When fleet decision-makers are thinking about operating electric vehicles (EVs), the AC charging cable is probably way down the list of their considerations ' and rightly so.
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Range, charging times and where and when to plug the EVs in are among the issues which have a higher importance when it comes to successfully operating battery electric vehicles (BEVs).
However, while cables also lack the glamour of the latest vehicles and developing battery technologies, they play a vital role in their operation.
Understanding their impact, knowing how to care for them and recognising when it is time for a replacement cable can save a fleet time and money, as well as ensuring the vehicles can be charged correctly so they are ready to use when needed.
Often drivers will just use the cable supplied with their vehicle and then put it in their boot, forgetting about it until is needed again.
But this approach could have negative implications for both the employee and fleet decision-maker, says James Louw, director of engineering at EV Cables.
'Charging cables not only deliver electric power from the charge point to your car's battery, they also influence the speed at which your vehicle charges,' he says.
'A damaged or inadequate cable could result in slower charging times, increased energy loss and, in extreme cases, could pose safety risks such as electric shocks or fires.
'For fleet operators, cable maintenance is even more critical as it directly impacts operational 'efficiency and safety on a large scale.'
A high-quality, well-maintained cable can 'minimise energy loss during the charging process, but a lower quality or deteriorated one may result in higher resistance, leading to wasted energy and longer charging times.
'This wasted energy is realised as heat and results in plugs that can get so hot that users burn themselves when trying to remove them from charge,' adds Louw.
'A cool cable is a happy cable. For businesses operating fleets of EVs, these small inefficiencies can add up to a significant expense and carbon footprint, and injuries caused by improperly 'maintained charging equipment leave businesses exposed to expensive legal claims.'
Louw recommends regular cable checks should form part of a daily or weekly maintenance schedule.
A simple, but effective, step is to inspect the cable for visible damage, such as cracks, frayed ends or exposed wires.
Drivers should be instructed to store cables in a clean, dry place when not in use. Moist environments can cause corrosion, while exposure to harsh sunlight may weaken the cable's outer layer.
Trying to yank the cable out of the vehicle or charge point is also discouraged; this can damage the connectors or the cable itself. Drivers should use the connector handle to remove the cable from a socket and not pull on the cable itself.
The most vulnerable parts of a charging cable are the electrical contacts, says Louw.
'By periodically using non-conductive contact cleaners, any corrosion can be cleaned away before oxide build-up can start causing a noticeable effect on cable performance,' he says.
There are three occasions when a charging cable should be replaced: physical damage, charging inconsistencies or scheduled replacement.
'If there are visible signs of wear and tear, such as fraying or cracks, it's time to replace the cable,' Louw adds.
'If you notice the charging time has increased inexplicably or if there are intermittent 'interruptions, the cable might be the culprit.
'A common mode of failure for EV charging cables is the breakage of the communication line within the cable. Because this core is usually thinner than the power cores, it is usually the first to break when the cable is exposed to excessive strain.'
Under the current Electricity at Work Regulations, there is no requirement for a charging cable to be PAT (portable appliance testing) tested but, for commercial vehicles, EV Cables recommends a yearly cable inspection and thorough testing of areas such as insulation resistance, contact 'resistance and continuity tests.
Louw adds all charging cables are rated for 10,000 insertion cycles, but, in reality, a cable 'will need to be replaced well before this. He 'recommends cables for commercial vehicles are replaced after three years.
'Planned lifecycles allow fleet operators to 'minimise downtime risk and budget for the equipment needed to keep their fleets charged and moving,' says Louw.
The Association of Fleet Professionals (AFP) is investigating discrepancies in the amount of energy lost between a charge point and a vehicle battery after some of its members reporting discrepancies of as much as 15%.
Fleets are able to monitor the respective values by comparing data from the charge point and a vehicle's telematics system.
' have been seeing, on average, a 5-7% loss. In some instances, it is as extreme as nearly 14% or 15%,' says Hollick.
The AFP wants to help fleets understand what is behind the apparent electricity loss, with consideration being given to how charge points are calibrated and the accuracy of telematics data.
