ccs2 ev connector

What CCS2 Is (Geometry and Standards)CCS2 (Combo 2) is a Type 2 AC inlet with two additional high-current DC contacts under the circular Type 2 portion. The upper section carries L/N or 3-phase AC plus CP/PP (control pilot/proximity).   The lower oval carries DC+ and DC− with low contact resistance. Physical interfaces reference IEC 62196-2 (AC) and IEC 62196-3 (DC). Communication during DC relies on PLC per ISO 15118 or DIN 70121.     Form Factor and Pin Functions• Type 2 section: AC phases, PE, CP (PWM duty announces permissible current), PP (plug presence and cable rating).• DC blades: large cross-section, silvered contact surfaces, spring-loaded force profile to stabilize R_contact across cycles.• Latch and microswitch: confirms mechanical lock; the charger inhibits contactor closure until lock is verified.     Power, Voltage, and CurrentLiquid-cooled CCS2 assemblies are designed for up to ~1000 V and ~500 A. That equals a headline ~360 kW, but sessions rarely sit there. Delivered power is bounded by:• the pack voltage curve vs state of charge (SoC),• the station’s sharing policy across dispensers,• thermal margins in cable, handle, and vehicle inlet. Temperature rise scales ~I²·R_contact. Above ~300–350 A, liquid cooling substantially lowers handle shell temperature and delays thermal derate.     AC vs DC Under CCS2Type 2 AC remains the workhorse for long dwell: 7.4 kW single-phase, 11–22 kW three-phase, with legacy 43 kW cases. CCS2 DC provides the step change for turnaround charging. The same inlet accepts both: a Type 2 plug for AC, a Combo 2 plug for DC.     Where CCS2 Is UsedCCS2 is standard across the EU and other Type 2 markets (Oceania, parts of MEA). North America historically adopted CCS1, but cross-region vehicles and site adapters exist. For planning, match the local vehicle park and regulations first; do not optimize for a single global connector.     When Liquid Cooling Becomes Non-NegotiableHigh current and high ambient shorten the thermal runway. Liquid-cooled leads, with internal coolant channels and NTC/RTD sensing near contacts, allow graded derate instead of abrupt cut-offs. In summer (≈35 °C) many vehicles sustain 180–220 kW through 40–70% SoC with liquid-cooled handles, whereas air-cooled leads hit temperature thresholds earlier and force down-ramps.     How a CCS2 DC Session Works 1. Mechanical lock; PP/CP validation. CP PWM duty sets a current envelope. 2. PLC link (ISO 15118/DIN 70121). Vehicle BMS and charger exchange V/I limits and safety budgets. 3. Pre-charge and contactor close; current ramps while the charger samples I, V, insulation status, and multiple temperature channels (handle shell, contact vicinity, power stack). 4. If any channel approaches a limit, the charger derates in steps. True faults trigger a controlled open. 5. As SoC rises, the BMS transitions to a constant-voltage phase and requests taper; the session ends cleanly.     Specification Snapshot Spec focus CCS2 (Combo 2) expert view AC base Type 2 (IEC 62196-2) DC interface Two high-current pins (IEC 62196-3) DC voltage window (typical) Up to ~1000 V DC current window (typical) Up to ~500 A with liquid-cooled cable Headline DC power Up to ~360 kW (vehicle/thermal budgets apply) AC capability 7.4 kW single-phase; 11–22 kW three-phase; legacy 43 kW Cooling options Air-cooled (mid-power) / liquid-cooled (high-power duty) Reliability drivers Low R_contact, clamp force stability, latch health, strain relief     Decision Matrix for Site Planning Site type Per-bay target Cable choice Notes that reduce risk Highway hub 250–350 kW typical Liquid-cooled CCS2 Favor 920–1000 V packs; keep leads short; stock spare handles Urban mixed-use 150–200 kW + AC bays Air-cooled DC + Type 2 AC Clear AC/DC wayfinding; bollards to prevent curb strikes Fleet depot 150–250 kW by schedule Liquid-cooled CCS2 (+ AC) Size to dwell; standardize inlet orientation across parking Workplace/retail 11–22 kW AC + 150 kW Type 2 AC + air-cooled DC AC carries the load; DC for top-ups and exceptions     Two Micro-Scenarios (Set Expectations)• Summer highway, 35 °C ambient: sustained 180–220 kW at 40–70% SoC is common with liquid-cooled handles; air-cooled often derates earlier.• Depot with predictable dwell: a steady 150–200 kW lane beats chasing 300 kW peaks—lower capex, fewer thermal events, higher net throughput.     Reliability and Maintenance (Threshold-Driven)Move from “best effort” to measured triggers:• Contact resistance: track in mΩ vs baseline; +20–30% enter watchlist; +50% schedule replacement.• Handle shell temperature: repeated >60–65 °C in 25–30 °C ambient indicates insufficient margin.• Latch and CP/PP stability: rising re-plug counts or CP duty jitter → inspect spring and guides.• Station KPIs: derate events per 1,000 sessions and dT/dt under standard ambient; use for spares and staffing.     CCS2 vs Type 2 Type 2 is the AC plug for longer stops. CCS2 looks the same plus two DC pins for fast charging. If your car has CCS2, you can use both AC (Type 2) and DC (Combo 2). If your car is Type 2-only, DC fast charging via CCS2 is not supported; the vehicle lacks DC hardware and signaling.     Compatibility Notes for Customer GuidesAdapters can bridge shapes. They cannot add DC capability the vehicle does not have. AC is forgiving; DC is strict. Make this explicit to reduce failed sessions and support calls.   Light Product Anchors • liquid-cooled DC connector options — for high-duty highway lanes and depots• Type 2 portable charger — for home and workplace AC needs     FAQWhat DC power should I design for at a highway bay?Target 250–350 kW per bay with liquid-cooled leads. Use cabinet power sharing to maintain utilization.   Why is live power below the label?Labels assume high pack voltage and stable current. Real sessions taper with temperature and SoC. Shared cabinets redistribute power across plugs.   Do all sites need liquid-cooled cables?No. Air-cooled serves mid-power and long dwell well. Use liquid-cooled for sustained high current and comfortable handle temperatures in summer.   Can one inlet cover AC and DC?Yes. A CCS2 inlet accepts a Type 2 AC plug and a CCS2 DC plug.   What should I log for preventive maintenance?Max handle temperature, contactor cycle count, latch-related aborts, derate frequency at normal ambient. Replace parts on resistance and temperature trends, not just visible wear.