Charging cable for electric cars
Fortunately, the big cable and plug chaos from the early days of electromobility is a thing of the past. Nevertheless, the topic of charging cables for electric cars is not as trivial as one might assume. In addition to different charging modes, there are different types of plugs. Here you will find a short and understandable description of all variants.
Charging modes for electric cars: The most important things in brief
In the case of electric cars, a distinction is made between four different types of charging. You need the right cable for each charging mode. There are these four charging modes:
- Mode 1 charging: Charging with alternating current at a normal socket
- Mode 2 charging: Charging with AC power at normal socket with in-cable control box
- Mode 3 charging: Charging with alternating current at a stationary charging station
- Mode 4 charging: Charging with direct current at a stationary charging station
What charging cables are there for e-cars?
The two most common car charging cables are the Mode 2 charging cable and the Mode 3 charging cable. The difference is quickly explained:
- The Mode 2 charging cable connects the e-car to any normal household socket. In order not to overload them, an in-cable control box (ICCB) is integrated to control the charging process. As a rule, this type of charging is only recommended for emergencies, as the charging process is not very efficient and the household socket is not designed for this high load.
- The Mode 3 charging cable connects the e-car directly to a charging station or wallbox. This is the most common way to charge an electric car.
Most e-car manufacturers include a Mode 2 charging cable with the vehicle. This allows the electric vehicle to be charged at any ordinary socket. Since a household socket does not have the control and protection functions of a wallbox – such as current limitation or DC fault monitoring – the in-cable control box takes over these functions.
The in-cable control box limits the charging current to a maximum of 13 amps. In addition, a temperature sensor is installed, which automatically ends the charging process if the socket overheats. The disadvantage: Due to the limited charging power, the charging time is considerably longer and the charging losses increase. Mode 2 charging cables are therefore also referred to as emergency charging cables by some car manufacturers.
The Mode 3 charging cable connects the vehicle directly to a wallbox or e-charging station. Mode 3 cables are available in different versions: in a single- or three-phase version and for currents of 16, 20 or 32 amps. The higher the possible current, the faster the charging process. However, a cable that can withstand a high current is also heavier and more expensive. Here it is important to find a good compromise between handling, costs and performance.
Mode 1 and Mode 4 charging cables
For the sake of completeness, it should be mentioned that there are two other charging modes. "Mode 1" is the term used to describe charging at a household socket with a cable without an ICCB box. The plug is connected directly to the socket on the mains side. This means that the charging interface is immediately energized. The maximum charging current is limited to 16 amps and 11 kW. It is strongly advised not to charge the e-car in this way. There is a high risk that cables or sockets will become too hot and cause a fire. To rule this out, the plugs usually do not fit together.
Last but not least, there is also the Mode 4 charging cable. This is always permanently installed on a Mode 4 charging station and is therefore not available in stores. It is a cable that enables particularly fast DC charging. In this process, alternating current is converted into direct current in the charging station and fed directly to the vehicle's battery. A Mode 4 charging station needs an input voltage of 480 volts or more. This type of charging is also known as "DC charging", where "DC" stands for "direct current".
The fastest form of DC charging is called "High Power Charging" (HPC) and enables a charging power of up to 350 kW. In China, ultra-fast 450 kW charging stations are already on the market. They are also to be available in Europe from autumn 2024. Porsche already presented a prototype in 2018 that enables charging with 450 kilowatts. This theoretically enables charging times of less than three minutes for a range of 100 kilometres.
Buying tips for e-car charging cables
Before purchasing a charging cable, you should be clear about the following points:
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Power: There are car charging cables for a maximum of 11 kilowatts or for a maximum of 22 kilowatts. 22-kilowatt cables are heavier, thicker and more expensive than 11-kilowatt cables, but enable faster charging – provided that the on-board charger of the electric car allows charging with 22 kilowatts. If it can only absorb 11 kilowatts, charging with a 22-kilowatt cable is possible. But it doesn't get any faster.
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Condition: Many drivers opt for a spiral-shaped e-car charging cable because it rolls itself up compactly and only rests on the ground at points. This will make it less dirty. If you have to bridge longer distances between the charging station and the connection to the car, a smooth charging cable is usually more practical because it is not energized. For smooth charging cables, there are reels that prevent knots in the cable.
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Length: Make sure you have a sufficient length. Don't use a standard extension cable if your charging cable is too short – the risk of overheating is too great. The most popular are charging cables with a length of five to ten meters.
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Colour: If you buy a charging cable for your electric car, opt for a coloured cable – it is easier to see, especially in the dark or in underground car parks, and is less likely to become a tripping hazard.
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Protection: A cap on the connector prevents moisture from clogging the contacts, extending the life of your cable.
Charging cable for electric cars: What types of plugs are there?
In addition to the different charging modes, there are also different types of plugs. Which plug your charging cable should have depends on which vehicle you drive and where you want to charge: at your home wallbox, at a public AC charging station, at the DC fast charging station or – in an emergency – at the household socket. You may need several cables.
