Power and control in one cable.
AC designs use 3 to 5 power cores and can incorporate up to 8 control cores for signal transmission. The number of control wires and sheath colour can be adapted to the project.
Discuss this requirement ← Automotive cablesCharging cable.
10 / AUTOMOTIVE · LEONI CABLE SOLUTIONS
Charging cable.
From AC to high-power DC.
LEONI EcoSense charging cables for wallboxes, public charging stations and vehicle charging systems. HB Cables helps you match the cable construction to the charger, connector and market requirements.
Discuss your charging project
AC charging · DC fast charging · Cooled high-power systems
AC / EVERYDAY CHARGING
Portable leads and wallbox connections.
LEONI’s AC range covers domestic and public charging, including portable cable leads and fixed installation at wallboxes. Straight and coiled options are available, with constructions designed for flexibility, bending resistance and abrasion resistance.
Discuss this requirement Choose the complete charging link.
Start with the connector system, operating current and target market. LEONI offers AC portfolios for European, international, Chinese, Japanese and North American requirements, including designs compatible with NACS connectors.
Discuss this requirement ECOSENSE NXT / NXT+ · OPTIMISED AC CHARGING
A lighter cable. Easier everyday handling.
LEONI EcoSense® Nxt improves the cable compounds, core design and manufacturing process to reduce diameter and weight. EcoSense® Nxt+ combines these improvements with power-optimised copper conductors for a further reduction in conductor cross-section.
The dedicated brochure describes Type 2 AC charging for Mode 2 and Mode 3, with designs intended to improve flexibility and handling while saving space. Jacket colours can be specified to suit the project.
Discuss EcoSense Nxt / Nxt+
| Design measure | EcoSense Nxt | EcoSense Nxt+ |
|---|---|---|
| Nominal outer diameter | 4% lower | 9% lower |
| Cable weight | 6% lower on average | 20% lower on average |
| Conductor cross-section | Same as the conventional model | Approximately 25% lower with power-optimised copper conductors |
These figures are LEONI’s brochure comparisons with conventional models, rather than guaranteed savings for every construction. Match the exact Nxt or Nxt+ design to the required current, connector, approval and operating conditions.
More efficient packing
LEONI reports around 9% higher packing density from the space-optimised design. The brochure links reduced cable weight and transport effort to an improved product CO₂ footprint; it does not specify a percentage reduction in CO₂ emissions.
Design for material efficiency
Smaller cable diameters and optimised materials support a more efficient design and cost basis. HB Cables can review the construction, samples and production quantities for your charging project.
Read the EcoSense Nxt / Nxt+ brochure · PDFEcoSense Nxt and Nxt+ examples
The following constructions are published for combined European EN 50620, Chinese GB/T 33594 and international IEC 62893 markets.
| Range | Cores × cross-section (mm²) | Nominal outer diameter (mm) | Published current (A) |
|---|---|---|---|
| EcoSense Nxt | 3 × 1.5 + 1 × 0.5 | 9.20 | 14 |
| EcoSense Nxt | 3 × 2.5 + 1 × 0.5 | 10.00 | 25 |
| EcoSense Nxt | 3 × 6.0 + 1 × 0.5 | 12.20 | 44 |
| EcoSense Nxt | 5 × 2.5 + 1 × 0.5 | 12.45 | 25 |
| EcoSense Nxt | 5 × 6.0 + 1 × 0.5 | 15.30 | 44 |
| EcoSense Nxt | 5 × 16 + 1 × 0.5 | 23.00 | 82 |
| EcoSense Nxt+ | 3 × 1.5 + 1 × 0.5 | 9.60 | 20 |
| EcoSense Nxt+ | 3 × 4.0 + 1 × 0.5 | 11.60 | 32 |
| EcoSense Nxt+ | 5 × 1.5 + 1 × 0.5 | 11.60 | 20 |
| EcoSense Nxt+ | 5 × 4.0 + 1 × 0.5 | 14.55 | 32 |
These are selected portfolio constructions, not a stock list. Published current values relate to the stated cable design; confirm the complete assembly rating, installation conditions and exact approval before selection. Control-wire arrangements can be customised.
