Charging Cable Test — IEC 62196 / IEC 62893

What Is Charging Cable?

The charging cable test evaluates the electrical safety, mechanical durability and temperature rise of the cable set and connectors between the vehicle and the charging station. The cable set is a component that is constantly plugged and unplugged, stepped on, and left outdoors; durability tests therefore carry significant weight.

Purpose of Charging Cable

The purpose is to verify that the cable and connector safely carry the declared current, retain their performance after repeated use, and withstand external influences.

Which Products Is Charging Cable Applied To?

Mode 2 and Mode 3 charging cables
AC and DC charging connectors (Type 1, Type 2, CCS)
Cable sets with a control box (IC-CPD)
Charging-station fixed cables

In Which Sectors Is Charging Cable Used?

AutomotiveElectrical & ElectronicsEnergy

Standards Related to Charging Cable

IEC 62196-1
IEC 62196-2
IEC 62196-3
IEC 62893 series
IEC 61851-1
IEC 60512

Charging Cable Conditions

Mating–unmating cycle: The number of cycles prescribed by the standard is applied; electrical properties are then remeasured
Temperature rise: The rise at the contact points is measured once steady state is reached at rated current
IP protection: Verified according to the IP class declared for the connector

Equipment for Charging Cable

Mating–unmating endurance rig
Temperature-rise test rig and thermocouples
High-voltage (dielectric-strength) tester
Micro-ohmmeter (contact resistance)
Crush, bend and pull test rigs
IP test rigs
Climate chamber

Sample Requirements for Charging Cable

Complete cable set (including connectors)
Multiple specimens are required for different tests; some are destructive
The declared rated current, voltage and IP class must be stated
Cable cross-section and length must represent the production configuration

Duration of Charging Cable

A typical campaign including durability and environmental tests takes several weeks; it varies according to the test list.

Charging Cable Procedure

1The specimen description, cross-section, length and rated values are recorded.
2Initial contact-resistance and dielectric-strength measurements are taken.
3The temperature-rise test is carried out at rated current.
4Mating–unmating endurance cycles are applied.
5Mechanical tests (crush, bend, pull, drop) are applied.
6Environmental tests (temperature, humidity, UV) are applied.
7Electrical measurements are repeated after the test and compared.

Charging Cable Acceptance Criteria

The acceptance criterion is the applied standard's temperature-rise limits, dielectric-strength requirements, and the permitted change in contact resistance after durability cycling. Values are taken from the standard's text.

Evaluation of Results

Comparing measurements before and after durability cycling is essential. An increase in contact resistance is the earliest indicator of an overheating problem in the field.

Charging Cable Report

Specimen description and rated values
Applied standards and list of tests
Temperature-rise measurement results
Electrical measurements before and after durability cycling
Mechanical and environmental test findings
Photographs

Accreditation

EUROLAB holds internationally recognised accreditation obtained from accreditation bodies party to the IAF and ILAC multilateral recognition arrangements, under ISO/IEC 17025 for laboratory testing, ISO/IEC 17020 for inspection and surveillance, and ISO/IEC 17021-1 and ISO/IEC 17065 for system and product certification. This chain ensures the reports and certificates issued are accepted worldwide.

Whether this test can be offered within accredited scope depends on your product and the standard applied; since accreditation is method-based, the scope is confirmed in writing at the quotation stage.

Scope and authorisations

Related Regulations

IEC 62196 connector requirements
Low Voltage Directive (LVD) scope

Otomotiv Testleri — What Does This Testing Field Cover?

The section below describes the field that the Charging Cable test belongs to; the conditions and acceptance criteria of this particular test are given in the sections above. The scope specific to your product is confirmed in writing at the quotation stage.

Automotive testing shows that a component keeps working under conditions representing the loads it will meet over the life of the vehicle. A vehicle is not a single product but an ENVIRONMENT: vibration, temperature cycling, salt water, stone impact, electrical transients and electromagnetic noise are all present at the same time and for years.

What distinguishes this family is that VEHICLE MANUFACTURER SPECIFICATIONS sit on top of the standards. ISO and SAE publications establish the common ground; but Volkswagen, BMW, Ford, Stellantis, Toyota and Renault define different severity levels, additional tests and different acceptance criteria in their own specifications. For a component, the phrase "complies with automotive standards" is not sufficient on its own; which manufacturer's specification, and which revision of it, must be answered.

The family carries three separate processes together and they are often confused. Homologation covers the type approvals a vehicle needs to enter traffic and runs under state authority. Supplier approval means passing the vehicle manufacturer's own quality and testing requirements and is a commercial relationship. The third is design verification: the engineering team demonstrating that its own design meets its targets.

At component level the test plan is built around the LOCATION OF USE. A module in the engine bay and a module in the boot do not go through the same temperature and vibration profile; a component inside a door and one in the roof console do not see the same water and dust exposure. The ISO 16750 series is the common framework for this location-based approach.

The shift to electric vehicles has reshaped the field. High-voltage safety, insulation coordination, battery safety, charging interface conformity and the electromagnetic behaviour of high-voltage components have been added to the classical automotive test set. In a quiet vehicle, acoustic and vibration expectations have changed too; sounds once masked by the combustion engine are now audible.

The quality system side cannot be separated from testing in this field. A manufacturer under IATF 16949 presents test results in the PPAP file; measurement system analysis, process capability study and the control plan stand around the test report. A single good result is not enough — the process must be shown to be able to repeat it.

Method groups in this field

Environmental and climatic
Temperature cycling, thermal shock, damp heat, salt spray, dust and water ingress (IP), solar radiation. Severity levels vary with the mounting location.
Mechanical
Sine and random vibration, shock, mechanical loads, fastener torque and durability cycles.
Electrical
Supply voltage variations, transients (ISO 7637), reverse polarity, overvoltage, short circuit and sleep current measurements.
EMC
Component emissions (CISPR 25), radiated and conducted immunity (ISO 11452 series), electrostatic discharge (ISO 10605).
Materials and emissions
Odour, fogging and VOC emissions from interior materials; flammability; UV ageing; coating durability and stone impact.
Functional safety and cyber security
Functional safety evidence under ISO 26262 and cyber security engineering under ISO/SAE 21434; these are tied to regulation through UNECE R155 and R156.

Commonly confused in this field

An automotive report without a specification reference is not accepted in the supply chain; which OEM specification and revision was applied must be stated.
Type approval and supplier approval are different processes. A component with E-Mark approval is not thereby considered to have passed the OEM's own acceptance tests.
A result obtained on a prototype does not carry over to series production; PPAP is done with series production parts.
On the EMC side, measuring emissions alone is incomplete; immunity is a separate body of work and is more critical in a vehicle.
On electric vehicle components, high-voltage safety is a distinct competence; classical 12 V test infrastructure is not sufficient.

Which decisions these results support

Supplier component approval and the PPAP file
UNECE type approval and E-Mark marking
Design verification and durability evidence
Root cause analysis of field complaints and warranty returns
Assessing the impact of a design or supplier change

Related Tests

Frequently Asked Questions About Charging Cable

Does the cable set require CE marking?

Cable sets with a control box (IC-CPD) fall under LVD and EMC scope as electrical equipment; conformity to the relevant product standards must also be demonstrated. Simple cable sets are also required to conform to cable and connector standards.