EV High-Voltage Cable

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ISO19642 HV Cable

EV High-Voltage Cable introduction:

On electric vehicles, the high-voltage electrical system is mainly responsible for starting, driving, charging and discharging, and air conditioning power. It mainly includes battery system, powertrain, high-voltage electronic control system, charging system, high-voltage equipment, and its wiring harness system. Electric vehicle high-voltage lines are used to connect the charging port and the battery, the interior of the battery, the battery and the engine and other components, as well as battery energy storage equipment and other fields, as the carrier of power transmission. Due to the harsh application environment in the vehicle, electric vehicle high-voltage cables have very high performance requirements. Application characteristics of cables for electric vehicles: small wiring space, high current and high voltage, high and low temperature environment, poor heat dissipation, bad driving environment with salt spray and electromagnetic field, oil pollution and chemicals, low smoke halogen-free flame retardant,

Test OMG EV high voltage cable (Part 1)

Test OMG EV high voltage cable (Part 2)

 

Common choices for EV high voltage cables:

Usage Environment Common specifications mm2 Material Features
Drive motor--MCU 35mm2、50mm2、70mm2*3 180°C silicone or 150°C XLPE  Thermosetting material, high temperature resistance, soft, shielding structure Structure, tear resistance
Air Conditioning System - PDU 2.5mm2、4mm2、6mm2*2 125°C XLPE  Soft, shielded construction
Small Battery-DC/DC 10mm2、16mm2、25mm2 125°C XLPE Soft
DC/DC--PDU 16mm2、25mm2*2 125°C XLPE Soft, shielded construction
MCU--PDU 35mm2、50mm2、70mm2*2 125°C XLPE Soft, shielded construction, tear-resistant
Car charger-battery 6mm2、10mm2 125°C XLPE Soft, shielded construction
Battery - PDU 50mm2、70mm2*2 125°C XLPE shielded construction
Battery - BMS 20AWG 200℃ FEP High temperature resistant, smooth
Battery - DC Charging Stand 35mm2、50mm2、70mm2*2 125°C XLPE High temperature resistance, anti-cracking

Related Product Links:

Liquid-cooled high voltage Cable

UL certified EV high voltage cables

IS0 19642 standard EV high voltage cable

ev high voltage cable-ev battery cable-ev motor cable


Product description for high voltage cables for road vehicles:

(Reference Standard: IS0 19642-2019-5、IS0 19642-2019-9)

E-MARK Approval No: E24*118R03/01*0375*00

Construction Features
1、Conductor1 1、Rated temperature :-40℃~+(125℃, 150℃)
  Material: Bare Copper 2、Rated Voltage:AC 600V/DC 900V;AC 1000V/DC 1500V
2、Insulation 3、Short-term Aging:240h,Comply with  IS0 19642
  Material: XLPE 4、Long-term Aging: 3000h,Comply with   IS0 19642 
  Color:Orange 5、Flame Test: Comply With   IS0 19642
3、Shielded 6、Bending Radius: 4*OD@OD﹤15mm ; 6*OD@OD≧15mm
  Material:Tinned Copper  7、Dielectric Voltage:10kVac/5min. No Breakdown
4、Sheath 8、Oil Resistance:Comply With  IS0 19642
  Material: XLPE 9、Anti-tear Performance :>20N/mm
  Color:Orange  10、Environmental Requirements:Compliant with RoHS 2.0 and REACH  

1.AC 1000V/DC 1500V (shielded High-voltage cable):

shielded EV High-voltage cable

AC 1000V/DC 1500V (shielded High-voltage cable):

Product Series Size Conductor Stranded OD mm ( Ref.) Max. Conductor resistance mΩ/m@20℃ Permissible ampacity A (Ref.) Over diameter    mm (Ref.)

