Jaya Skandamoorthy BASEC

1. EV CHARGING CABLE – STANDARDS,
TESTING AND CERTIFICATION
Presentation at EV Charging Infrastructure UK 2022
CentrEd at Excel, London
Monday 27th June 2022
Jaya Skandamoorthy
Regional Technical Manager – UK & Europe
T: +44(0)1908 264468
M: +44(0)7584 195474
E: Jaya.Skandamoorthy@basec.org.uk
All Content © BASEC

2. 2
EV CHARGING CABLE –
STANDARDS, TESTING, AND
CERTIFICATION
Content
1. Introduction to BASEC
2. Overview of cable certification & type testing
3. Common types of cable failure and non-compliance
4. Analysis of EV market drivers & impact on cables
5. UK Government climate change policy & drivers
6. EV charging modes & standards (IEC and EN)
7. Rigorous cable testing - Four main testing areas
8. Charging cable supply chain and stages of testing
components and systems
9. Charging infrastructure cables – Case study
10. BASEC approval and guidance
11. Summary & Close
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3. 3
“
Jaya Skandamoorthy
Regional Technical Manager
UK & Europe
Jaya joined BASEC in June 2020 and brings considerable technical
and commercial experience in the construction industry. He
previously worked for a building research, testing and certification
body, where he led innovation projects and business growth in the
UK, Europe and China.
Jaya graduated in Civil Engineering from Imperial College London
and has conducted testing on buildings and civil infrastructures,
such as underground tunnel linings and highway bridges. He has
worked on the European Design Codes and the Construction
Products Directive and has significant expertise in policies,
regulations and standards.
Jaya is a qualified assessor for the CEEQUAL infrastructure
standard, a BREEAM professional and holds a post-graduate
diploma from the Chartered Institute of Marketing.
Biography
Contact Details
T: +44(0)1908 264468
M: +44(0)7584 195474
jaya.skandamoorthy@basec.org.uk

4. 1. Established in 1971
2. Long and stable history;
Strong heritage and trust -
impartial & independent.
3. Independent Third Party
Approvals body accredited
by UKAS.
4. Scope of certification covers
power, control, signal and
datacom cables.
5. Trusted and recognised in
over 28 countries.
A quality mark
that you can trust.
Our Purpose: “Continuously improving quality and safety.”

5. Operating on a worldwide basis and auditing in 28 countries
Bosnia and Herzegovina
Czech Republic, Greece,
Italy, Lithuania
Netherlands
Poland, Portugal
Spain, Switzerland
Turkey
Egypt
Kuwait
Oman
Qatar
Saudi Arabia
United Arab Emirates
Bangladesh
China
Hong Kong
India
Taiwan
Thailand
Trinidad and Tobago
USA
MEAF
21%
Asia / ROW
16%
Europe
33%
UK (England, Scotland,
Wales & Northern Ireland)
Republic of Ireland
UK & Ireland
30%
UK & Ireland
30%
Europe
33%
Middle East & Africa
21%
Asia / ROW
16%
BASEC Limited (Notified Body No. 2661) is able to issue UKCA System 1+ (sample selection, factory
inspection, type testing, and continuous assessment) & UKCA System 3 (basis of type testing)
BASEC Conformity Limited (Notified Body No. 2851) is able to issue CE System 1+
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6. 6
What is Certification? Type Test Report vs Product Approval Certificate
A key part of certification is to ensure that the claims of conformity made by cable manufacturers about their cable
are valid. The various cable standards refer to many supporting material standards, specifications and defined test
methods. The role of a third party testing is to verify that the design, electrical, mechanical, material properties of
cable at a ‘given time’, as well as any specialist performance needs, for reaction to chemicals or fire. A test report is
issued to verify the cable meets the necessary requirements (type tests). The role of a third party approval is to
certify the ‘on-going’ factory production control and quality management systems to ensure cables consistently
meet the performance requirements. A certificate is issued and valid for 3 years subject to ongoing compliance.
None

7. 7
Product & training certification Integrated triple standards
BASEC is accredited by UKAS for ISO/IEC
17065 for product certification, ISO/IEC 17025
for testing, and ISO/IEC 17021-1 for quality
management systems and environmental
management systems certifications.
CPR
Construction
Products
Regulation
PCR
Product
Certification
Rules &
Requirements
Testing
Laboratory
and on-site
testing
Stockist
Procurement
Selling &
compliance
practises
Preparation &
storage of
samples
Auditing and certification services
across product and management systems
New Schemes - Introducing new schemes for
solar PV, EV charging, datacoms, compounds, etc.

