EV-CP-2x0.5
EV Charging Cable with Signalling Control Pair (CP / PP)
The control pilot and proximity pair carried inside the same sheath, screened so the PWM signal survives next to the phases.
Two thin conductors decide whether an AC charge session starts at all. The control pilot carries a 1 kHz PWM signal on a ±12 V line from the charge controller to the vehicle, and the duty cycle of that signal is the current limit the car obeys. The proximity pilot is a resistor loop that tells the car how much current the attached cable is rated for, and it is also the circuit that stops the car driving off with the connector still in.
Because that resistor sits in the connector and the conductor sits in the cable, the two have to be specified together or the vehicle will draw more current than the copper was built for. Voltcore carries 2 × 0.5 mm² tinned copper for the pair, screens it where the design needs a clean signal, and lays it into the assembly so it sits clear of the phases rather than being crushed against them during cabling.
Specification
| Item | Value |
|---|---|
| Interface standard | EN 62196-2, Type 2 |
| Rated voltage | 250 V AC single-phase / 480 V AC three-phase |
| Signalling conductor | 2 × 0.5 mm² flexible tinned copper, Class 5 |
| Signalling loop resistance | ≤ 78 Ω/km at 20 °C for the 0.5 mm² pair |
| Screen | Aluminium/polymer tape with drain wire, optional |
| Power conductor range | 1.5 – 16 mm² |
| Proximity resistor values | 1.5 kΩ (13 A), 680 Ω (20 A), 220 Ω (32 A), 100 Ω (63 A) |
| Control pilot signal | 1 kHz ±12 V PWM, duty cycle sets the current limit |
| Insulation | TPE elastomer, 0.8 mm nominal |
| Sheath | TPU or TPE, oil and UV resistant |
| Service temperature | −30 °C to +90 °C |
| Flame behaviour | IEC 60332-1-2 |
Layer-by-layer construction
Listed from the conductor outward. Read this alongside the specification table — the two together tell you whether the cable will survive its installation method.
- 1. Power conductorClass 5 flexible plain copper, 1.5–16 mm², colour identified to EN 62196-2 practice
- 2. InsulationTPE elastomer over each power core, 0.8 mm nominal
- 3. Signalling pair2 × 0.5 mm² tinned copper, laid as a pair and wrapped in aluminium/polymer tape with a drain wire where screened
- 4. BinderNon-woven tape to keep the pair separate from the phases under the sheath
- 5. SheathTPU or TPE, 1.2–1.6 mm nominal, oil, UV and abrasion resistant
- 6. MarkingSheath print with EN 62196-2, configuration, rated current and metre mark
Reference dimensions and weights
| Power core cross-section (mm²) | Configuration | Signalling pair (mm²) | Sheath thickness (mm) | Approx. overall diameter (mm) | Approx. weight (kg/km) | Rated current (A) |
|---|---|---|---|---|---|---|
| 1.5 | 5 cores + 2 × 0.5 | 2 × 0.5 | 1.2 | 11.4 | 188 | 16 |
| 2.5 | 5 cores + 2 × 0.5 | 2 × 0.5 | 1.3 | 12.6 | 258 | 20 |
| 4 | 5 cores + 2 × 0.5 | 2 × 0.5 | 1.3 | 14.0 | 348 | 25 |
| 6 | 5 cores + 2 × 0.5 | 2 × 0.5 | 1.4 | 15.8 | 478 | 32 |
| 10 | 5 cores + 2 × 0.5 | 2 × 0.5 | 1.5 | 19.1 | 708 | 44 |
| 16 | 5 cores + 2 × 0.5 | 2 × 0.5 | 1.6 | 22.7 | 1058 | 63 |
Reference figures for preliminary sizing and drum planning. Overall diameter and weight vary with strand construction and sheath thickness tolerance; certified drawings are issued with each quotation.
Engineering characteristics
- The 2 × 0.5 mm² pair is carried inside the same sheath as the phases, so there is no second cable on the charge post.
- Screening with aluminium/polymer tape and a drain wire keeps the 1 kHz PWM signal clean next to three loaded phases.
- Proximity resistor is set in the connector to match the cable's own current rating: 220 Ω for a 32 A cable, 100 Ω for 63 A.
- Tinned copper on the signalling pair keeps a low-resistance contact at the connector pin over repeated mating cycles.
- The pair is laid clear of the phases under a binder tape, which prevents crushing during repeated coiling.
- Loop resistance ≤ 78 Ω/km at 20 °C, low enough that the voltage at the car end of the control line stays within the EN 62196-2 window.
Typical applications
- Assembled Type 2 mode 3 charging leads for public charge points
- Wallbox and charge controller production under OEM supply
- Fleet depot charging posts with cable management arms
- Three-phase 32 A and 63 A charge points on commercial premises
- Replacement leads for charge point operators maintaining an installed base
Ordering options
- Screened or unscreened 2 × 0.5 mm² signalling pair
- Proximity resistor fitted in the vehicle connector: 1.5 kΩ, 680 Ω, 220 Ω or 100 Ω
- TPU or TPE sheath, matt or gloss
- Supplied as bulk cable, or cut and terminated to your pin-out
- OEM printing and private-label packaging for charge point brands
Standards manufactured to
- EN 62196-2
- IEC 62196-2
- IEC 60228
- IEC 60332-1-2
- RoHS
Manufactured to other standards on request. Send the standard number with your RFQ and we will quote against it rather than against a near-equivalent.
Price and availability for EV Charging Cable with Signalling Control Pair
Include cross-section, core count, voltage grade, route length and installation method — those five determine price more than anything else on the page.
- Engineer-reviewed before pricing
- Reference drawings issued with the quotation
- Free sample up to free sample up to 5 m
EV Charging Cable with Signalling Control Pair — frequently asked questions
What does the proximity resistor do and who sets its value?
It sits between the proximity pilot contact and protective earth in the vehicle connector and tells the car the maximum current the attached cable can carry. The values are fixed: 1.5 kΩ for 13 A, 680 Ω for 20 A, 220 Ω for 32 A and 100 Ω for 63 A. It has to be set to match the conductor cross-section, and Voltcore sets it at assembly to match the cable built.
Does the signalling pair need to be screened?
On short single-phase leads next to lightly loaded cores, unscreened usually works. On a 63 A three-phase lead or any run alongside other power cable, screening is worth specifying: the control pilot is a ±12 V 1 kHz signal and induced noise can make the vehicle misread the duty cycle and stop the session. Voltcore supplies both.
Can I order cable only and fit my own connectors?
Yes. Voltcore supplies bulk cable on drums, and the documentation gives the core colours, the signalling pair identification and the termination sequence for the EN 62196-2 pin-out. If you are fitting connectors, the one thing to get right is the proximity resistor value: it must match the cross-section you are terminating, not the connector rating.
How flexible is the assembly in cold weather?
With a TPU sheath it stays workable at −30 °C, which covers a Nordic or Canadian winter. TPE sheathing keeps its flexibility to about −20 °C and costs less, which suits portable leads and indoor depots. If the cable has to be coiled daily in a cold climate, TPU is the specification to write.