DC Vehicle Connector CCS2 (300A)

Product name

European standard DC charging gun

Model number

CPED300A****E-V2xx

(...Indicates rated current, * * * * indicates cable length, xx represents the serial number)

Rated voltage

DC1000V

Rated current

Power line: 300A signal line: 2A

Number of terminals

Power wire: 2 ground wire: 1 signal wire: 2

Applicable standards

• IEC 62196.1-2014 Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive charging f electric vehicles - Part 1: General requirements

• IEC 62196.3-2014 Plugs, socket-outlets, vehicle connectors and vehicle inlets - Conductive charging of electric vehicles –Part 3: Dimensional compatibility and interchangeability requirements for d.c. and a.c./d.c. pin and contact-tube vehicle couplers

• IEC 61851.1-2001 Electric vehicle conductive charging system - Part 1: General requirements

• IEC 60309.1-2012 plugs, socket-outlets and couplers for industrial purposes - Part 1: General requirements

Operating Ambient temperature range

﹣35～+50℃

Both use under condensation and freeze is prohibited.

Degree of protection

IP44

Dimension

Charging gun

(L) 274 * (W) 74 * (H) 175 (mm)

Cable

Length according to customer requirements

Cable cross section

Resistance wiring diagram

（The resistance 3 # line is connected

the 3 # ground wire, and the resistance 4 #

is connected to the PP signal terminal）

Core number

Core color

Terminal

Sectional area of core conductor (mm2)

300A

1

Brown

DC+

3x35

2

Blue

DC-

3x35

3

Yellow /

Green

PE + Resistance lead

35

4

Black

PP (Resistance lead)

0.75

5

Orange

CP

0.75

6

Violet

WK1+

（The negative lines oftemperature sensors WK1 and WK2 are connected to line 8 #）

7

Pink

WK2+

Serial number

Part name

Material

surface treatment

Remarks

1

Charging gun shell

PBT+PC

-

Color: Cold gray

2

Charging gun head

PA66+GF25

-

Color: Black

3

Ground terminal

Brass + red copper

silver

-

4

Signal terminal

brass

silver

-

5

Power terminal

Brass + red copper

silver

300A

Brass

silver

6

Sealing ring

(inside the housing)

Silica gel

-

-

7

Cable snap ring (inside the housing)

Aluminum alloy

anodic oxidation

-

8

Resistance

(inside the housing)

-

-

-

9

Temperature sensor (inside the housing)

-

-

-

10

Electric vehicle cable

TPU (outer sheath)

-

-

1) Charging gun shell

Consists of high-incombustibility, -insulation and – weather resistance resin materials, PBT+PC (UL94-V-0）.

2) Charging gun head

Composed of high incombustibility, insulation and wear resistance nylon plus glass fiber material, PA66 + GF25 (UL94- V-0)

3) Ground terminal, Power  terminal

Composed of brass alloy and pure copper, the whole terminal is silver plated, T2 or H62.

4) Power terminal (300A)

It is composed of a stainless steel sleeve that wraps the jack end of the high-conductivity copper material, and then cooperates

with the crimping end of the pure copper material. The entire terminal is silver-plated, T2.

5) Signal terminal

Composed of brass material, the terminal is silver plated, H62.

6) Sealing ring

Composed of high incombustibility, insulation and weather resistance silicone material

7) Cable snap ring

The cable snap ring suitable for 300A cable is forged by aluminum alloy material;

8) Resistance

Resistance R=1500 ± 1% Ω.

9) Temperature sensor

Model: PT1000, R0 ℃ = 1000Ω.

10) Electric vehicle cable

The structure is shown in Table 3, 5 and figure 3. 10-1) Reference standard:

• IEC 60228 Conductors of insulated cables

• IEC 62893-1 Charging cables for electric vehicles for rated voltages up to and including 0,6/1 kV - Part 1: General Requirements

• IEC 62893-2 Charging cables for electric vehicles for rated voltages up to and including 0,6/1 kV - Part 2: Test methods 10-2) technical requirements:

(1) Rated voltage: 1000V;

(2) Ambient temperature: - 40 ~ 90 ℃;

(3) Conductor resistance (20 ℃): 35mm2≤0.554Ω/Km、0.75mm2≤26Ω/Km；

(4) Main line: line-line insulation impedance: 1000V DC 15min ≥ 500m Ω; leakage current: 3500V DC 15min ≤ 5mA;

(5) Bending radius of cable: ≤ 6D;

(6) UV resistance: ISO 4892-3 (1000H, no discoloration, no cracking, tensile strength retention rate, elongation at break

≥80%);

(7) Weather resistance, friction resistance, halogen-free, rocking test, low temperature impact test, meandering test, damp heat test, high and low temperature cycle test, anti-extrusion test, compatibility test, chemical liquid resistance and other tests refer to IEC60228 , IEC62893-1 and IEC62893-2.

