National Standard DC Electric Vehicle Charging Cable (90°C)

Executive Standards
- GB/T 33594-2017: "Cables for electric vehicle charging" (core national execution standard).

Model Code Definitions
- EVDC: Represents the DC electric vehicle charging cable series.
- (R): Conductor adopts flexible construction (stranded fine copper wires).
- S / S90: Insulation and sheath use specific thermoplastic elastomer or synthetic rubber; 90 indicates a rated operating temperature of 90 °C.
- P / P2: Shielding code for signal/control cores (P – copper wire braided shield; P2 – copper tape wrapped shield).

Product Specification Range
The cable adopts a composite construction design, covering four major functional modules: power, earthing, auxiliary power supply, and communication:
1. Main power cores: 2 cores × (10 – 95) mm² (responsible for high-power DC transmission).
2. Earth core: PE core.
3. Auxiliary power cores: 2 cores × (4 – 6) mm² (supplying power to the on-board charger or control system).
4. Signal or control cores: (4 – 12) cores × (0.75 – 2.5) mm² (usually with P/P2 shielding, responsible for BMS communication).

Core Technical Parameters
1. Rated voltage (U): 1000 V.
2. Rated operating temperature: The maximum continuous permissible conductor operating temperature is 90 °C.
3. Electrical performance: The cable features low DC resistance characteristics, reducing heat loss under high current; the insulation layer possesses high dielectric strength, and the finished product passes a power-frequency voltage withstand test.
4. Physical and weather resistance characteristics:
   - Crush resistance: Capable of withstanding accidental vehicle crushing at charging stations without structural damage.
   - Oil and chemical resistance: Sound resistance to grease and coolant.
   - UV resistance: Passes a 1008-hour xenon lamp ageing test, suitable for long-term outdoor exposure environments.
   - Long-life flexing: Supports tens of thousands of frequent flexing cycles, meeting the high-intensity usage requirements of charging connectors.

Cable Structural Characteristics
- Composite core construction: A special stranding lay length process is adopted, scientifically combining large cross-section power cores with small control shielded cores to ensure uniform internal stress distribution when the cable is bent, preventing core breakage or twisting deformation.
- High-efficiency communication shielding: The signal cores are configured with a high-coverage metallic shielding layer (P/P2), effectively blocking electromagnetic field interference generated by high DC voltage on CAN communication signals.
- Environmentally friendly protective layer: Both insulation and sheath materials are low-smoke zero-halogen, non-toxic, and environmentally friendly, with a smooth, abrasion-resistant, and slip-resistant feel, and sound self-extinguishing flame retardant properties.

Applicable Scenarios
- DC fast charging stations: High-voltage DC charging piles at highway service areas, urban fast charging centers, and large logistics parks.
- Special-purpose vehicle energy replenishment: Fixed or mobile charging equipment for electric buses, electric trucks, and special operation vehicles.
- DC distribution connections: Connection branch circuits from the power distribution cabinet inside the charging station to the charging terminal.

Selection and Maintenance Recommendations
1. Power matching: Select the corresponding main core cross-section according to the maximum output current of the charging pile (e.g., 120 A, 250 A, or higher) to ensure the cable temperature rise is controlled.
2. Communication protocol compatibility: Confirm that the number of BMS control cores (4 – 12 cores optional) meets the communication handshake requirements between the vehicle and the charging pile.
3. Installation practices: When routing cables at charging stations, maintain a reasonable bending radius and avoid friction between the cable and sharp metal edges.
4. Regular inspection: DC fast charging involves high power loss. It is recommended to periodically check the cable outer sheath for cracking or severe mechanical damage, and monitor abnormal cable temperature rise during the charging process.