EV Charging Cable Selection Guide

What does an EV charging cable have to do?

An EV charging cable combines power conductors with control or communication functions and is handled far more often than a fixed installation cable. It must match the charging equipment, connector, current, environment and destination approvals.

The IEC 62893 series covers EV charging cables up to 0.6/1 kV. Its first part covers charging modes 1 to 4 as defined in IEC 61851-1, so the charging mode is a useful starting point when you read a datasheet or a quotation. Confirm which parts and editions apply to your product.

For the product range, see the EV charging cable page.

How do you define the charging duty?

The charging duty sets the conductor size and temperature rise to check. Write these down before requesting a quotation:

1. AC or DC charging system. DC fast-charging assemblies can have larger conductors and need thermal-management checks.
2. Charging mode under IEC 61851-1, with the voltage and number of phases.
3. Maximum continuous charging current, not a short peak.
4. Ambient temperature and grouping with other cables, both of which reduce current capacity.

Ampacity depends on installation method, construction and ambient temperature, so take it from the manufacturer datasheet for the exact charging cable rather than a rule of thumb.

Which cores, conductors and voltage drop limits matter?

The core arrangement must match the charging standard and the connector. Power conductors carry the charging current, the protective earth conductor must be present, and pilot and communication conductors carry the control signals between the vehicle and the charging equipment. Confirm the core count against the connector drawing. Outer diameter and flexibility also affect connector and strain relief design.

Conductor class matters for flexing. In IEC 60228, class 5 is flexible and class 6 is more flexible still, and both classes are used for flexible cables and cords. Ask for the conductor class in the datasheet and check the maximum resistance for that class and size in IEC 60228, because the resistance limits differ by class and by conductor size.

Check voltage drop over the actual cable length, especially for long runs at high current. For a three-phase circuit, a common approximation is ΔU = √3 × I × L × (R cos φ + X sin φ), using the resistance and reactance of the cable. For a DC assembly, use the DC resistance of the conductors. The acceptable limit depends on local rules. IEC 60364-5-52 Annex G (informative, Table G.52.1) gives 5 % for other uses when an installation is supplied directly from a public LV network, and national rules may differ.

Which items belong in the specification?

Use this table as a checklist when you write the request for quotation.

Take every numerical rating from the manufacturer datasheet.

How do handling and environment change the cable?

Users coil, drag and step on the cable repeatedly, so the flexibility and bend recovery of the finished assembly matter as much as the conductor. Test flexing at the lowest service temperature for the product, and ask the supplier for the minimum bending radius in the datasheet.

For outdoor use, choose the sheath for sunlight, water, oil and abrasion. Ingress protection is commonly stated with the IEC 60529 IP code. IP66 means dust-tight and protected against powerful water jets, while IP68 means continuous immersion under conditions stated by the manufacturer. Ask which rating applies to the complete assembly, including the connector, not only to the cable.

As an example of a flexible rubber construction, H07RN-F to EN 50525-2-21 is rated 450/750 V and uses EPR insulation, a polychloroprene sheath and a class 5 conductor. Take its maximum conductor temperature from the datasheet, as values differ.

Weight and surface temperature also matter: a heavy or stiff cable is harder to handle, and the surface temperature of the cable and connector during continuous charging should be checked against the charging duty.

Which compliance and approvals apply?

Regional approvals and charging standards differ, so one cable can need different tests in different markets. Confirm the destination market and certification route before tooling or bulk production.

Complete charging-cable assemblies must be evaluated with their connector and the requirements of the charging equipment. A cable that meets its own standard test is not the same as an assembly approved for the connector and charger it will be used with.

Frequently asked questions