GB/T 33594-2025Charging cables for electric vehicles (English PDF)

3.1 Nominal value

It refers to the specified magnitude which is often used in forms.

Note. In this standard, the magnitude which is usually introduced by the nominal value is verified through measurement under the consideration of the specified tolerance.

3.2 Median value

It refers to the middle value of the several values obtained from test AND arranged in the order of ascending (or descending) if the number of values is odd, OR the average of the middle two values if the number of values is even.

3.3 Rated voltage

It refers to the reference voltage which is used for cable design, use and electrical performance test.

3.4 Routine tests

It refers to the test performed by the manufacturer on all the manufacturing length of the cable to verify that all cables comply with the specified requirements.

3.5 Sample tests

It refers to the test performed by the manufacturer on the finished cable sample OR on some components from the finished cable to the required frequency, to verify that the cables comply with the specified requirements.

3.6 Type tests

It refers to the test performed on one type of cables covered in this standard in accordance with general commercial principles before the cable is supplied, to demonstrate that the cable has good properties that satisfy the intended service conditions.

4.1 Rated voltage

AC. U0/U is 450/750 V and below. DC. U0 is 1.0 kV and below.

4.2 Temperature range

Ambient temperature range is -40 °C ~ +50 °C, AND it shall select appropriate cables during use based on environmental needs.

5.1 Code

5.1.1 Product code

EV. electric vehicle AC (can be omitted). for AC charging DC. for DC charging

5.1.2 Conductor structure

(Omitted). the fifth copper conductor R. the 6th copper conductor

5.1.3 Insulation material code

S. Thermoplastic elastomer at continuous working temperature 70 °C (TPE) S90.Thermoplastic elastomer at continuous working temperature 90 °C (TPE) E. The ethylene-propylene rubber or similar synthetic rubber at continuous working temperature 90 °C EY. Rigid ethylene-propylene rubber or similar halogen-free synthetic material

5.1.4 Sheath (inner sheath) material code

S. Thermoplastic elastomer at continuous working temperature 70 °C (TPE)

5.2 Models

5.2.1 The cable model composition and arrangement sequence are as shown

in Figure 1.

5.2.2 Common cable model and name are as shown in Table 2.

6.1 Conductor

Conductor shall be of the 5th or 6th annealed copper conductor with/without metal plating in GB/T 3956-2008.Signal or control core conductors are allowed to be reinforced with a suitable material. Conductor nominal cross-sectional area is as shown in Table 3.

6.2 Isolation layer

It is allowed for conductor to be wrapped with a layer of suitable material to form an isolation layer.

6.3 Insulation (including main insulation core, grounding core, auxiliary

power core)

6.3.1 Structure

The insulation shall be wrap tightly around the conductor or isolation layer, AND shall be able to be stripped without damaging the insulation, conductor or tin plating, if any.

6.3.2 Materials

Insulation shall use one of the extruded molding insulation material mixtures as listed in Table 1.

6.3.3 Thickness

The nominal thickness of the insulation is as shown in Table 4, AND the thickness of any isolation layer shall not be included in the insulation thickness.

The average value of the insulation thickness measurement shall not be less than the specified nominal thickness, wherein the minimum measurement value shall not be less than 90% of the nominal value ~ 0.1 mm.

6.3.4 Spark test

Insulated core shall be subjected to the working frequency spark test as specified in Table 5 of GB/T 3048.9-2007 as an intermediate inspection.

6.4 Signal or control core

6.4.1 Structure

It is allowed for one or more signals or control cores.

If there is shielding, the signal or control core may be shielded in two ways.

bare copper or tinned copper wire braided shield; or aluminum-plastic composite tape wrapped shield plus bare copper or tinned copper wire braided composite shield.

6.5 Cable core and filler

6.5.1 Structure

All insulated cores (which may include signals or control cores) shall be twisted together. The signal or control cores may be twisted into a unit that is stranded with the other cores, BUT they shall not be in the center of the cable core.

It is allowed to use fillers when stranding the insulated cores.

