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Charging Cable Structure and Specifications Explained

Last updated Sep 23, 2026

The test report covers EVC H05BZ5-F and EVC H07BZ5-F cables for electric vehicle conductive charging systems. Their confirmed construction includes a black TPU outer jacket, filler and tape, XLPO insulation, copper power conductors, and control or signal cores. The conductor size, cable diameter and test results depend on the individual cable construction.

Important: The values below apply only to the cable constructions identified in the report. Do not apply the specifications of one cable to a different model or product version.

Which cable families are covered?

  • EVC H05BZ5-F
  • EVC H07BZ5-F

These are cable family designations. The full marking, including the conductor configuration, is needed to identify a specific cable.

How is the cable constructed?

From the outside to the inside, the report-based structure is:

  1. TPU outer jacket
  2. Filler and tape
  3. XLPO insulation
  4. Power conductors
  5. Control or signal cores
Cable part Confirmed material or construction Purpose
Outer jacket Black EVM-1 TPU, 1185D-EMS-1138S Protects the cable from mechanical stress and outdoor exposure
Filler and tape Present beneath the outer jacket Forms part of the internal cable structure
Insulation EVI-2 XLPO, MG80019S-125 Provides electrical protection around the power and control or signal conductors
Power conductors 99.98% copper wire, Class 5 flexible conductor Carries electrical power
Control or signal cores Flexible conductors in the confirmed sizes listed below Used for CP and CC control signals


What power conductor sizes are covered?

The report covers cable constructions with the following power conductor cross-sections:

  • 1.5 mm²
  • 2.5 mm²
  • 4 mm²
  • 6 mm²
  • 10 mm²
  • 16 mm²
  • 25 mm²
  • 35 mm²

This does not mean that every cable contains all these conductor sizes. The applicable size is identified by the complete cable specification.

How do the tested cable specifications differ?

Tested cable Power conductors Control conductor Average outer diameter
H07BZ5-F 5×2.5+0.75 5 conductors, 2.5 mm² each 0.75 mm² 12.8 mm
H07BZ5-F 3×35+0.75 3 conductors, 35 mm² each 0.75 mm² 30.7 mm

The conductor cross-section and the complete cable construction affect the cable diameter. The outer diameter is not the same as the cross-sectional area of an individual conductor.

What are the control and signal conductor specifications?

The report lists the following conductor sizes and strand counts for control or signal cores:

Conductor size Number of strands
0.5 mm² 25
0.75 mm² 37
1.0 mm² 50

For the H07BZ5-F 5×2.5+0.75 sample, the measured CP core capacitance was 119 pF/m. The specified limit was no more than 150 pF/m, and the sample passed.

What flexibility and durability tests were completed?

Tested cable Test Result
H07BZ5-F 5×2.5+0.75 30,000 cycles and 60,000 movements No interruption or short circuit
H07BZ5-F 3×35+0.75 10,000 cycles No cracks

For confirmed low-temperature test conditions and results, see Does the Charging Cable Stay Flexible in Cold Weather?.

What electrical ratings were tested?

The report covers rated voltage classes of AC 300/300 V and AC 450/750 V. The applicable rating depends on the cable designation and construction.

During the voltage withstand test, the cable was tested at AC 3.5 kV for 15 minutes. No electrical breakdown occurred.

What environmental tests were completed?

Test category Result
Low-temperature test at −40°C Pass
UV exposure Pass
Ozone exposure Pass
Oil and chemical exposure Pass
Flame test Pass

The chemical exposure tests included engine oil, gasoline, diesel, urea solution, antifreeze and brake fluid. No cracks were found after the confirmed tests.

These results describe performance under the specified test conditions. They do not mean that the cable is completely waterproof, immune to damage or suitable for every environment.

How do I identify the cable on my product?

  1. Find the full cable designation.

    Check the cable marking or the technical information in the product manual. Record the complete designation, including the conductor configuration after H05BZ5-F or H07BZ5-F.

  2. Check the product version.

    Use the rated power, model and version shown on the product label or in your order information.

  3. Open the matching manual.

    For a portable charger, use the Portable AC Charger User Manuals – 3–22 kW Series. For an AC Wallbox, use the 7/11/22 kW Wallbox User Manual page.

  4. Do not substitute specifications from another cable.

    If the complete marking does not match the examples in this article, refer to the manual for that product or contact dé support. Prepare a photo of the product label, a photo of the cable marking, your order number and the country of purchase.

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