8. Aside from limited availability of fast, reliable
charge points, the most common causes of
charging cable failures are:.
▪ Component or accessory failures
▪ Weathering impacts, or
▪ Temperature rises due to cyclic use
▪ User damage
By nature charging cables, once installed in charge
points, will be left to their devices – so are these
cables at more risk than those in fixed systems?
Charging cables will be unmanned in public places,
subjected to handling of different levels and types
depending on the user, exposed to the elements:
wind, rain, sun, snow, and at risk of overheating
Common types of cable failures and non-compliance risks
Fake Approval Marking on Earthing
Cable
Non-compliant PVC Flex cable
Non-compliant armoured cable
Non Compliant
PVC Flexible
Cable
Sheath cracking – UV & heat
fatigue
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9. PEST Analysis – EV market drivers & impact on cables
1. Political
a) Climate Change – significant shift
in focus on ‘resilience’ and
climate adaptation; COP26;
b) Energy Security – Major
implications for UK market for
safety, compliance & assurance.
c) EV transition - policy for
transition from fossil fuel vehicles
to EV vehicles by 2030
2. Economic
a) EV Fiscal Stimulus – Package of
intervention measures and
high investment in UK EV
market and strategic
infrastructure programme.
b) Material shortage – Global
shortage of supply and
distribution (high price / low
quality); supply risks & quality
3. Social
a) Customers – local energy
generation by customers
b) Covid19 – travel restrictions
and impact on assurance
c) De-manning – engineering
assistance & support
d) Training – up-skilling & new
skills; greater competence;
4. Technical
a) Regulation – Changes to
England & Wales Regulation;
New Scottish Building Regs.
b) Smart systems – renewable
energy supply, real-time
monitoring, battery storage
c) Defects Liability – Latent vs
Patent / Inspection Regimes
Key Priorities
1. Risk – reduction, mitigation &
controls, management; supply chain
2. Resilience & Reliability – complex
energy systems / high performance
3. Assurance – Compliance to changing
regulations. Defects Liability
All Content © BASEC

10. Inflation construction and services
UK Government’s Climate Change Policy & Drivers
Leading Industry Response
– Roadmap
• Sustainability – Fire
• Sustainability – Reliability
• Sustainability – Resilience
Green Industrial Revolution – 10 Point Plan
On the 18th November 2020, the UK government launched its
Ten Point Plan for a Green Industrial Revolution (“Plan”) which
aims to mobilise £12 billion of government investment to directly
create up to 250,000 highly skilled green jobs and lever an
additional £38 billion of private sector investment by 2030.
• Point 1: Offshore wind: To produce enough offshore wind
energy to power every home in the UK, which would mean
scaling up its current production from 10GW to 40GW by
2030, and support up to 60,000 jobs.
• Point 4: Electric vehicles: To grow a world-leading EV
manufacturing base and accelerate the transition to electric
vehicles by ending the sale of new petrol and diesel cars
and vans by 2030 and transforming the UK’s national
infrastructure to better support electric vehicles.
• Point 7: Green buildings: To make UK’s homes, schools
and hospitals greener, warmer and more energy efficient,
with a target to install 600,000 heat pumps every year by
2028, whilst creating 50,000 jobs by 2030.
All Content © BASEC

