EV fast charging test: cable choice makes or breaks speed
Uncooled EV fast-charging cables: the hidden bottleneck
EV fast charging test: cable choice makes or breaks speed
Sweden test with Volvo EX90 shows uncooled EV fast-charging cables can cap power. Phoenix Contact beat Amphenol, holding 500 A and cutting charge time.
2025-10-13T20:34:21+03:00
2025-10-13T20:34:21+03:00
2025-10-13T20:34:21+03:00
Fast-charging performance is usually attributed to station output and battery design, yet a new test in Sweden showed the cable itself can be the decisive factor. Two uncooled charging cables were tested at 600 kW with a Volvo EX90, and the difference between them was hard to ignore.The first cable, made by Amphenol, held a peak 500 amps for only six minutes: contact temperature climbed to 80 degrees Celsius, prompting the system to cut current to 225 A. As a result, charging power fell from 190 to 100 kW. Even in mild weather, thermal protection kicked in too early—exactly the kind of drop drivers feel at the plug.The second cable, from Phoenix Contact, proved steadier. Under the same conditions it maintained 500 A for more than 15 minutes without exceeding 50 degrees, keeping power consistent at 190–200 kW and avoiding thermal throttling altogether. In practice, that meant the car charged almost a third quicker with this lead.Experts concluded that the cable is often the system’s bottleneck. Even with powerful 400–600 kW stations and modern 400 V battery architectures, an inefficient conductor curbs current because of heat. Cars running 800 V systems (Hyundai, Porsche, Kia) are less affected, since they require lower current to achieve the same power.Until the industry fully moves to 800 V, choosing the right cable will remain critical. The test shows that even without liquid cooling, a well-engineered cable can speed up a session and trim thermal losses—saving time and energy where it counts.
EV fast charging, charging cable test, uncooled cables, Phoenix Contact, Amphenol, Volvo EX90, 500 A, 600 kW, thermal throttling, 400 V vs 800 V, bottleneck, DC fast charger performance
2025
Michael Powers
news
Uncooled EV fast-charging cables: the hidden bottleneck
Sweden test with Volvo EX90 shows uncooled EV fast-charging cables can cap power. Phoenix Contact beat Amphenol, holding 500 A and cutting charge time.
Michael Powers, Editor
Fast-charging performance is usually attributed to station output and battery design, yet a new test in Sweden showed the cable itself can be the decisive factor. Two uncooled charging cables were tested at 600 kW with a Volvo EX90, and the difference between them was hard to ignore.
The first cable, made by Amphenol, held a peak 500 amps for only six minutes: contact temperature climbed to 80 degrees Celsius, prompting the system to cut current to 225 A. As a result, charging power fell from 190 to 100 kW. Even in mild weather, thermal protection kicked in too early—exactly the kind of drop drivers feel at the plug.
The second cable, from Phoenix Contact, proved steadier. Under the same conditions it maintained 500 A for more than 15 minutes without exceeding 50 degrees, keeping power consistent at 190–200 kW and avoiding thermal throttling altogether. In practice, that meant the car charged almost a third quicker with this lead.
Experts concluded that the cable is often the system’s bottleneck. Even with powerful 400–600 kW stations and modern 400 V battery architectures, an inefficient conductor curbs current because of heat. Cars running 800 V systems (Hyundai, Porsche, Kia) are less affected, since they require lower current to achieve the same power.
Until the industry fully moves to 800 V, choosing the right cable will remain critical. The test shows that even without liquid cooling, a well-engineered cable can speed up a session and trim thermal losses—saving time and energy where it counts.
