EV Charger Cable Assemblies
EV charger cable assemblies are the tethered charging cable and connector, IEC 62196 Type 2 for AC or CCS2 for DC, engineered for the flex cycles, current rating and outdoor exposure a public charge point sees over years of daily use. NLS Power sources and supplies replacement and OEM cable assemblies for AC and DC chargers installed across Saudi Arabia.
A charger cable assembly is the connector, cable and strain relief that runs from a charging unit to the vehicle, and it takes more physical abuse over its service life than almost any other part of the installation. A public or commercial charge point cable gets coiled, dropped, run over and left in direct sun on a routine basis, so the assembly needs to hold up to a rated number of mating cycles, a specific bend radius and flex fatigue tolerance, and, in Saudi conditions specifically, UV and thermal resistance well beyond what a residential cable would need.
AC cable assemblies use the IEC 62196 Type 2 connector and typically run 5m to 7.5m, sized to reach the parking envelope a bay is designed around without excess slack that becomes a trip hazard or a wear point where it drags on the ground. DC cable assemblies use CCS2 and carry a heavier, often liquid-cooled cable for the higher current a fast or ultra-fast charger delivers, since a passively cooled cable at that current rating would need to be too thick and heavy for a driver to handle comfortably.
Cable assemblies are also one of the more common wear items on a charging network. Connector pins and latching mechanisms take repeated mechanical cycling, and a damaged cable is usually what takes a charger out of service long before the power electronics inside the unit fail, which makes assembly quality and connector durability a real factor in total cost of ownership over a multi-year deployment, alongside the upfront charger price.
NLS Power sources and supplies both AC Type 2 and DC CCS2 cable assemblies, as OEM components for new installations and as replacement parts for chargers already in service across Saudi Arabia.
Specifications
- ✓AC connector: IEC 62196 Type 2, typically 5m to 7.5m tethered cable length
- ✓DC connector: CCS2, liquid-cooled cable option for high-current fast and ultra-fast charging
- ✓Durability: rated mating cycle count, bend radius and flex fatigue tolerance for daily public use
- ✓Environmental resistance: UV-stabilized outer jacket and thermal rating suited to Saudi outdoor exposure
- ✓Strain relief: reinforced connector-to-cable transition to resist the pulling and dropping cycle of daily use
- ✓Availability: OEM assemblies for new installs and replacement assemblies for chargers already in service
Frequently Asked Questions
Why do EV charger cables wear out faster than the charger itself?+
The cable and connector take direct mechanical abuse, coiling, dropping, being run over, on every single charging session, while the power electronics inside the unit sit protected in an enclosure. A damaged cable is usually what puts a public charger out of service long before its internal components fail.
What's the difference between AC and DC charger cable assemblies?+
AC cables use an IEC 62196 Type 2 connector and a lighter cable since they carry lower current. DC fast charging cables use CCS2 and are often liquid-cooled internally, because passively cooling a cable rated for DC fast-charging current would make it too thick and heavy to handle comfortably.
Can a damaged EV charger cable be replaced without replacing the whole unit?+
In most cases yes. The cable assembly is a serviceable component, and replacing it is far cheaper and faster than replacing the charger, provided the replacement assembly matches the original connector type and current rating.