When it comes to ev charging stations, there is one component that has to be mentioned, and that is the "cable". The cable for EV charging station is the wire to connect the grid and evse. Today I will analyze some key knowledge points of the cable for ev charging station and teach you how to choose a good cable for ev charging station.
A good cable for ev charging station needs to have the following criteria.
1. Conductor part.
(1) the number of cores: 2 cores, 3 cores, 4 cores, 5 cores with or without signal control line. (Note: The conductor belongs to EN 60228, category 6 conductors.)
(2) Conductor surface tinned or untinned.
(3) Recommended conductor cross-section sizes: 0,5 mm², 1 mm², 1,5 mm², 2,5 mm², 4 mm², 6 mm², 10 mm², 16 mm2.
2. Isolation layer.
The standard for charging pile cables allows the use of a suitable and appropriate material as an isolation layer to wind the conductor.
3. Insulation.
(1) The conductor must be wrapped with the specified insulation material and no material other than that specified in the standard may be used without permission.
(2) The insulation must be extruded and must be solid and homogeneous. The insulation must be removed without damaging the insulation itself and the conductor or the possible tinned layer mentioned earlier.
(3) The value of the insulation thickness must be in accordance with the specified standard value. The average value of the insulation thickness must not be less than the specified value, and the thickness of the thinnest part of the insulation must not be less than 90 % of the specified value.
4. Core wire and filling.
(1) The core wire must be stranded.
(2) According to the standard for charging post cables, the use of central filler is permitted in charging post cables.
5. Inner sheathing.
(1) The stranded core must be covered by an inner sheath made of the same material as the outer sheath or insulation.
(2) The inner sheath must be extruded over the insulated core, allowing the gaps between the insulated cores to be embedded to form a virtual circle.
(3) There must be no harmful negative interaction between the inner sheath and the insulation.
(4) The inner sheath must not adhere to the insulating core.
(5) The thickness of the inner sheath must meet the thickness specified in the standard.
6. Shielding.
(1) A shield of bare copper wire or tinned copper wire braid shall be wrapped around the top of the inner sheath.
(2) The nominal diameter of the copper wire shall be in accordance with the given value of the charging post cable standard.
(3) The total number of strands, the angle of stranding and the filling factor of the shield within a length of 100 mm must fully comply with the requirements of the standard.
7. Sheathing or outer sheathing.
(1) The shield or stranded core must be covered with the specified sheathing material.
(2) The outer sheath shall be a single extruded sheath and shall exist in close proximity to each other, but shall not be adherent to the shield or core.
(3) The specified value of the sheath thickness must be in accordance with the provisions of the standard.
(4) The average value of the sheath thickness must not be less than the value specified in the standard for charging post cables and the thickness of the weakest part of the sheath must not be less than 85% of the specified value.
How to calculate how big a cable to use for an ev charging station?
1. There are single-phase and three-phase charging piles, regardless of whether they are two-phase or single-phase, the first step is to convert to how large the AC incoming current is.
(1) For single-phase charging pile (AC charging pile) I=P/U
(2) For a three-phase charging post (DC charging pile) I=P/(U*1.732)
After calculating the current in this way, select the cable according to the current size.
2. Cable selection can be done by relevant manuals or regulations such as
(1) Single-phase charging pile is generally 7KW (AC charging pile) I=P/U=7000/220=32A Copper core cable of 4 square mm should be used.
(2) Three-phase charging pile (DC pile)
15KW Current 23A Cable 4 mm2
30KW Current 46A Cable 10 mm2
60KW Current 92A Cable 25 mm2
90KW Current 120A Cable 35 mm2
All charging posts should have a zero and earth wire. So a single-phase one should have a three-core cable and a three-phase one should have a five-core cable.
Charging pile cable use precautions.
1. regular inspection of circuit insulation performance
Generally good quality charging pile cable has a good insulation effect, but long-term work in the open environment of the charging voltage will inevitably wear and tear, in order to protect the charging pile can be safe and normal use, we have to regularly check the charging pile cable, switches and sockets and other cables and wires whether the external leakage, only then can ensure the safety and durability of the charging pile cable.
2. away from water and wet location
Although the charging pile cable has a waterproof function, there are still certain hidden dangers when working in a humid environment for a long time. Therefore, the charging pile cable should be installed away from water sources to avoid short circuit problems caused by moisture. When using mobile charging pile cables, try to choose dry, flat ground so as to ensure the safe use of charging pile cables.
3. avoid overload
Nowadays, domestic professional EV charger station cables have several different power sockets, which can realize the requirements of charging electric vehicles with different powers. However, you should pay attention to one point: the same charging pile should not use more than one power appliance at the same time to avoid damage to the charging pile cable due to excessive load.
Luoyang Grasen Power Technology Co., Ltd is a professional AC home charger and DC fast charger EV supercharger manufacturer for 11 years in China, the charging connectors can be any two of CCS1/CCS2/CHAdeMO/GBT. Please enter our website for more information: https://www.grasen.com. Please send email to sales@grasen.com for inquiry.
-- Marcus Groll，A Charging Station Owner in UKRAINE
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