Charging cables for electric vehicles of rated voltages up to and including 0,6/1 kV - Part 4-2: Cables for DC charging according to mode 4 of IEC 61851-1 - Cables intended to be used with a thermal management system

IEC TS 62893-4-2:2021(E) applies to cables for DC charging according to mode 4 of IEC 61851-1. These cables are intended to be used with a thermal management system such as that specified in IEC 61851-23.
Charging cables specified in IEC 62893 (all parts) are intended to be used for electrical appliances of class II equipment.
Maximum conductor operating temperature for the cables in this document is 90 ºC.
The test methods specified are given in IEC 62893-2, IEC 60227-2, IEC 60245-2, IEC 60332 1 2, IEC 62821-1:2015, Annex B and in the relevant parts of IEC 60811.
IEC 62440 is intended to be used as guidance on the safe use of cables in this document together with specific guidance in Clause 6 of this document.

General Information

Status
Published
Publication Date
16-Jun-2021
Technical Committee
Current Stage
PPUB - Publication issued
Completion Date
17-Jun-2021
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IEC TS 62893-4-2:2021 - Charging cables for electric vehicles of rated voltages up to and including 0,6/1 kV - Part 4-2: Cables for DC charging according to mode 4 of IEC 61851-1 - Cables intended to be used with a thermal management system
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IEC TS 62893-4-2
Edition 1.0 2021-06
TECHNICAL
SPECIFICATION
Charging cables for electric vehicles of rated voltages up to and including
0,6/1 kV –
Part 4-2: Cables for DC charging according to mode 4 of IEC 61851-1 – Cables
intended to be used with a thermal management system
IEC TS 62893-4-2:2021-06(en)
---------------------- Page: 1 ----------------------
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---------------------- Page: 2 ----------------------
IEC TS 62893-4-2
Edition 1.0 2021-06
TECHNICAL
SPECIFICATION
Charging cables for electric vehicles of rated voltages up to and including
0,6/1 kV –
Part 4-2: Cables for DC charging according to mode 4 of IEC 61851-1 – Cables
intended to be used with a thermal management system
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 29.060.20; 43.120 ISBN 978-2-8322-9915-9

Warning! Make sure that you obtained this publication from an authorized distributor.

® Registered trademark of the International Electrotechnical Commission
---------------------- Page: 3 ----------------------
– 2 – IEC TS 62893-4-2:2021 © IEC 2021
CONTENTS

FOREWORD ........................................................................................................................... 4

1 Scope .............................................................................................................................. 6

2 Normative references ...................................................................................................... 6

3 Terms and definitions ...................................................................................................... 7

4 General purpose cables – Heavy duty flexible cables ...................................................... 8

4.1 Code designation .................................................................................................... 8

4.2 Rated voltage ......................................................................................................... 8

4.3 Construction ........................................................................................................... 8

4.3.1 Conductor material .......................................................................................... 8

4.3.2 Sizes of cable .................................................................................................. 8

4.3.3 Insulation ......................................................................................................... 8

4.3.4 Screen(s) (optional) ......................................................................................... 8

4.3.5 Tubes .............................................................................................................. 9

4.3.6 Core identification ............................................................................................ 9

4.3.7 Assembly ......................................................................................................... 9

4.3.8 Sheath ............................................................................................................. 9

4.3.9 Marking ........................................................................................................... 9

4.3.10 Inductance between power cores ................................................................... 10

4.4 Requirements ....................................................................................................... 10

5 Liquid coolants .............................................................................................................. 10

5.1 Type of coolant ..................................................................................................... 10

5.2 Pressure tests for tubes ........................................................................................ 10

6 Guidance on use of cables ............................................................................................ 11

(normative) Tests for completed cables ................................................................. 13

(normative) Tables for cable dimensions and insulation resistance ........................ 15

(normative) Bending test ........................................................................................ 17

C.1 Test method .......................................................................................................... 17

C.2 Apparatus ............................................................................................................. 17

C.3 Results and calculations ....................................................................................... 17

(normative) Screen ................................................................................................ 19

(informative) Cable inductance between DC+ and DC− .......................................... 20

E.1 General ................................................................................................................. 20

E.2 Test method .......................................................................................................... 20

E.3 Specimen .............................................................................................................. 20

E.4 Results and calculations ....................................................................................... 20

(normative) Compatibility test of coolant ................................................................ 21

F.1 General ................................................................................................................. 21

F.2 Apparatus ............................................................................................................. 21

F.3 Preparation of samples ......................................................................................... 21

F.4 Procedure ............................................................................................................. 21

F.5 Results and calculations ....................................................................................... 22

Bibliography .......................................................................................................................... 23

Figure C.1 – Apparatus for cyclic bending ............................................................................. 18

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IEC TS 62893-4-2:2021 © IEC 2021 – 3 –

Table 1 – Intended use of charging cables for EV (environmental conditions) ....................... 11

Table 2 – Recommended use of charging cables for EV........................................................ 12