AC examples for Japan and North America
EcoSense PSE — Japan
| Range | Cores × cross-section (mm²) | Nominal outer diameter (mm) | Published current (A) |
|---|---|---|---|
| EcoSense PSE | 3 × 1.5 + 1 × 0.75 | 11.2 | 13 |
| EcoSense PSE | 3 × 2.5 + 1 × 0.75 | 11.9 | 16 |
| EcoSense PSE | 3 × 6.0 + 1 × 0.75 | 17.0 | 32 |
EcoSense for NACS — North America, UL 2263
| Range | Cores × cross-section (AWG) | Nominal outer diameter (mm) | Published current (A) |
|---|---|---|---|
| EcoSense for NACS | 3 × 16 + 1 × 22 | ≈ 9.3 | 13 |
| EcoSense for NACS | 3 × 14 + 1 × 22 | ≈ 10.1 | 18 |
| EcoSense for NACS | 3 × 12 + 1 × 22 | ≈ 11.2 | 25 |
| EcoSense for NACS | 3 × 10 + 1 × 22 | ≈ 12.7 | 50 |
| EcoSense for NACS | 2 × 9 + 1 × 10 + 1 × 22 | ≈ 13.9 | 60 |
| EcoSense for NACS | 2 × 8 + 1 × 10 + 1 × 22 | ≈ 15.0 | 70 |
| EcoSense for NACS | 2 × 7 + 1 × 9 + 1 × 22 | ≈ 16.2 | 80 |
| EcoSense for NACS | 2 × 6 + 1 × 8 + 1 × 22 | ≈ 17.5 | 85 |
The North American table uses AWG conductor sizes, not mm².
DC / PUBLIC & FAST CHARGING
Three routes to a DC charging design.
LEONI’s DC portfolio includes NACS connector applications, uncooled CCS Combo cable and cooled cable for higher power classes and Megawatt Charging System applications.
Flexible connector solutions.
DC designs for NACS applications include reduced wall thickness, highly flexible insulation materials and project-specific performance classes.
Discuss this requirementPublished portfolio up to 375 / 400 A.
LEONI lists uncooled CCS Combo cable designs up to 375 / 400 A, with approved types in accordance with IEC and UL. Match the chosen design to the connector and charger requirements.
Discuss this requirement 500 to 3,000 A across the range.
The cooled portfolio covers charging currents from 500 to 3,000 A. Options include indirect cooling with water-glycol coolant or direct cooling with suitable non-conductive coolants.
Discuss this requirement DC current figures describe the published portfolio. They are not ratings for every cable or connector. Cooling method, coolant compatibility, thermal management and the complete charging-system design must be specified together.
GLOBAL MARKETS
The right approval for the destination.
The brochures list regional standards for LEONI’s charging portfolios. Confirm the certification and applicable edition for the exact cable construction and intended market.
| Market | AC | DC |
|---|---|---|
| International | IEC 62893 series | IEC 62893 series |
| Europe | EN 50620 | EN 50620 |
| North America | UL 2263 | UL 2263 |
| China | GB/T 33594 | GB/T 33594 |
| Japan | PSE-LAW | JCS 4522 |
SPECIFY WITH HB CABLES
Send us the charging brief.
Whether you need a published EcoSense design or a customised charging cable, send us the key requirements so we can review the right construction with LEONI.
Send your specification- Charging system: AC or DC, connector type and destination market.
- Electrical requirements: operating voltage, current and duty cycle.
- Cable construction: power-core sizes, control wires, length and diameter limits.
- Handling and environment: straight or coiled, flexibility, temperature and exposure.
- For cooled designs: direct or indirect cooling, coolant and thermal-management requirements.
- Supply requirement: sample lengths, production quantities and delivery schedule.
LEONI PRODUCT INFORMATION