Common charging plugs:
- Type 1
- Type 2 ("Mennekes plug")
- Type 3
Special plugs:
- CSS Connector
- CHAdeMO Connector
- Tesla Supercharger Plug ("NACS")
Charging plug type 1
The Type 1 connector is a single-phase connector. It allows a charging power of up to 7.4 kilowatts (230 volts, 32 amps). This plug is mainly used in the USA and Asia. In Europe, the type 1 plug is rather uncommon. Therefore, there are only a few charging stations with a permanently attached Type 1 charging cable. If you drive an electric car from Hyundai, Nissan or Ford, for example, you will need a charging cable with a type 1 plug to be able to charge on the road.
Charging plug type 2
The most common plug in Europe is called the Type 2 or Mennekes plug. It has established itself as the standard. It is a three-phase plug. This plug has a locking function that can be used on the vehicle and station side. In addition to the power connections, the Type 2 plug also has two contacts for communication between the charging station and the charger in the vehicle. With a charging cable with a type 2 plug, you can charge at home with up to 22 kilowatts (400 volts, 32 amps). At public charging stations, charging capacities of up to 43 kilowatts (400 volts, 63 amps) are even possible.
CSS Connector
The CCS connector is a type 2 connector with two additional power contacts for direct current. It is also called a combo plug. This allows you to charge both alternating current and direct current. You can only find this type of plug on permanently attached charging cables at DC fast charging stations. Theoretically, a charging capacity of up to 350 kilowatts is possible at these stations. However, so far there are only a few electric cars that can absorb this power. The charging station therefore automatically throttles the charging power to the power that your car's battery can absorb.
CHAdeMO Connector
The CHAdeMO connector was developed in Japan. This enables fast charging processes of up to 100 kilowatts. However, only 50 kW of power is available at most public charging stations. This plug is a discontinued model and is rarely found.
Tesla Supercharger plug
Tesla has developed its own type of plug for its Supercharger. It is a modification of the Mennekes plug. For example, the battery of the Tesla Model S can be fully charged within 30 minutes with a charging power of up to 120 kW (direct current). At more and more Superchargers in Europe, charging with a third-party brand is now possible. In the USA, this type of plug even seems to be the new standard. It is now also referred to as NACS (North-American Charging Standard), and around 60 percent of all fast chargers on the other side of the Atlantic are now equipped with it.
Our e-car expert Ove Kröger explains what you need to consider when it comes to charging cables:
FAQ: Charging cable for electric cars
Below you will find answers to the most frequently asked questions about charging cables for electric cars.
Is charging at the socket possible as an alternative to the wallbox?
Charging at a standard household socket with an extension cord is possible, but not recommended. It takes longer, is more expensive and, above all, can be very dangerous. This is because when charging electric vehicles via a normal socket, overheating can easily occur. In the worst case, the heat released in the cable leads to a fire. Charging at a socket is also not financially worthwhile. It is true that you save the money for installing a wallbox. On the other hand, charging at the socket costs up to 30 percent more electricity. So you can recoup the wallbox costs thanks to the more efficient charging process.
Why do you need a special charging cable for your electric car?
When charging an electric car, high voltages and currents are involved. Even a privately used charging connection in the garage with three phases and a nominal voltage of 230 volts achieves a charging power of 22 kilowatts. That's about ten times as much as an oven consumes in an hour. A normal cable would be overwhelmed with such currents and would get too hot. Charging cables for e-cars are therefore very thick and particularly well insulated. At the same time, the losses due to line resistance should be as low as possible. Despite their massive size, charging cables for electric cars must be flexible and elastic so that they can still be handled well. Only a special charging cable for e-cars meets all these requirements. It is therefore not worth saving on the charging cable.
When should you charge your e-car?
Frequent heavy discharge of the battery does not harm the battery. If you want to save your batteries, you can charge when the battery is still about 10 to 20 percent full. If you don't have a long distance ahead of you, it also makes sense not to fully charge the electric car. For everyday use, it is usually sufficient if you only charge the battery of your electric car to 80 percent. This extends the life of the battery.
Are all e-car charging cables the same?
No – charging cables for e-cars differ in thickness, length, power and plug. You can find a detailed explanation of the differences by scrolling up this page.
Where can you dispose of charging cables for e-cars?
Broken charging cables are considered electronic waste. You can hand them in at the nearest recycling center or at the pollutant mobile - usually free of charge. Large electrical retailers who offer electronic products on a sales area of more than 400 square meters must also accept electronic waste and dispose of it properly. The same applies to supermarkets that sell electronic products. It doesn't matter where you bought the cable. Electronic waste should never be disposed of in household waste, as it contains metals such as lead, copper or mercury. These substances contaminate the soil and can enter drinking water via groundwater.
source : Charging cable for electric cars: which one is the right one? | mobile.de
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