Hollick says it is too early to draw conclusions, but suggested that some of the electricity being lost could be down to the EV charging cable, with its length potentially playing a part.
Lorna McAtear, fleet manager at National Grid, says: 'There's more than just the cable that needs to be factored into this, it's not just that.'
She said there are 'so many variables' including the efficiency of the charger and the impact of different systems within the car on its energy usage and storage.
'It might not be the cable that's losing anything at all, it might be what the manufacturer has stated versus what you're physically able to get.'
Research conducted by German automobile club ADAC last year showed that charging losses vary greatly, depending on how charging is carried out ' at home using a domestic AC plug socket, using a wallbox with up to 11kW or with half the power.
It found that charging losses at the household socket are between 10-30%, while charging losses via a wall box are between only 5-10%
It noted that the on-board electronics and some of the vehicle's control units are active during the entire charging process, and therefore consume electricity.
When charging with AC, the rule of thumb applies, it says. 'The higher the charging power, the shorter the charging process and thus the time in which charging loss occurs,' adds ADAC.
EV Cables has done its own research on this issue, and found the power loss increases as the cable gets longer.
'I believe concerns people more when investigating longer cable runs,' says James Louw, director of engineering at EV Cables.
This feature was taken from our special Electric Fleet Report, which will help organisations take the next step to fully decarbonise their
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As electric vehicles (EVs) continue to grow in popularity, the need for reliable and efficient charging solutions becomes increasingly important. Choosing the right EV charging cable is crucial to ensure your vehicle charges safely and efficiently.
At Cableworld, we're leading suppliers of specialist electrical cables in the UK, offering a wide range of EV charging cables and accessories suited for any job or project. In this guide, we'll look at the different types of EV charging cables available and their specific uses.
EV charging cables, also known as electric vehicle charging cables, are essential for connecting EVs to charging stations. These cables come with specific connectors that must be compatible with both the vehicle and the charging station. Selecting the right cable ensures efficient charging and prevents potential damage to the vehicle's electrical system.
Type 1 connectors, often found on older or imported EVs from North America and some Asian markets, are single-phase with a 5-pin design. These connectors provide a simple and effective way to charge your vehicle.
Type 1 charging cables are typically used for home charging stations and are compatible with vehicles that have Type 1 inlets, such as the Nissan Leaf and Mitsubishi Outlander PHEV.
Type 2 connectors are the standard in Europe and are becoming increasingly common worldwide. Capable of handling both single-phase and three-phase power, these connectors offer greater versatility than Type 1 connectors.
Type 2 charging cables are suitable for both home and public charging stations and can be used with a wide range of modern EVs, including the BMW i3, Tesla Model S, and Renault Zoe. At Cableworld, we provide Type 2 to Type 2 EV Charging Cables designed for efficient and reliable charging of vehicles with Type 2 connectors.
Type 1 to Type 2 adapter cables are essential for ensuring compatibility between different types of EV connectors. These adapters allow vehicles with Type 1 connectors to charge at Type 2 charging stations, bridging the gap between different standards.
This ensures that EV owners can charge their vehicles at more locations, regardless of the connector type. The Type 1 to Type 2 EV Adapter Cable from Cableworld enables Type 1 vehicles to connect to Type 2 chargers, providing compatibility and flexibility for diverse charging needs.
The EV-Ultra® charging cable is a cutting-edge solution tailored specifically for electric vehicle charge points. This cable combines power conductors with a screened 2-core data cable, all within a double-sheathed design, providing enhanced protection and versatility.
Key Features
Power and Data Combined: The integration of power and data cables within a single sheath simplifies installation and enhances functionality.
Double-Sheathed Design: This design ensures robust protection against environmental factors and mechanical damage.
Versatile Installation Options: The EV-Ultra® cable can be installed in various ways, including air installations, surface clipping, cable tray/ladder work, and embedding in concrete.
Suitable for Direct Ground Installation: With appropriate mechanical protection, this cable is suitable for direct burial, making it a versatile choice for various installation environments.
