Comparison of EV Charging Cable Material Standards: EN 50620 vs. IEC 62893

Charging cables are one of the key components of new energy vehicles (NEVs) and electric vehicles (EVs). At present, the two most widely recognized standards for EV charging cables in the global market are the European standard EN 50620 and the international standard IEC 62893.

Today, EV charging cables mainly use TPU, TPE, XLPE, and EPR materials for insulation and sheath applications. Among them, TPU has become the preferred material for charging cable jackets because of its excellent abrasion resistance and outstanding mechanical protection. For the insulation layer, manufacturers typically select XLPE, EPR, or TPE according to cable design requirements and application scenarios.

From a material engineering perspective, this article compares EN 50620 and IEC 62893, explains the requirements of EVM-1/EVM-2 and EVI-1/EVI-2, and discusses the performance differences, test methods, test conditions, and engineering applications of different material systems.

1. EN 50620 vs. IEC 62893: Why Are There Different Standards for EV Charging Cables?

The rapid evolution of electric vehicle charging technologies has significantly changed the operating conditions of EV charging cables.

In the early stages of electric vehicle development, AC charging was the dominant charging method. Charging power was relatively low, and cable design focused primarily on flexibility, safety, and user convenience.

As demand for longer driving range increased, DC fast charging technology developed rapidly. Modern charging cables are now required to withstand higher voltages, larger currents, and greater thermal loads.

Against this background, EN 50620 and IEC 62893 were developed as two important standard systems for EV charging cables.

EN 50620 is mainly applied in the European market and focuses on the safety and reliability of charging connection cables. Since AC charging is widely used in European households and public parking facilities, the standard places particular emphasis on cable flexibility, mechanical performance, low-temperature performance, and halogen-free environmental protection.

IEC 62893 has a broader international scope and is intended for the global electric vehicle market. With the rapid adoption of 800 V vehicle platforms and high-power DC charging, IEC 62893 provides better support for high-voltage charging cable applications.

From an engineering perspective, neither standard is inherently superior to the other. Instead, each standard is designed to meet different application requirements.

In general, EN 50620 is better suited for charging cables where flexibility and everyday handling are the primary considerations, while IEC 62893 is more aligned with the future development of high-power DC fast charging and next-generation charging infrastructure.

2. EN 50620 vs. IEC 62893: Comparison of Key Technical Requirements

From a Material Engineering Perspective: How Standards Influence Material Selection

From a material engineering perspective, differences between standards directly affect material formulation and application scenarios.

For example, an EV charging cable designed for residential AC charging is handled by users every day. The cable must remain soft and flexible to ensure a comfortable user experience.

By contrast, a DC fast charging cable installed at highway charging stations is exposed to continuous dragging, abrasion against the ground and nearby vehicles, as well as higher operating temperatures. As a result, the jacket material must provide significantly greater durability and mechanical protection.

3. EV Charging Cable Construction: Why Is TPU Used for Jackets While TPE or XLPE Is Used for Insulation?

An EV charging cable mainly consists of a conductor, insulation layer, shielding layer, and outer jacket.

The insulation layer is applied directly over the conductor and serves as the primary electrical barrier to prevent current leakage and dielectric breakdown. The outer jacket is the cable's first line of defense against external mechanical and environmental damage.

Because these two layers perform different functions, they require different material systems.

For the jacket, TPU (Thermoplastic Polyurethane) has become one of the preferred materials for high-performance EV charging cables.

Compared with conventional PVC and many general-purpose thermoplastics, TPU offers superior abrasion resistance, tear strength, and elastic recovery.

During everyday use, charging cables are frequently subjected to demanding operating conditions, including:

• Repeated dragging by users

• Continuous abrasion against the ground

• Frequent bending in low-temperature environments

If the jacket material does not provide sufficient mechanical strength, surface wear, scratches, and crack propagation may occur after prolonged service.

The key advantage of TPU is its ability to maintain excellent flexibility while providing outstanding mechanical protection. For this reason, TPU has become the preferred jacket material for high-frequency EV charging cable applications.

4. EVM-1 vs. EVM-2: Understanding Jacket Material Classifications

Under the EN 50620 standard, EVM designates the performance classification of jacket materials for EV charging cables.

EVM-1 is intended for general operating environments, such as residential AC charging or applications with relatively low usage frequency.

The primary performance requirements for EVM-1 include:

• Good flexibility

• Adequate mechanical strength

• Environmental resistance

EVM-2, on the other hand, is designed for more demanding applications, including public charging stations, high-frequency charging environments, and outdoor installations.

The difference between EVM-1 and EVM-2 is not simply a matter of higher or lower performance. Instead, each classification is designed for a different service environment.

A residential charging cable may only be used a few times each week, while a public DC fast charging cable can experience frequent plugging, unplugging, dragging, and bending every day.

