A practical B2B checklist for specifying EV high-voltage cable requirements, including voltage class, conductor size, shielding, temperature, environment, termination, compliance evidence, quantity and destination.
High-voltage cable quotations become slower and less comparable when the request contains only a cable name or a photo. A useful RFQ should describe the electrical, mechanical, environmental and documentation requirements that the supplier must quote against. This guide is a preparation checklist, not an engineering approval or a substitute for the vehicle or equipment manufacturer's specification.
1. Identify the exact application
State whether the cable is for a traction battery, power distribution unit, inverter, on-board charger, DC charging equipment, energy-storage equipment or an auxiliary high-voltage circuit. Explain whether you need bulk cable, a cut length or a completed assembly. The same conductor size can require different insulation, shielding, flexibility and termination choices in different locations.
2. State the system voltage and cable class
Provide nominal voltage, maximum continuous voltage and any transient requirement defined by your engineering team. ISO 19642-1:2023 defines terminology used across the ISO 19642 automotive-cable family, including 60 V, 900 V and 1,500 V cable categories. The correct part depends on conductor material and construction, so ask the supplier to identify the exact standard, edition and evidence for the offered part.
3. Give conductor and current requirements
- Copper or aluminium conductor and required cross-sectional area.
- Continuous current plus any peak-current profile.
- Ambient temperature, bundling, routing and cooling assumptions.
- Maximum voltage drop if it is part of the approved design.
A catalogue current rating is not universal. Cable temperature depends on conductor size, insulation, ambient conditions, bundling, terminals and duty cycle. Request the manufacturer's rating conditions.
4. Define construction and mechanical constraints
- Single-core or multi-core; shielded or unshielded.
- Insulation and jacket requirements.
- Maximum outside diameter, minimum bend radius and flexibility.
- Colour, marking, cut length, tolerance and stripping requirements.
If the cable must fit an existing connector, gland or routing clip, include the approved drawing and dimensional limits.
5. Describe the operating environment
List temperatures and exposure to water, dust, oils, coolant, road salt, abrasion, vibration and flame requirements. If an IP rating is required for an assembly, state whether it applies mated, unmated or after a defined sequence. IEC 60529 covers ingress-protection coding, but the exact configuration and test evidence still matter.
6. Separate requirements from certification evidence
For EV charging cable, UL Solutions lists UL 2263, EN 50620 and the IEC 62893 series for different markets and scopes. On-board vehicle cable may use a different standard family. When certification is mandatory, request the certificate number, issuing body, product scope and matching part number. A brochure logo is not enough.
7. Add commercial and logistics data
- Sample, first-order and forecast quantities with units.
- Destination, requested Incoterm and schedule.
- Packaging, labelling and traceability requirements.
- Whether alternatives are allowed and which parameters cannot change.
FAQ
Can cable size be selected from current alone?
No. Voltage drop, thermal environment, duty cycle, conductor material, routing, terminals and the approved safety design also matter.
Why not request a fixed public price?
Quantity, specification, testing, packaging, destination and commercial terms affect project quotations.
Primary references
Next step: submit the part number or drawing, quantity, destination and non-negotiable requirements. Compliance, availability, lead time and commercial terms remain subject to document review and quotation.