6.5.2 Filler material

The material used as the filler shall be suitable for the operating temperature of the cable AND compatible with the insulation and sheathing material of the cable. In the case of halogen-free cables, the filler shall comply with the halogen content assessment in Table 13.

6.6 Inner sheath

6.6.1 Structure

If there is an overall shield, the cable core outside shall have extruded inner sheath.

6.7 Overall shield (if any)

The shield shall be braided into the inner sheath by bare copper or tinned copper wire.

The nominal diameter of the copper wire or tinned copper wire used for braiding is as shown in Table 6.

6.8 Sheath

6.8.1 Materials

Cable sheath shall be an extrusion-molded sheathing material mixture as listed in Table 1, which is wrapped around the braided shield or cable core.

Sheath shall be single-layer extruded, which shall be closely contacted with the insulated core or shield layer BUT not stick to each other.

6.8.2 Thickness

The nominal thickness of the sheath for each type and model of cable is as shown in Table 7 ~ Table 10.

6.9 Cable outer diameter

When user has requirement for the upper limit and lower limit of the average outer diameter, it shall follow the requirements of the user. The upper limit and lower limit of the average outer diameter of the cable as shown in Table 7 ~ Table 10 are for reference purposes only.

7.1 General requirements

Cable shall have the continuous marking of the manufacturer name, product code, cable model specifications and rated voltage. The manufacturer name marking may be the manufacturer's name or trademark.

Cable model is as shown in 5.2.

The marking may be printed with ink or embossed on the sheath.

7.2 Marking continuity

The distance between the end of a complete marking on the sheath surface and the beginning of the next complete marking shall not exceed 550 mm.

7.3 Clarity and rub resistance

All markings shall be clearly written.

Printing markings shall be rub resistance. The following tests shall be carried out to check whether the requirements are complied with. Wipe it gently with absorbent cotton or cotton cloth soaked in water for 10 times, AND then visually check that the printing on the cable surface shall be basically unchanged.

8.1 General requirements

The main insulated cable core shall be color-coded AND shall comply with 8.2.

Cable auxiliary power core, signal or control cores and other extension cores can be color or number identified, AND shall comply with the provisions of 8.2 and 8.3.

8.2 Color chromatography

8.2.1 General requirements

Cable insulated cores shall be identified by coloring the insulation or other suitable methods.

Except for cores identified in green/yellow color combinations, only one color per insulated core of the cable shall be used. Green and yellow cannot be used as independent colors.

8.2.2 Color chromatography

The coloring of the cable main insulated core shall give preference to the chromatography as follows.

8.2.3 Green/yellow combination

The core color distribution of the green/yellow combination shall comply with the following requirements. for each insulated core of 15 mm in length, one of the colors shall cover at least 30% and not more than 70% of the surface of the insulated core AND the other color shall cover the rest of the insulated core.

8.3 Number identification

8.3.1 General requirements

Auxiliary power cable cores, signal or control cores and other extension cores can use number identification.

The core insulation shall be of the same color and arranged in numerical order, except for the green/yellow core (if any).

8.3.2 Prioritized arrangement of numbers

The number markings shall be repeated at equal intervals along the insulated cores AND the two adjacent complete number markings shall be reversed to one another.

8.3.3 Rub resistance

Number markings shall be rub-resistant, AND it shall make inspection in accordance with the inspection method as specified in 7.3 to determine whether it complies with requirements.

9.1 Conductor DC resistance test

Finished cable shall be kept at the appropriate temperature in the laboratory for at least 12 h before conducting conductor DC test.

Conductors DC resistance test shall be performed in accordance with the requirements of GB/T 3048.4-2007.

Resistance measurements shall be corrected to the value equivalent to 1 km length at 20 °C in accordance with the formula and coefficient as specified in GB/T 3956-2008.

The conductor DC resistance at 20 °C of each conductor shall not exceed the corresponding maximum value as specified in GB/T 3956-2008.

9.2 Voltage test

Voltage test shall be carried out at ambient temperature, AC charging cable shall be tested in accordance with the requirements of GB/T 3048.8-2007,

9.3 Spark test

Insulated core shall be subjected to spark test in accordance with 6.3.4 and 6.4.4. ......