vehicles to act as a generator during power outages by returning power to the home or grid. CCS (combined charging system) Is a charging connector which combines the AC charging with two DC conductors and has two additional power contacts. The CCS is capable of very fast charging.

“We started with 125 amps at 500 volts. That comes out to a little over 50 kilowatts. About ten-years-ago that was sort of like the fast charging DC standard,” said Kirk Hilbourn, EV charging product marketing manager at JAE. “But now moving forward, we are in the process of developing a CCS type-1with output capabilities of up to 200 kilowatts. And as we’re trying to develop this, we are already hearing, okay, we need to see 300 amps.”

KW1C series connectors from JAE are CHAdeMO compliant and designed to be used with fast chargers. Approximately 20% lighter with the use of a weather resistant resin material, KW1C was designed with stainless steel for critical components to maintain high reliability. The design has been enhanced for user-friendly charging.

Design Notes

SAE J1772 (J plug) is a 5-pin connector. When attached to a standard home power socket, it supports single-phase AC charging at 1.44 kW. When installed on a higher-speed EV charging stations it can reach 19.2 kW. The J plug carries single-phase AC power on two conductors, signalling on two additional conducts, and a protective earth connection on the fifth conductor.

Type 2 Mennekes is a 7-pin connector design that carries single-phase or three-phase AC power, which allows vehicles to charge at up to 43 kW (although many Type 2 chargers max at 22 kW or less. Similar to the J plug, it features two pins for signalling pre-insertion and post-insertion, and has a protective earth, a neutral, and three conductors for the three AC phases.

CCS accommodates both AC and high-speed DC charging. Combo 1, used in the North American market (and some Asian countries) combines a Type 1 J1772 AC connector with two large DC conductors. Combo 2, used in the European market, combines a Mennekes connector with two large DC conductors.

ITT Cannon’s CCS 1 DC Fast Charging connector designed to SAE J1772 standards provides up to 150A continuous charging and power up to 150kW. Various amperage and cable length options make it suitable for a wide variety of customer applications.

CHAdeMO, developed primarily for fast-charging applications, can deliver up to 400 kW. Primarily used in Japan, despite Japanese automakers backing a proposal for global use in 2010, it was the first standard that set out to provide DC fast charging to EVs regardless of manufacturer. It features CAN bus pins for communication between vehicle and charger. A CHAdeMo 3.0 standard (ChaoJi) has been in development since 2018. It features a completely new 7-pin connector design, developed in partnership with the Standardization Administration of China. ChaoJi uses liquid-cooled cabling to reach, ideally, charging rates up to 900 kW, while running at 1.5 kV and delivering a full 600 amps.

The name CHAdeMO, short for “CHArge de MOve”, derives from a Japanese phrase that translates to English as “How about a cup of tea?”, referring to the time it would take to charge a car.

T

iConnector’s EU AC 32A Plug has a rated voltage of 250/440V AC and a rated current of 16A/32A 1 or 3 Phrase.

GB/T 20234.3 standard, used only in China, covers both single-phase AC and DC fast charging. Rated to run at up to 1,000V DC and 250 amps, it provides charging speeds up to 250 kW.

Markets, Sectors, and Applications

• Automotive
• EVs and HEVs
• eVTOLs
• electric marine vehicles

Suppliers

Amphenol Communications Solutions, BizLink, iConnector,  ITT Cannon, and JAE

Related products:

• J1772 connectors
• Type 2 Mennekes connectors
• CCS chargers
• CHAdeMo chargers

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