EV Charging Cables
Source CCS1/CCS2/NACS/Type 2 charging cables from verified China OEMs. UL 2594 and IEC 62196 certified, 150A-350A DC fast charging, liquid-cooled options, custom branding available.
What is an EV Charging Cable?
An EV charging cable is the physical connection between a charging station and an electric vehicle, delivering AC or DC power to the vehicle's battery system. Unlike home appliance cords, EV cables must handle high current (16A-350A), resist extreme temperatures (-40°C to +85°C), and survive 10,000+ insertion/removal cycles under harsh outdoor conditions.
DC fast charging cables (CCS1, CCS2, NACS, CHAdeMO, GB/T) carry 150A-350A at 200-1000V DC for rapid charging (30-80% charge in 15-30 minutes). High-power cables (200A+) use liquid cooling to dissipate heat—coolant circulates through the cable and connector to maintain safe operating temperatures. AC charging cables (Type 1, Type 2) carry 16A-32A at 230-400V AC for slower overnight charging (4-8 hours).
Key cable components include: conductor core (copper, typically 16mm² to 95mm² cross-section for DC cables),insulation layer (silicone rubber or XLPE rated to 1000V), outer jacket (TPU or PVC for abrasion/UV resistance),shielding (aluminum foil + copper braid for EMI protection), and integrated safety circuits(temperature sensors, current sensors, proximity detection).
When sourcing charging cables from China OEMs, verify UL 2594 certification (North America DC cables),UL 2251 (North America AC cables), IEC 62196-3 (Europe DC), or IEC 62196-2 (Europe AC). Request temperature rise test reports showing conductor temperature stays below 90°C at rated current, and pull force testing showing connectors withstand 100N longitudinal force without separation.
Charging Cable Standards & Options
| Standard | Target Market | Current Rating | Voltage Range | Required Certification |
|---|---|---|---|---|
| CCS1 (Combo 1) | North America | 150A-250A DC | 200-920V DC | UL 2594 |
| CCS2 (Combo 2) | Europe/Global | 150-200A DC | 200-920V DC | IEC 62196-3 |
| NACS (Tesla) | North America | Up to 250A DC | 50-1000V DC | SAE J3400 |
| Type 2 (IEC 62196-2) | Europe/China | 16A-32A AC | 230V/400V AC | IEC 62196-2 |
| CHAdeMO | Japan/Asia | Up to 200A DC | 200-500V DC | CHAdeMO Assoc. |
| GB/T | China | Up to 250A DC | 200-750V DC | GB/T 20234 |
Use Cases & Applications
Public DC Fast Charging
Highway rest stops, urban charging hubs. CCS1/CCS2/CHAdeMO cables rated 150-350A for 30-minute charging sessions.
Typical Requirements:
Liquid cooling, 150-350A rating, IP54 ingress protection, 5m cable length, UL 2594 or IEC 62196-3
Fleet/Depot Charging
Commercial fleet depots, bus/truck charging. Durable AC cables for overnight Level 2 charging (Type 1/Type 2).
Typical Requirements:
32A-40A AC, TPU cable jacket (abrasion resistant), -30°C to 50°C operation, 7.5m length
Portable/Emergency Charging
Mobile charging units, roadside assistance. Lightweight AC/DC cables with compact connectors for transport.
Typical Requirements:
16A-32A AC or 100A DC, compact design, weather-resistant, coiled cable option
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OEM Customization Services
Cable Specifications
- Length: 3m-10m
- Conductor: 10-95mm²
- Jacket: TPU/PVC color
- Coiled cable option
Connector Options
- CCS1/CCS2/NACS
- Type 1/Type 2 AC
- CHAdeMO/GB/T
- Dual-connector cables
Cooling Systems
- Passive cooling (80-125A)
- Liquid cooling (150-350A)
- Custom coolant fittings
- Temperature monitoring
Branding & Testing
- Logo molding/printing
- Custom packaging
- UL/IEC test coordination
- Translation services
Frequently Asked Questions
What's the difference between liquid-cooled and passive-cooled DC cables?
Liquid-cooled cables circulate coolant through the cable to handle 150-350A continuous current without overheating. Passive cables (no cooling) are limited to 80-125A. For fast charging (150kW+), liquid cooling is mandatory per UL 2594.
How do I verify a cable's UL 2594 or IEC 62196 certification?
Check UL Product iQ database (database.ul.com) for UL 2594. For IEC 62196, request test reports from TUV/SGS showing temperature rise testing (<50K above ambient), dielectric withstand (2000V AC for 1 min), and 10,000 insertion/removal cycles. Don't accept photos—verify in official databases.
What cable length is optimal for DC fast charging?
5 meters (16.4 ft) is standard. Shorter cables (3m) reduce voltage drop but limit vehicle positioning. Longer cables (7m+) increase weight and voltage drop. For 200A+ cables, voltage drop should be <0.5V per meter to maintain efficiency.
Can I source custom cable lengths and connector combinations?
Yes. Most OEMs offer 3m-10m lengths, CCS1/CCS2/NACS/CHAdeMO connectors, custom branding, and TPU/PVC jacket colors. MOQ typically 200-500 units for full customization. Sample lead time 7-14 days.
What's the typical MOQ and pricing for DC charging cables?
CCS1/CCS2 150A cables: $160-$280 FOB, MOQ 200-500 units. 200A liquid-cooled: $280-$450 FOB, MOQ 200 units. NACS cables: $200-$350 FOB, MOQ 300 units. Lead time 30-40 days after deposit.
How do I prevent counterfeit UL/CE certificates from Chinese suppliers?
Verify UL certificate number in UL Product iQ. Request original TUV/SGS test reports with lab signature and hologram. Cross-check factory name on certificate matches business license. We verify all certifications before recommending OEMs.
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