IEC TS 62893-4-2:2021

Overview

IEC TS 62893-4-2:2021 specifies requirements for charging cables designed for electric vehicles (EVs) with rated voltages up to and including 0.6/1 kV. This technical specification applies to cables for DC charging according to mode 4 of IEC 61851-1, specifically addressing cables intended for use with a thermal management system such as outlined in IEC 61851-23. The standard supports safer, more efficient high-power EV charging by ensuring compatibility with active cooling systems, critical for advancing fast-charging infrastructure.

All charging cables covered by IEC 62893 (all parts) are intended for class II electrical equipment. This document also specifies a maximum conductor operating temperature of 90 ºC, and outlines relevant test methods for performance and safety. Compliance with this standard ensures reliability and longevity in demanding applications, supporting international harmonization of EV charging solutions.

Key Topics

• Scope and Purpose: Applies to heavy-duty flexible charging cables for direct current (DC) fast-charging of electric vehicles, with integrated thermal management.
• Design and Construction: Covers cable types with various sheath compounds and cable sizes, detailing requirements for conductors, insulation, sheathing, and marking.
• Thermal Management Integration: The cables are intended for use with systems utilizing liquid cooling or other thermal management methods to enable higher power transfer and safe operation under increased thermal loads.
• Test Methods and Performance:
  • Mechanical and electrical testing as per IEC 62893-2, IEC 60227-2, IEC 60245-2, IEC 60332-1-2, and other related standards.
  • Chemical compatibility and pressure tests for coolant-carrying tubes.
  • Flexibility, UV-resistance, crush resistance, fire performance, and insulation resistance.
  • Specific tests for cable bending, burst pressure, and coolant compatibility.
• Guidance on Use: Provides recommendations for safe use and environmental suitability, referencing IEC 62440 for guidance on low voltage cables.

Applications

• DC Fast-Charging Infrastructure: The standard enables the safe deployment of high-current charging cables for public, commercial, and fleet charging stations employing mode 4 charging as per IEC 61851-1.
• Thermally Managed EV Cables: Essential for charging stations that utilize active cooling or liquid-cooled cable assemblies to support rapid EV charging while minimizing overheating risks.
• Outdoor and Indoor EV Chargers: The specification includes guidance on the use of various cable types for both indoor and outdoor environments, ensuring robust performance against water, chemicals, mechanical wear, and environmental factors.
• Class II Electrical Equipment: Ensures cable compatibility and safety for equipment with double insulation, as required for most EV charging applications.

Related Standards

• IEC 61851-1: Electric vehicle conductive charging system - General requirements; defines charging modes including mode 4 for DC charging.
• IEC 61851-23: DC electric vehicle charging station; details requirements for stations using liquid-cooled cables.
• IEC 62893-1 & IEC 62893-2: General requirements and test methods for EV charging cables, forming the foundation for this document.
• IEC 60227-2 / IEC 60245-2: Test methods for PVC and rubber insulated cables, respectively.
• IEC 60332-1-2: Fire performance testing for cables.
• IEC 60811: Test methods for non-metallic materials in cable construction.
• IEC 62440: Guidance on the safe use of low voltage electrical cables.
• IEC 62821-1: Requirements for halogen-free, low smoke, thermoplastic cables for safety-critical environments.

Practical Value

Adopting IEC TS 62893-4-2:2021 ensures that DC charging cables for electric vehicles are safe, reliable, and optimized for use with modern high-power charging stations. By complying with its design and testing criteria, manufacturers and EV charging infrastructure providers can deliver robust solutions compatible with effective thermal management, enhancing the safety and efficiency of EV charging for end-users around the world. Integration with related IEC standards further supports global market access and interoperability across EV charging platforms.