Explain

Unit

Cable specification

300A

structure

DC line structure

Conductor

Specification structure

mm²

3*35

Insulation

Colour

-

Brown, Blue

PE line structure

Conductor

Specification structure

mm²

1*35

Insulation

Colour

-

Yellow / Green

Signal line

structure

Conductor

Specification structure

mm²

（4*0.75）P

Insulation

Colour

-

Black, Orange, Purple, Pink

Outer sheath

Texture of material

-

TPU

External diameter

mm

37.5±0.05

Colour

-

black

Reference standard

Items

IEC62196-1 15

Resistance to ageing of rubber and thermoplastic material.

IEC62196-1 20

IP degree and humidity

IEC62196-1 21

Insulation resistance and dielectric strength.

IEC62196-1 23

Normal operation

IEC62196-1 24

Temperature rise

IEC62196-1 25

Pull force on cord anchorage

IEC62196-1 26

2. Impact blow test, 3. Drop test, 4. Flexing test,

IEC62196-1 27

Torque test on screws or nuts

IEC62196-1 29

Resistance to heat, fire and tracking

IEC62196-1 30

Corrosion and resistance to rusting

IEC62196-1 31

Conditional short-circuit current withstand test

Items

Decision criteria

1

Appearance

The accessible surface of the charging gun should be free of burrs, flashes and similar sharp edges; the casing of the charging gun should be marked with the manufacturer's name or trademark, product model, rated voltage and rated current, etc.

2

Dimension

The external dimensions of the charging gun meet the requirements of the IEC62196-3 standard

3

Temperature rise

The maximum allowable temperature rise of the terminal should not exceed 50K

4

Insulation resistance

> 10MΩ (Applied voltage: 500V DC, 1 minute)

5

Withstand voltage

3500V AC Leakage current ≤10mA, no breakdown or flashover in 1 minute

6

Charge gun insertion/withdrawal

force

< 100N

7

Cable retention force

The cable must not fall out of the charging gun case.

8

Drop test

The specimen shall not be damaged and there shall be no separation or fall off of any parts in the gun shell

9

Vehicle drive over test

The specimen shall not be damaged and there shall be no separation or fall off of any parts in the gun shell

10

Service life test

Conduct no-load live plugging 10000 times, during the test, there shall be no continuous flash arc, after the test, there shall be no:

1. Deterioration without shell or partition;

2. No electrical connection or mechanical connection is loose;

3. Keep the continuity of signal transmission between contacts;

4. There shall be no flashover or breakdown during dielectric strength test (voltage reduced by 500V);

11

Protection level

Internal protection of gun shell IP67

12

High temperature resistance test

The sample is not damaged and can be used normally (check the sample after returning to room temperature.)

13

Low temperature resistance test

The sample is not damaged and can be used normally

(check the sample after returning to room temperature.)

Items

Test Method

1

Appearance

Check the surface condition visually and manually.

2

Dimension

Matching test

3

Temperature rise

Supply current according to product specification, measure the temperature of the following points.

Test point: 

- DC terminal contact point surface

-Shell surface

4

Insulation resistance

Insulation resistance tester plus 500V DC voltage to measure the insulation resistance between adjacent terminals and between each terminal and the shell

5

Withstand voltage

Apply 3500V AC voltage between adjacent power terminals and between power terminals and housing for 1 minute

6

Charge gun

insertion/withdrawal

force

When the vehicle charging base is fixed, measure the insertion / pull-out force of the charging gun head at the specified speed (excluding the insertion / pull-out force of the rubber seal of the vehicle charging base).

7

Cable retention

force

In charging gun fixed condition, apply 753±1 N×120s to cable out direction from charging gun.

8

Drop test

Lift the test sample to a predetermined height, and then let it fall freely according to the predetermined state and collide with the impact table.

9

Vehicle drive over

test

Roll over the connector which is placed naturally on concrete floor with the wheel of 2t vehicle.

10

Service life test

10,000 times of no-load live plugging and unplugging.

11

Protection level

• Swing tube type water spray test: 

select a swing tube of appropriate radius so that the height of the sample table is at the diameter of the swing tube, place the sample on the sample table so that the distance from the top of the sample to the sample spout is not more than 200mm, the sample table Does not rotate. 

• Test condition: 

The water flow is calculated according to the number of spray holes of the pendulum tube, and each hole is 0.07 L / min.

When spraying water, spray water from the spray holes in the 90 ° arcs on both sides of the midpoint of the pendulum tube to the sample. 

The test sample is placed in the center of the semicircle of the pendulum tube. 

The swing tube swings 180 ° on both sides of the vertical line for a total of 360 °. 

Each swing (2 × 360 °) is about 12s. 

• Test time: 

continuous watering for 10 min.

12

High temperature

resistance test

Put the charging gun in the thermostat (105 ℃ × 1000 hours).

13

Low temperature

resistance test

Put the charging gun in the thermostat (- 35 ℃ × 120 hours).