Mode 4 DC EV Charging Cable, 1.5 kV

DC EV charging cable carries power, protective earth and the specified control or pilot circuits between a charging station and the vehicle connection. This range covers a class 6 flexible Mode 4 construction and separate class 5 S1BZ5-F and Type 126 constructions. The DC voltage class is 1.5 kV; the additional AC rating is stated only for the relevant construction.

Start with the required circuit arrangement. A class 6 reference combines two DC power conductors, one protective-earth conductor and a six-core control/pilot group. Other tables use paired auxiliary circuits or a different power-core arrangement. Match the count and cross-section to the charger, vehicle connector and termination drawing before checking the outside diameter.

Select the complete material and operating envelope. The class 6 construction uses rubber insulation and a halogen-free polyurethane sheath. S1BZ5-F uses HEPR type EVI-2 insulation and an EVM-1 TPU sheath, while the Type 126 construction lists EVI-2 insulation and an EVM-1 sheath compound. Their conductor classes, bending rules, short-circuit conditions and installation temperatures are separate parameters.

Provide the DC voltage, current duty, ambient temperature, cut length and connector interface with the enquiry. Check the installed bend, pulling load and movement conditions together with the equipment design. The class 6 current table retains its 30°C basis and temperature correction factors. Terminate every power, earth and auxiliary core for its assigned circuit and provide mechanical strain relief at the lead ends.

Explore the industrial cable range for related configurations.

For lower-voltage AC charging leads and hybrid power-plus-signal dispenser assemblies, compare these EV charging cable constructions: EV Charging Power and Data Composite Cable, 0.6/1 kV (for 0.6/1 kV composite AC/DC charging cables combining main power cores with shielded data and control pairs); H05BZ5-F / H07BZ5-F EV Charging Cable (for 300/500 V and 450/750 V Mode 1–3 AC charging leads with halogen-free EVI-2 / PUR sheaths). Verify maximum DC bus voltage, thermal sensor pair count, and outdoor driveway abrasion resistance before ordering.

Construction

The representative class 6 Mode 4 cable is 2 × 16 + 1G16 mm² with 1 × (6 × 1 mm²) control/pilot conductors. It has three equal large insulated copper conductors in a compact triangular arrangement and six smaller auxiliary cores grouped above them, within a black PUR-HF sheath.

Applications

Select a flexible Mode 4 lead for the charging-station-to-vehicle connection. Match the required power, protective-earth and control/pilot circuits to the connector system and charger design.

• Mode 4 DC vehicle charging leads for public and commercial charging stations.
• Trailing plug connections to the vehicle with cable movement controlled by the charger layout, bend limits and end supports.
• Class 6 flexible leads using the six-core auxiliary group or class 5 S1BZ5-F / Type 126 leads with the specified auxiliary configuration.
• The class 6 Mode 4 construction includes an AD7 temporary-immersion reference; define the actual water-exposure conditions with the equipment requirements.
• Select environmental, oil, UV, ozone and mechanical test requirements for the exact construction; retain its own standard references.
• Arrange strain relief, protective-earth termination and preparation of all auxiliary cores at the lead ends.

For jacket oil-resistance classifications on forecourt dispensers and shielded onboard EV battery cables, consult these references: Oil Resistant Cable: PR I vs PR II (comparing hydrocarbon, diesel, and hydraulic fluid immersion ratings for industrial elastomer and PUR jackets); FHLR2GCB2G Shielded EV Cable 0.6/1 kV (for 0.6/1 kV EMC-screened vehicle internal high-voltage traction interconnects). Confirm cooling mode, minimum cold-bend temperature, and gland sealing class.

Specifications

The class 6 current values apply at 30°C ambient. Apply the listed ambient-temperature correction factor and coordinate the installed current with routing, loading and equipment conditions.

Each dimension row retains its conductor count and auxiliary grouping. Three pairs, four pairs, six individual auxiliary cores and a six-core grouped unit are different configurations.

The class 6 Mode 4 electrical test lists 3500 V DC for power cores and a separate 2000 V reference for control/pilot cores. These are test conditions, not additional operating ratings.

The Type 126 250°C and 200°C short-circuit limits apply to bare and tinned conductor constructions respectively, for a maximum of 5 s. Do not apply them to the class 6 160°C reference.

Select connector compatibility, circuit assignment, cut length, water-exposure conditions and installation support with the charger and vehicle-interface requirements.

Standards