Specification for CCS2 Portable EV Charger

1. General Overview

This specification outlines the requirements for a portable electric vehicle (EV) charger utilizing the Combined Charging System Type 2 (CCS2) standard. The charger is designed for both home and public use, offering fast, efficient, and safe charging for compatible EVs.

2. Technical Requirements

2.1 Electrical Characteristics
Input Voltage  : 230V AC ± 10%, single phase, 50/60 Hz.
Output Voltage  : 200 500V DC.
Output Current  : Adjustable from 16A to 32A.
Power Rating  : Up to 22 kW.
Efficiency  : ≥ 95% at full load.
Power Factor  : ≥ 0.98.

2.2 Connector and Cable
Connector Type  : CCS2 compliant.
Cable Length  : 5 meters standard, with options for 7 and 10 meters.
Cable Type  : High flexibility, UV resistant, and weatherproof cable.

3. Mechanical Characteristics

3.1 Dimensions and Weight
Dimensions  : Maximum 300mm (L) x 200mm (W) x 100mm (H).
Weight  : Not exceeding 5 kg.

3.2 Enclosure Material
Material  : Durable, impact resistant plastic (e.g., polycarbonate) with flame retardant properties.
Ingress Protection  : IP67 rated for dust and water resistance.

3.3 User Interface
Display  : LCD or LED display showing charging status, current, voltage, power, and error messages.
Buttons  : Start/stop button, current adjustment buttons.

 4. Environmental and Durability Requirements

4.1 Operating Conditions
Temperature  :  25°C to +50°C.
Humidity  : 5% to 95% relative humidity, non condensing.
Altitude  : Up to 2000 meters.

4.2 Durability
Drop Resistance  : Capable of withstanding a drop from 1 meter height without functional damage.
UV Resistance  : Suitable for outdoor use with UV resistant materials.

5. Safety and Protection Features

5.1 Protection Mechanisms
Overvoltage Protection  : Automatic shutdown if voltage exceeds safe limits.
Overcurrent Protection  : Automatic shutdown if current exceeds safe limits.
Short Circuit Protection  : Immediate shutdown to prevent damage and hazards.
Ground Fault Protection  : Integrated ground fault circuit interrupter (GFCI).
Overheat Protection  : Thermal sensors to shut down the charger if it overheats.

5.2 Compliance and Certification
Standards  : IEC 61851 1, IEC 62196 2, IEC 62196 3, and ISO 15118.
Certification  : CE, TUV, and RoHS compliant.
EMC Compliance  : EN 61000 6 1, EN 61000 6 3.

6. Connectivity and Communication

6.1 Communication Protocols
Communication  : ISO 15118 compliant for vehicle to grid (V2G) communication.
Networking  : Optional Wi Fi and Bluetooth for remote monitoring and control via a smartphone app.

6.2 Smart Features
Load Management  : Dynamic load balancing to optimize power distribution.
Scheduling  : Programmable charging times to take advantage of off peak electricity rates.

7. Testing and Quality Assurance

7.1 Factory Testing
Functional Testing  : Verification of all electrical and mechanical functions.
Safety Testing  : Ensuring all safety mechanisms are operational.
Environmental Testing  : Simulated extreme conditions to verify durability.

7.2 Documentation
Test Reports  : Detailed test reports for each unit.
User Manual  : Comprehensive manual including installation, operation, and troubleshooting instructions.

8. Packaging and Labeling

8.1 Packaging
Material  : Recyclable, robust packaging materials to protect the charger during transit.
Inclusions  : Charger, user manual, warranty card, and any necessary mounting accessories.

8.2 Labeling
Information  : Product name, model number, serial number, input/output specifications, safety certifications, and manufacturer details.

9. Warranty and Support

9.1 Warranty
Period  : Minimum 2 years from the date of purchase.
Coverage  : Covers manufacturing defects and functional failures under normal use conditions.

9.2 Technical Support
Availability  : 24/7 customer support through phone, email, and online chat.
Service Centers  : Network of authorized service centers for repairs and maintenance.

This specification ensures the CCS2 portable EV charger meets high standards for performance, safety, and user convenience.