EVRP-125 

(Rated temperature :-40℃~+125℃)


EVRP-150

  (Rated temperature :-40℃~+150℃)

 2.5mm2 2.00 7.60 30 6.30
4mm2 2.60 4.71 40 7.30
6mm2 3.40 3.14 52 8.10
10mm2 4.40 1.82 75 9.80
16mm2 5.50 1.16 100 11.00
25mm2 7.00 0.743 125 13.40
35mm2 8.30 0.527 165 14.80
50mm2 10.00 0.368 215 17.00
70mm2 11.80 0.259 260 19.00
95mm2 13.80 0.196 320 21.60
120mm2 15.50 0.153 370 23.30

2. AC1000V/DC 1500V (unshielded High-voltage cable):

unshielded EV High-voltage cable

AC1000V/DC 1500V (unshielded High-voltage cable):

Product Series Size Conductor Stranded OD mm ( Ref.) Max. Conductor resistance mΩ/m@20℃ Permissible ampacity A (Ref.) Over diameter    mm (Ref.)

EVR-125 

(Rated temperature :-40℃~+125℃)


EVR-150 

(Rated temperature :-40℃~+150℃)

2.5mm2 2.00 7.60 30 3.50
4mm2 2.60 4.71 40 4.30
6mm2 3.40 3.14 52 5.10
10mm2 4.40 1.82 75 6.50
16mm2 5.50 1.16 100 7.60
25mm2 7.00 0.743 125 9.70
35mm2 8.30 0.527 165 11.00
50mm2 10.00 0.368 215 13.10
70mm2 11.80 0.259 260 15.00
95mm2 13.80 0.196 320 17.10
120mm2 15.50 0.153 370 18.80


3 AC 600V/DC 900V (unshielded High-voltage cable):

unshielded EV High-voltage cable

 AC 600V/DC 900V (unshielded High-voltage cable):

Product Series Size Conductor Stranded OD mm ( Ref.) Max. Conductor resistance mΩ/m@20℃ Permissible ampacity A (Ref.) Over diameter mm (Ref.)

EVR-125

(Rated temperature :-40℃~+125℃)


EVR-150 

(Rated temperature :-40℃~+150℃)  

2.5mm2 2.00 7.60 30 2.80
4mm2 2.60 4.71 40 3.50
6mm2 3.40 3.14 52 4.30
10mm2 4.40 1.82 75 5.70
16mm2 5.50 1.16 100 6.90
25mm2 7.00 0.743 125 8.40
35mm2 8.30 0.527 165 10.00
50mm2 10.00 0.368 215 12.00
70mm2 11.80 0.259 260 14.00
95mm2 13.80 0.196 320 16.50

4、AC 600V/DC 900V (shielded High-voltage cable):

shielded EV High-voltage cable

AC 600V/DC 900V (shielded High-voltage cable):


Product Series Size Conductor Stranded OD mm ( Ref.) Max. Conductor resistance mΩ/m@20℃ Permissible ampacity A (Ref.) Over diameter mm (Ref.)

EVRP-125

(Rated temperature :-40℃~+125℃)


EVRP-150 

(Rated temperature :-40℃~+150℃)  

2.5mm2 2.00 7.60 30 4.50
4mm2 2.60 4.71 40 5.20
6mm2 3.40 3.14 52 6.40
10mm2 4.40 1.82 75 7.90
16mm2 5.50 1.16 100 9.40
25mm2 7.00 0.743 125 11.00
35mm2 8.30 0.527 165 12.90
50mm2 10.00 0.368 215 15.00
70mm2 11.80 0.259 260 17.00
95mm2 13.80 0.196 320 19.60

5、AC600V/DC 900V (multi-core shielded High-voltage cable):

multi-core shielded EV High-voltage cable

AC600V/DC 900V (multi-core shielded High-voltage cable):

Product Series Cores Size Conductor Stranded OD mm ( Ref.) Max. Conductor resistance mΩ/m@20℃ Permissible ampacity A (Ref.) Over diameter mm (Ref.)

QBJP2-C

(Rated temperature :-40℃~+125℃)


QBJP2-D

(Rated temperature :-40℃~+150℃)

2 1.5mm2 1.60 12.70 13 7.60
3 11 8.00
4 10 8.60
5 9 9.20
2 2.5 mm2 2.06 7.60 18 8.60
3 16 9.20
4 14 9.90
5 13 10.80
2 4 mm2 2.70 4.71 26 10.10
3 22 10.60
4 20 12.00
5 18 13.20
2 6 mm2 3.40 3.14 33 11.80
3 29 12.60
4 26 13.60
5 23 14.80

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