The EV-Ultra® + Cat5e cable builds on the foundation of the EV-Ultra® by incorporating Cat5e data capabilities. This makes it an ideal choice for installations requiring both power and high-speed data transmission.
Key Features
Integration of Power Conductors and 2-Core Screened Data Cable: This design meets the needs of modern EV charge points, providing both power and reliable data transmission.
Availability in 3-Core and 5-Core Variations: These variations ensure compatibility with both single-phase and three-phase EV charge points.
Compliance with Single and Three-Phase EV Charge Points: The cable meets the specific requirements of various charging systems, ensuring broad compatibility.
Versatile Installation Options: Similar to the EV-Ultra® cable, this version supports multiple installation methods, including air, surface clipping, cable tray/ladder work, and embedding in concrete.
In the UK, the absence of a recognised British Standard for EV charging cables presents a challenge for installers. According to BS, installers are responsible for ensuring the safety and compliance of the equipment they use, even when it is not covered by national or international standards.
Full third-party accreditation is crucial to demonstrate the safety and performance of EV charging cables. This accreditation provides installers with the confidence that the cables meet rigorous safety and performance standards.
Cableworld's EV-Ultra® cables have undergone thorough third-party testing and accreditation through BASEC (British Approvals Service for Cables).
The BASEC accreditation process is as follows:
The accreditation process involves rigorous testing to ensure the cables meet the highest safety and performance standards.
The EV-Ultra® cables received positive feedback from the BASEC Data Laboratory manager, which highlighted that 'the data properties of the cable had exceeded all expectations,', underscoring the dedication of our Research and Development team. This accreditation adds significant value, providing installers with a reliable and accredited product they can trust.
The EV-Ultra® cable incorporates CarbonTek technology, a specially developed compound that enhances its performance and durability.
The high abrasion resistance ensures the cable can withstand harsh conditions and physical wear, and impact resistance protects the cable from damage due to physical impacts.
With thermal and UV stability, the cable's performance is maintained even in extreme temperatures and when exposed to sunlight for a prolonged amount of time.
Thanks to the enhanced flexibility of the cable, the installation process becomes much simpler, quicker and neater.
EV-Ultra® incorporates screened, twisted pair data cables and a lay length designed to reduce interference. Third-party data testing under BASEC approval confirms the successful design solution, ensuring excellent data transmission without interference.
By choosing Cableworld's specialised EV charging cables, you can ensure efficient, reliable, and compliant charging solutions for your electric vehicle needs.
Selecting the correct EV charging cable is important for ensuring the safe and efficient charging of electric vehicles.
Make sure the cable is compatible with your vehicle's connector type (Type 1 or Type 2). Check your vehicle's manual or contact the manufacturer if you're unsure.
Verify that the cable matches the connector type of the charging station you plan to use. Many public charging stations in Europe use Type 2 connectors.
Choose a cable length that suits your typical charging setup. Longer cables offer more flexibility but can be more cumbersome to store and manage.
Consider the power rating of the cable to match your vehicle's charging capabilities. Higher-rated cables can handle faster charging speeds.
Make sure the cable is suitable for your intended installation environment, whether it's for home, public, or commercial use. Check for features like weather resistance and mechanical protection if the cable will be exposed to harsh conditions.
Type 1 connectors are typically used with older or imported EVs and are single-phase, whereas Type 2 connectors are the European standard and can handle both single-phase and three-phase power, making them more versatile.
Yes, a Type 1 to Type 2 adapter cable allows vehicles with Type 1 connectors to charge at stations with Type 2 connectors. However, always ensure the adapter is compatible with your specific vehicle and charging station.
EV-Ultra® cables offer a combination of power and data transmission in a single cable, enhanced protection with a double-sheathed design, versatility in installation options, and advanced features like CarbonTek technology for improved durability and flexibility.
Use cables that have third-party accreditation, such as those from BASEC, which confirms they meet rigorous safety and performance standards. Follow the installation and usage guidelines outlined by relevant regulations like BS.
Consider the installation environment, cable length, power rating, and compliance with safety regulations. Ensure the cable is installed securely and protected from environmental factors. Professional installation by a qualified electrician is recommended for optimal safety and performance.