Introduction
The global EV charging infrastructure market requires cables that meet stringent safety, electrical, and durability standards. Unlike standard power cables, EV charging cables carry communication signals (CP and PP per IEC 61851) alongside power conductors, and must maintain performance through years of outdoor use, vehicle run-over, and repeated coiling/uncoiling. This guide covers the types, standards, and selection criteria for EV charging cables.
Charging Modes — IEC 61851
Mode 2 (Portable Charger)
Connects the EV to a standard household socket (AC 230 V, up to 16 A in Europe; 120 V, up to 12 A in North America). An in-cable control box (IC-CPD) provides the safety functions: ground fault detection, temperature monitoring, and communication with the vehicle. Mode 2 cables are typically supplied with the vehicle.
Mode 3 (Wallbox and Public Charger)
Permanently connected to a dedicated EV charging station (3.7–22 kW AC). The charging station provides the safety functions; the cable carries power (single-phase or three-phase) plus CP and PP signals. Mode 3 is the standard for residential wallboxes and public AC charging infrastructure.
Mode 4 (DC Fast Charging)
High-power DC charging (50–350+ kW) with liquid-cooled cables. Requires the most advanced cable construction — not covered in this guide.
Connector Standards by Region
| Region | AC Standard | AC Connector | DC Standard |
|---|---|---|---|
| Europe | IEC 62196-2 Type 2 | Mennekes | CCS2 |
| North America | SAE J1772 Type 1 | J1772 | CCS1 |
| China | GB/T 20234 | GB/T AC | GB/T DC |
| Japan | JEVS G105 | CHAdeMO | CHAdeMO |
Cable Construction
A standard AC charging cable includes five functional conductors:
- L, N (1-phase) or L1/L2/L3/N (3-phase): Power conductors, 2.5–6 mm² per phase
- PE: Protective earth — same cross-section as phase conductors
- CP (Control Pilot): 0.5 mm² — communicates charging current limit from EVSE to vehicle via PWM signal
- PP (Proximity Pilot): 0.5 mm² — resistor-coded cable current rating detected by the vehicle
XLPE insulation (+90 °C continuous) is preferred over PVC (+70 °C) because sustained 16 A / 32 A charging current generates conductor heating that can degrade PVC over time.
Key Selection Criteria
- Current rating: 16 A (3.7 kW) or 32 A (7.4 kW 1-phase / 22 kW 3-phase)
- Cable length: 5 m standard, 7.5–10 m for special applications. Voltage drop over cable length must stay within limits
- Jacket: PUR for outdoor (UV + vehicle run-over), TPE for halogen-free, both to -40 °C
- Standards: IEC 62196-2, EN 50620, UL 62 (per market)
- Certifications: CE + TÜV (Europe), UL (North America), CCC (China)
Why Yichi Cable for EV Charging
We manufacture AC Mode 2 and Mode 3 charging cables with XLPE insulation, PUR or TPE jackets, and full CE + TÜV certification — at factory-direct pricing with flexible order quantities.