Table A.1 – Tests for cable types 62893 IEC 129, 130 and 131 ............................................ 13

Table B.1 – General data for type 129 (EVM-1) ..................................................................... 15

Table B.2 – General data for type 130 (EVM-2) and type 131 (EVM-3) .................................. 16

---------------------- Page: 5 ----------------------
– 4 – IEC TS 62893-4-2:2021 © IEC 2021
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
CHARGING CABLES FOR ELECTRIC VEHICLES
OF RATED VOLTAGES UP TO AND INCLUDING 0,6/1 kV –
Part 4-2: Cables for DC charging according to mode 4 of IEC 61851-1 –
Cables intended to be used with a thermal management system
FOREWORD

1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising

all national electrotechnical committees (IEC National Committees). The object of IEC is to promote international

co-operation on all questions concerning standardization in the electrical and electronic fields. To this end and

in addition to other activities, IEC publishes International Standards, Technical Specifications, Technical Reports,

Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC Publication(s)”). Their

preparation is entrusted to technical committees; any IEC National Committee interested in the subject dealt with

may participate in this preparatory work. International, governmental and non-governmental organizations liaising

with the IEC also participate in this preparation. IEC collaborates closely with the International Organization for

Standardization (ISO) in accordance with conditions determined by agreement between the two organizations.

2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international

consensus of opinion on the relevant subjects since each technical committee has representation from all

interested IEC National Committees.

3) IEC Publications have the form of recommendations for international use and are accepted by IEC National

Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC

Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any

misinterpretation by any end user.

4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications

transparently to the maximum extent possible in their national and regional publications. Any divergence between

any IEC Publication and the corresponding national or regional publication shall be clearly indicated in the latter.

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services carried out by independent certification bodies.

6) All users should ensure that they have the latest edition of this publication.

7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and

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other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and

expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC

Publications.

8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is

indispensable for the correct application of this publication.

9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of patent

rights. IEC shall not be held responsible for identifying any or all such patent rights.

IEC TS 62893-4-2 has been prepared by IEC technical committee 20: Electric cables. It is a

Technical Specification.
The text of this Technical Specification is based on the following documents:
DTS Report on voting
20/1942/DTS 20/1961/RVDTS

Full information on the voting for its approval can be found in the report on voting indicated in

the above table.

The language used for the development of this Technical Specification is English.

---------------------- Page: 6 ----------------------
IEC TS 62893-4-2:2021 © IEC 2021 – 5 –

This document was drafted in accordance with ISO/IEC Directives, Part 2, and developed in

accordance with ISO/IEC Directives, Part 1 and ISO/IEC Directives, IEC Supplement, available

at www.iec.ch/members_experts/refdocs. The main document types developed by IEC are

described in greater detail at www.iec.ch/standardsdev/publications.
This document is to be read in conjunction with IEC 62893-1:2017,
IEC 62893-1:2017/AMD1:2020 and IEC 62893-2:2017.

A list of all parts in the IEC 62893 series, published under the general title Charging cables for

electric vehicles of rated voltages up to and including 0,6/1 kV, can be found on the IEC website.

The committee has decided that the contents of this document will remain unchanged until the

stability date indicated on the IEC website under webstore.iec.ch in the data related to the

specific document. At this date, the document will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
---------------------- Page: 7 ----------------------
– 6 – IEC TS 62893-4-2:2021 © IEC 2021
CHARGING CABLES FOR ELECTRIC VEHICLES
OF RATED VOLTAGES UP TO AND INCLUDING 0,6/1 kV –
Part 4-2: Cables for DC charging according to mode 4 of IEC 61851-1 –
Cables intended to be used with a thermal management system
1 Scope

This part of IEC 62893 applies to cables for DC charging according to mode 4 of IEC 61851-1.

These cables are intended to be used with a thermal management system such as that specified

in IEC 61851-23.

Charging cables specified in IEC 62893 (all parts) are intended to be used for electrical

appliances of class II equipment.

Maximum conductor operating temperature for the cables in this document is 90 ºC.

The test methods specified are given in IEC 62893-2, IEC 60227-2, IEC 60245-2,
IEC 60332-1-2, IEC 62821-1:2015, Annex B and in the relevant parts of IEC 60811.

IEC 62440 is intended to be used as guidance on the safe use of cables in this document

together with specific guidance in Clause 6 of this document.
2 Normative references

The following documents are referred to in the text in such a way that some or all of their content

constitutes requirements of this document. For dated references, only the edition cited applies.

For undated references, the latest edition of the referenced document (including any

amendments) applies.