Consequently, EVM-2 requires significantly higher abrasion resistance and long-term mechanical durability.

In practical material development, high-performance TPU compounds are commonly selected to meet the requirements of EVM-2 jacket applications.

5. EVI-1 vs. EVI-2: Choosing Between TPE and XLPE Insulation Materials

EVI defines the insulation material classification for EV charging cables.

EVI-1 places greater emphasis on flexibility and ease of processing. As a result, TPE (Thermoplastic Elastomer) is widely used for this category.

TPE combines rubber-like elasticity with the processing advantages of thermoplastic materials. In AC charging applications such as 7 kW and 11 kW residential charging stations, charging cables are frequently bent, coiled, and stored. TPE provides excellent flexibility and handling characteristics under these conditions.

By comparison, XLPE (Cross-linked Polyethylene) is better suited for DC fast charging applications that demand higher reliability.

The cross-linked molecular structure of XLPE significantly improves its thermal stability, allowing the insulation to maintain excellent mechanical and electrical properties even under elevated temperatures.

During DC fast charging, higher current levels generate more heat inside the cable, while the insulation is subjected to continuous electrical stress. Materials with insufficient heat resistance may experience accelerated aging and insulation degradation.

For these reasons, XLPE offers clear advantages for EVI-2 insulation systems, particularly in high-power and high-voltage charging applications.

6. Comparison of Test Methods and Minimum Performance Requirements: EN 50620 vs. IEC 62893

Compliance with EN 50620 or IEC 62893 is determined by comprehensive testing rather than simply by the type of material used.

Both standards reference the IEC 60811 series of test methods for evaluating the mechanical, thermal, and environmental performance of cable insulation and jacket materials.

Although EN 50620 and IEC 62893 share many common test methods, the minimum performance requirements vary depending on the material classification, including EVI-1, EVI-2, EVM-1, and EVM-2.

Therefore, the required mechanical and thermal properties are determined by the material category rather than by a single universal requirement within the standard.

（1）Tensile Strength and Elongation at Break

Tensile testing evaluates the mechanical reliability of insulation and jacket materials.

Test Standard: IEC 60811-501

Standard dumbbell-shaped specimens are prepared and tested using a tensile testing machine to determine both tensile strength and elongation at break.

Typical minimum requirements for EV charging cable materials include:

• Tensile strength: ≥ 10 MPa

• Elongation at break: ≥ 300%

（2）Thermal Aging Test

During charging, cable conductors continuously generate heat. Therefore, insulation and jacket materials must demonstrate long-term thermal stability.

Test Standard: IEC 60811-401

Typical test condition:135°C × 168 hours

Mechanical properties are measured before and after thermal aging.

Typical acceptance criteria include:

• Tensile strength change: within ±30%

• Elongation at break change: within ±30%

This test is widely used to evaluate the long-term heat resistance of TPE, XLPE, and TPU materials.

（3）Hot Set Test

The Hot Set Test is primarily applicable to cross-linked insulation materials such as XLPE.

Typical test conditions:Temperature: 200°C、Mechanical load: 20 N/cm²

The test measures:

• Elongation under load at elevated temperature

• Permanent deformation after cooling

Typical requirements include:

• Maximum elongation under load: ≤ 175%

• Permanent elongation after cooling: ≤ 15%

The Hot Set Test is one of the most important methods for verifying whether the cross-linking degree of XLPE insulation is sufficient for long-term service.

It should be noted that EN 50620 is a product standard that references test methods such as IEC 60811 and IEC 60245, while IEC 62893 also adopts the IEC 60811 series for material testing. However, the minimum performance requirements are specified according to the individual material classifications (EVI-1, EVI-2, EVM-1, and EVM-2), rather than applying one identical requirement across all cable types.

For example, certain properties—including minimum tensile strength—are defined by the specific material class, not by the overall standard itself.

For EV charging cable manufacturers, the most effective material solution is not simply to select a single high-performance material. Instead, the optimal approach is to develop a scientifically balanced material system based on the requirements of EN 50620 and IEC 62893, while considering the performance classifications of EVM-1/EVM-2 and EVI-1/EVI-2. By selecting the appropriate combination of TPU, TPE, and XLPE, manufacturers can produce highly reliable EV charging cables that meet the evolving demands of the electric vehicle industry.

Recommended Products: Angreen's EV Charging Cable Material Solutions for EN 50620 and IEC 62893

As charging power continues to increase in the electric vehicle industry, different charging scenarios place different performance requirements on insulation and jacket materials.

Angreen New Materials offers a comprehensive range of EV charging cable material solutions that comply with the requirements of EN 50620 and IEC 62893. Whether for AC charging, DC fast charging, or outdoor public charging stations, different material systems can be selected according to the target application and product positioning.