11. 11
EV charging modes
cables
IEC / EN 61851-1 specifies different charging
modes and for each mode a different type of cable:
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12. EV charging cable standards
IEC 62893 series EN 50620
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13. IEC 62893 series
▪ 62893-1 – general requirements for
construction, dimensions and test
requirements for cables with extruded
insulation and sheath up to and including
600/1000 V and 1500V DC
▪ 62893-2 – test methods for cables with
extruded insulation and sheath, with the
same ratings as part 1 above
▪ 62893-3 – specifies types of EV cables,
applicable to AC charging modes 1, 2 and 3
of IEC 61851-1 up to and including
450/750V or ordinary duty cables 300/500V
as permitted in charging mode 1
EN 50620
▪ Specifies design, dimensions and test
requirements for halogen-free cables with
extruded insulation and sheath
▪ Voltage ratings up to and including 450 /
750V
▪ Applicable to flexible applications, under
severe conditions for power supply between
the charging station and the EV
▪ Relevant to modes 1, 2 and 3 of EN 61851-1
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14. Fire Testing
Chemical Testing
Material Testing
Electrical & Mechanical Testing
Rigorous cable testing - Four main testing areas ensures the quality of cables
BASEC is accredited by the United Kingdom Accreditation Services (UKAS) for ISO/IEC 17065 for product certification, ISO/IEC
17025 for testing, and ISO/IEC 17021-1 for quality management systems and environmental management systems certifications.
All Content © BASEC

15. Associated standards
As with all approvals a
certificationis made
up of a collection of
tests which together offer
the completecable
assessment
EN 50620
IEC 62893-2
BS EN 50620
Annex D
Chemicals
IEC EN
60811-507
Hot Set
BS EN 50620
Annex F
IEC 62893-2
Weathering/ UV
IEC 62893
series
IEC EN
60811–503
Shrinkage
ISO 48 for EVI-2
ISO 7619-1 or
HD605:S2 for
EVI-1
Shore Hardness
IEC 60811-509
Heat Shock
BS EN 50525-
1 IEC 62821-1
Assessment of
Halogens
IEC 62893-2
EN 50620
Annex C
Cold Impact
IEC EN 60811-
404
Mineral Oil
Immersion
IEC EN
60332-1-2
Vertical Flame
Propagation
IEC EN 60228
Conductor
Resistance
IEC 60245-2
EN 50395
Voltage Test
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16. 16
Charging cable supply chain and testing of components and systems
Cable
Manufacturer
Charge Unit
Assembly
Distribution
or EV OEM
Electrical
Contractor
Installation &
Maintenance
IEC 62196
standard includes cable
tests to assess
temperature rise, cable
pull, torque and cable
flexing
Once a cable is manufactured and gains certification via the rigorous testing
outlined by a third party approval body the ‘testing’ processes do not end here
As the approved cable moves through the supply chain, at each stage testing is
conducted to ensure components and systems are working as intended
In-house testing
coupled with
third party approval
testing
Testing to assess
compatibility of
charging cable to EV
and time taken to
charge
Testing to
assess assembly
functions as expected
quality check prior to
install
Installation testing
commissioning
and simulation of EV
charging to measure
outputs
Material quality testing
Functional testing
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17. Electric vehicle charging infrastructure power and data cables
British owned cable
manufacturer Doncaster Cables
has recently gained a BASEC
Certificate of Assessed Design
(CAD) certification for their
bespoke EV UltraTM cable
products. This cable is available
in 8 key variants, of which the 3
core is the most popular. The
data cable element of the
product is a CAT5e foil screened
twisted pair.
Case Study: Doncaster’s EV Cable BASEC Certificate
All Content © BASEC

18. 18
What is Certification? Type Test Report vs Product Approval Certificate
A key part of certification is to ensure that the claims of conformity made by cable manufacturers about their cable
are valid. The various cable standards refer to many supporting material standards, specifications and defined test
methods. The role of a third party testing is to verify that the design, electrical, mechanical, material properties of
cable at a ‘given time’, as well as any specialist performance needs, for reaction to chemicals or fire. A test report is
issued to verify the cable meets the necessary requirements (type tests). The role of a third party approval is to
certify the ‘on-going’ factory production control and quality management systems to ensure cables consistently
meet the performance requirements. A certificate is issued and valid for 3 years subject to ongoing compliance.
None

19. BASEC Guide for EV Charging Cables – Free Guide Download
Scan QR code to
download your free
BASEC guide to EV
Charing Cable
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20. Visit us at www.basec.org.uk
or call on +44 (0)1908 267 300
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@BASECCables
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Thank you
Download
BASEC guide
to EV Charging
Cable
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BASEC Cable
Certification
Application
Jaya Skandamoorthy
Regional Technical Manager – UK & Europe
E: Jaya.Skandamoorthy@basec.org.uk
T: +44(0)1908 264468
M: +44(0)7584195474
All Content © BASEC