IEC 60227-2:1997, Polyvinyl chloride insulated cables of rated voltages up to and including

450/750 V – Part 2: Test methods
IEC 60227-2:1997/AMD1:2003

IEC 60245-2, Rubber insulated cables – Rated voltages up to and including 450/750 V – Part 2:

Test methods
IEC 60245-2:1994/AMD1:1997
IEC 60245-2:1994/AMD2:1997

IEC 60332-1-2, Tests on electric and optical fibre cables under fire conditions – Part 1-2: Test

for vertical flame propagation for a single insulated wire or cable – Procedure for 1 kW pre-

mixed flame

IEC 60364-5-54, Low-voltage electrical installations – Part 5-54: Selection and erection of

electrical equipment – Earthing arrangements and protective conductors

IEC 60445:2017, Basic and safety principles for man-machine interface, marking and

identification – Identification of equipment terminals, conductor terminations and conductors

IEC 60811-401:2012, Electric and optical fibre cables – Test methods for non-metallic materials

– Part 401: Miscellaneous tests – Thermal ageing methods – Ageing in an air oven
IEC 60811-401:2012/AMD1:2017
---------------------- Page: 8 ----------------------
IEC TS 62893-4-2:2021 © IEC 2021 – 7 –

IEC 60811-501, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 501: Mechanical tests – Tests for determining the mechanical properties of insulating and

sheathing compounds

IEC 61851-1, Electric vehicle conductive charging system – Part 1: General requirements

IEC 61851-23, Electric vehicle conductive charging system – Part 23: DC electric vehicle

charging station

IEC 62440:2008, Electrical cables with a rated voltage not exceeding 450/750 V – Guide to use

IEC 62821-1:2015, Electric cables – Halogen-free, low smoke, thermoplastic insulated and

sheathed cables of rated voltage up to and including 450/750 V – Part 1: General requirements

IEC 62893-1:2017 Charging cables for electric vehicles of rated voltages up to and including

0,6/1 kV – Part 1: General requirements
IEC 62893-1:2017/AMD1:2020

IEC 62893-2:2017, Charging cables for electric vehicles of rated voltages up to and including

0,6/1 kV – Part 2: Test methods

IEC Guide 117:2010, Electrotechnical equipment – Temperatures of touchable hot surfaces

ISO 1402, Rubber and plastics hoses and hose assemblies – Hydrostatic testing

EN 50289-1-12:2005, Communication cables – Specifications for test methods – Part 1-12:

Electrical test methods – Inductance
3 Terms and definitions

For the purposes of this document the terms and definitions given in IEC 62893-1 and the

following apply.

ISO and IEC maintain terminological databases for use in standardization at the following

addresses:
• IEC Electropedia: available at http://www.electropedia.org/
• ISO Online browsing platform: available at http://www.iso.org/obp
3.1
auxiliary power core

core in the cable that is used to provide auxiliary power to operate on-vehicle electrical devices

during the charging process without using battery power (e.g. climate control)
3.2
temperature sensor core

core in the cable that is used to provide temperature signals to operate an electric vehicle

supply equipment (EVSE)
3.3
tube
element in the cable carrying a cooling medium
---------------------- Page: 9 ----------------------
– 8 – IEC TS 62893-4-2:2021 © IEC 2021
4 General purpose cables – Heavy duty flexible cables
4.1 Code designation

The code designation is 62893 IEC 129 for halogen free cables with sheath compound EVM-1

and 62893 IEC 130 for halogen free cables with sheath compound EVM-2.
The code designation is 62893 IEC 131 for cables with sheath compound EVM-3.
4.2 Rated voltage
0,6/1 kV AC up to and including 1,5 kV DC conductor to conductor.
4.3 Construction
4.3.1 Conductor material

The conductor material and its construction shall be in accordance with 8.1 of IEC 62893-1:2017.

4.3.2 Sizes of cable
The sizes of cable shall be:
• Power cores:
2 2
16 mm to 150 mm – two or more cores.
• Control or pilot cores:
Number not specified, for size see 8.2 d) of IEC 62893-1:2017.
• Optional PE conductor – one core:

Minimum size of PE or PEM conductor shall be in accordance with either Table B.1 or

Table B.2 or, in the case where there is agreement between manufacturer and customer

about the short-circuit requirements, the nominal cross-section of the PE or PEM conductor

shall comply with the calculations specified in IEC 60364-5-54 or with IEC 61851-23.

• Auxiliary power cores (optional):
2 2
2,5 mm to 6 mm – two cores.
• Temperature sensor cores (optional):
Number not specified, for size see 8.2 d) of IEC 62893-1:2017.

In case the copper conductor is in direct contact with the coolant media, a corrosion test of the

conductor shall be made in accordance with Annex F (see Table A.1, Ref No. 14).
4.3.3 Insulation

The insulation for power cores shall be a compound of Type EVI-2 in accordance with

IEC 62893-1:2017.

In case the insulation is also used as a tube of the power core, a space between the conductor

and insulation is permitted.

The insulation for control or pilot cores, auxiliary power cores and temperature sensor cores

shall be a compound of Type EVI-1 or EVI-2 in accordance with IEC 62893-1:2017.
4.3.4 Screen(s) (optional)

The screen over a core or an assembly of cores (such as pairs or quads) shall consist of a

copper braid with
...

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