IEC 62893-4-1:2020

Charging cables for electric vehicles of rated voltages up to and including 0,6/1 kV - Part 4-1: Cables for DC charging according to mode 4 of IEC 61851-1 - DC charging without use of a thermal management system

IEC 62893-4-1:2020 applies to cables for DC charging according to mode 4 of IEC 61851-1. These cables are not 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.
The maximum conductor operating temperature for the cables in this document is 90 °C.
The test methods specified are given in IEC 62893-2, 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 Clause 5 of this document.
This document is to be read in conjunction with IEC 62893-1:2017 and IEC 62893-2:2017.

General Information

• Status: Published
• Publication Date: 06-May-2020
• ICS: 29.060.20 - Cables
• ICS: 43.120 - Electric road vehicles
• Technical Committee: TC 20 - Electric cables
• Drafting Committee: WG 17 - TC 20/WG 17
• Current Stage: PPUB - Publication issued
• Start Date: 07-May-2020
• Completion Date: 29-May-2020

Overview - IEC 62893-4-1:2020 for DC charging cables (Mode 4)

IEC 62893-4-1:2020 specifies requirements for charging cables for electric vehicles used for DC charging (Mode 4) without a thermal management system. It applies to heavy‑duty, flexible DC charging cables for rated voltages up to and including 0,6/1 kV (AC) and up to 1,5 kV DC, intended as Class II equipment. The standard defines construction, marking, testing and safe-use guidance for cables not designed to work with the thermal management systems described in IEC 61851‑23.

Key technical topics and requirements

• Scope & purpose: Cables for DC Mode 4 charging where no thermal management system is used; maximum conductor operating temperature 90 °C.
• Rated voltage: 0,6/1 kV AC; up to 1,5 kV DC for power cores.
• Cable types and materials: Designations 62893 IEC 126, 127 and 128 with sheath compounds EVM‑1 / EVM‑2 / EVM‑3 and insulation types EVI‑1 / EVI‑2.
• Conductor sizes: Power cores from 4 mm² to 150 mm² (two or more cores); optional PE and auxiliary power cores (2,5–6 mm²); temperature sensor and pilot/control cores as required.
• Screening: Optional copper braid screens with minimum 80% optical coverage for cores or assemblies.
• Construction details: Twisted cores, no centre-core, specified insulation and sheath thicknesses (Annex B), core identification (colours or durable numbering), and circular sheath finish.
• Marking: Continuous code designation, rated voltage, number and cross‑section of power and PE conductors.
• Tests & test methods: References to IEC 62893‑2 (test methods), IEC 60245‑2, IEC 60332‑1‑2 (flame), IEC 62821‑1:2015 (halogen‑free, low smoke) and relevant parts of IEC 60811. Annexes cover completed‑cable tests, bending, screens and inductance.

Practical applications - who uses this standard

• Cable manufacturers designing and certifying EV DC charging cables for Mode 4 applications.
• EVSE (charging station) manufacturers and integrators ensuring compatible, safe cable assemblies.
• Testing and certification labs performing the normative tests and issuing conformity reports.
• Procurement/spec writers, fleet operators and installers who need compliant cable specifications for fast DC charging without active cooling.
• Safety and compliance engineers using the standard to verify insulation, marking, temperature limits and fire performance.

Related standards

• IEC 62893‑1:2017 (general requirements)
• IEC 62893‑2:2017 (test methods)
• IEC 61851‑1 (EV conductive charging - general) and IEC 61851‑23 (DC charging stations - thermal management)
• IEC 62440 (guidance on safe use of cables)
• IEC 60332‑1‑2, IEC 60811, IEC 62821‑1 and IEC 60245‑2 (test and material standards)

This standard ensures safe, interoperable EV charging cables for DC fast charging Mode 4 applications where passive cable cooling is required.

Standards Content (Sample)

IEC 62893-4-1 ®
Edition 1.0 2020-05
INTERNATIONAL
STANDARD
Charging cables for electric vehicles of rated voltages up to and including
0,6/1 kV –
Part 4-1: Cables for DC charging according to mode 4 of IEC 61851‑1 –
DC charging without use of a thermal management system
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IEC 62893-4-1 ®
Edition 1.0 2020-05
INTERNATIONAL
STANDARD
Charging cables for electric vehicles of rated voltages up to and including

0,6/1 kV –
Part 4-1: Cables for DC charging according to mode 4 of IEC 61851‑1 –

DC charging without use of a thermal management system

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 43.120; 29.060.20 ISBN 978-2-8322-8252-6

– 2 – IEC 62893-4-1:2020 © IEC 2020
CONTENTS
FOREWORD . 3
1 Scope . 5
2 Normative references . 5
3 Terms and definitions . 6
4 General purpose cables – Heavy duty flexible cables . 6
4.1 Code designation . 6
4.2 Rated voltage . 6
4.3 Construction . 6
4.3.1 Sizes of cable . 6
4.3.2 Insulation . 7
4.3.3 Screen(s) (optional) . 7
4.3.4 Core identification . 7
4.3.5 Assembly . 7
4.3.6 Sheath . 7
4.3.7 Marking . 8
4.3.8 Inductance between power cores . 8
4.4 Requirements . 8
5 Guidance on use of cables . 8
Annex A (normative) Tests for completed cables . 10
Annex B (normative) Tables for cable dimensions and insulation resistance . 12
Annex C (normative) Bending test . 14
Annex D (normative) Screen . 16
Annex E (informative) Cable inductance between DC+ and DC− . 17
Bibliography . 18

Figure C.1 – Apparatus for cyclic bending . 15

Table 1 – Intended use of charging cables for EV (environmental conditions) . 9
Table 2 – Recommended use of charging cables for EV. 9
Table A.1 – Tests for cable types 62893 IEC 126, 127 and 128 . 10
Table B.1 – General data for type 126 (EVM-1) . 12
Table B.2 – General data for type 127 (EVM-2) and type 128 (EVM-3) . 13

INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
CHARGING CABLES FOR ELECTRIC VEHICLES OF
RATED VOLTAGES UP TO AND INCLUDING 0,6/1 kV –

Part 4-1: Cables for DC charging according to mode 4 of IEC 61851‑1 –
DC charging without use of a thermal management system

FOREWORD
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rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 62893-4-1 has been prepared by IEC technical committee 20:
Electric cables.
The text of this International Standard is based on the following documents:
FDIS Report on voting
20/1908/FDIS 20/1911/RVD
Full information on the voting for the approval of this International Standard can be found in the
report on voting indicated in the above table.
This document has been drafted in accordance with the ISO/IEC Directives, Part 2.
This document is to be read in conjunction with IEC 62893-1:2017 and IEC 62893-2:2017.

– 4 – IEC 62893-4-1:2020 © IEC 2020
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 "http://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.
CHARGING CABLES FOR ELECTRIC VEHICLES OF
RATED VOLTAGES UP TO AND INCLUDING 0,6/1 kV –

Part 4-1: Cables for DC charging according to mode 4 of IEC 61851‑1 –
DC charging without use of 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 not 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.
The maximum conductor operating temperature for the cables in this document is 90 °C.
The test methods specified are given in IEC 62893-2, 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 Clause 5 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 60245-2:1994, Rubber insulated cables – Rated voltages up to and including 450/750 V –
Part 2: Test methods
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 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
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
– 6 – IEC 62893-4-1:2020 © IEC 2020
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 voltages 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 62893-2:2017, Charging cables for electric vehicles of rated voltages up to and including
0,6/1 kV – Part 2: Test methods
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 EVSE
4 General purpose cables – Heavy duty fl
...