Electric vehicle charging often happens outdoors. Your cable and charger might sit in the rain, in frost, in road grit, or even in standing water. This is why weatherproofing is not optional but essential. The industry uses IP ratings like IP65, IP66 and IP67 to describe how well a piece of equipment resists the intrusion of dust and water. These ratings tell you whether a charging cable or wallbox can handle real European weather conditions safely and reliably.
This article explains what these IP ratings mean, how the tests are performed, which materials make true weatherproofing possible, and why expert engineers insist on high ingress protection for outdoor EV charging. We put a strong focus on charging cables, because they are the component most exposed to the elements, with a reference example in the IP67 rated Voldt Type 2 cable.
What IP65, IP66 and IP67 Actually Mean
The IP rating system is defined by the IEC 60529 standard. It uses two digits: the first indicates protection against dust and the second indicates protection against water.
A first digit of 6 is the maximum dust protection level. It means dust tight. No particles are allowed to enter the enclosure. This is important because dust can create abrasion, corrosion or reduced conductivity over time.
The water protection level is indicated by the second digit:
IP65: Protected against water jets from any direction.
IP66: Protected against powerful water jets.
IP67: Protected against temporary immersion in water up to one metre for 30 minutes.
In simple terms:
IP65 handles heavy rain.
IP66 handles extreme storms or cleaning with a hose.
IP67 handles complete short term submersion.
This is why IP67 is considered the gold standard for EV charging cables that are used outdoors, where puddles, wet ground or heavy weather are always possible.
How IP Ratings Are Tested: Inside the Lab
IP testing is not arbitrary. It follows strict procedures and calibrated equipment, such as:
Dust Ingress Tests (IP6X)
To verify the dust rating, the product is placed in a sealed chamber filled with fine talcum powder. The dust is kept in motion for as long as 8 hours. In many cases a controlled vacuum is applied to the enclosure to actively pull dust toward any potential gaps. To pass IP6X, absolutely no dust may enter. After testing, the enclosure is opened and inspected for contamination. This ensures the cable or charger will not accumulate sand or grit during daily outdoor use.
Water Jet Tests (IPX5 and IPX6)
Water jet testing uses specific nozzles and flow rates:
IPX5 uses a 6.3 millimetre nozzle spraying approximately 12.5 litres per minute.
IPX6 uses a 12.5 millimetre nozzle spraying approximately 100 litres per minute.
During testing, the product is sprayed from every angle for several minutes. Water ingress must not occur. These tests simulate heavy rainfall, driving rain and even occasional cleaning with a garden hose.
Immersion Test (IPX7)
For IP67, the equipment is submerged under one metre of water for 30 minutes. After immersion, the device is opened to confirm that no water entered any cavity. Passing this test proves that the charger or cable can survive accidental flooding scenarios.
Because EV charging equipment can spend hours on the ground while in use, immersion resistance is extremely valuable. A puddle or sudden downpour should never compromise safety.
