You've Got the Power — An Essential Guide to EV Charging

The electric vehicle (EV) landscape is rapidly evolving and growing. This growth is driven by innovations in batteries and charging technologies, government incentives for EV development, and investments in charging infrastructure.

This landscape is also diverse: Passenger vehicles, commercial EVs, electric trucks or buses have different charging needs. Long-haul trucks, for example, require ultra-fast mega-watt-class chargers due to their large battery capacity. While this infrastructure can be installed in private depots for fleets that return to base overnight, public fast charging along highways must be available for electric long-haul trucking, regardless of route.

Beyond transportation, EVs are placing new demand on the power grid and built environment. As adoption rises, scaling EV charging infrastructure presents significant challenges while managing safety, reliability and speed to market.

Automakers, manufacturers, original equipment manufacturers (OEMs) of EV charging systems, and EV charging owners and operators face pressure to meet this diversified demand for charging, mitigate potential new risks and comply with evolving regulations, codes and standards.

Ultra-fast charging, bidirectional charging and compliance mandates reinforce the need to deliver a safer, more reliable and interoperable charging infrastructure. Testing and certification services for EV charging and bidirectional charging help mitigate risks and promote safety, consumer trust and industry alignment.

Getting ready for an EV boom

2024 alone saw a major increase in EV sales and adoption:

• Global EV sales grew 25%, surpassing 17 million vehicles.¹
• In China, EV sales rose 40%, with EV and plug-in electric hybrids (PHEVs) making up more than half of the country’s new vehicle sales by mid-year.^2,3
• In Norway, nearly 90% of new light-duty car sales were fully electric, supported by progressive policies and subsidies. By mid-year, only 45 gasoline-fueled cars were sold in the country.^4,5
• While slower to grow than other markets, the United States gained momentum and set a record of 7% growth overall and 12% growth in Q4.^6,7
• The number of public EV chargers in the U.S. doubled between 2020 and the end of 2024.⁸
• China has invested $230 billion with the aim of achieving full charging coverage in cities and highways by 2030.⁹

There are three main challenges to look out for when it comes to charging:

• Keeping pace with innovation – Rapid breakthroughs in charging technologies can introduce new risks, requiring ongoing reassessments of standards to determine whether they adequately advance safety, performance and interoperability.
• Evolving standards and regulations – While regulators focus on decarbonizing transportation, industry stakeholders must keep up with continuous changes to standards, codes and regulations across jurisdictions and markets.
• Significant demand growth – As EV sales grow,¹⁰ an entire network of EV charging infrastructure needs to be established that meets the needs of all types of electric fleets.

With so much for stakeholders to navigate, independent, third-party testing and certification can help automakers and charging equipment manufacturers, operators and service providers proactively identify issues and address them before deploying products on the market.

Common safety concerns in EV charging and how to address them

Electrical safety – Charging infrastructure manufacturers, OEMs and charging operators must address hazardous voltage risks through ground fault and isolation monitoring. These features are critical to prevent electric shock and meet personnel protection requirements.¹¹

What to do:

• Perform regular inspection and maintenance of charging stations for safer operations.
• For North America, comply with the National Electrical Code in the U.S. and Mexico and the Canadian Electrical Code along with ANSI/UL 2594, the Standard for Electric Vehicle Supply Equipment (EVSE) or ANSI/UL 2202, the Standard for DC Charging Equipment for Electric Vehicles. See the Appendix for the full designations.
• For Europe and other regions following IEC/EN standards:
• Use the IEC 60364 series for electrical installation requirements, including protection against electric shock and proper grounding.
• For charging infrastructure:
  • Apply the relevant parts of the IEC 61851 series, which covers safety and performance requirements for Electric Vehicle Conductive Charging Systems.
  • For Mode 2 charging follow IEC 62752, which defines requirements for In-Cable Control and Protection Devices (IC-CPDs).

Fire safety – High-capacity batteries in EVs and the many components and systems needed for charging infrastructure mean fire risks pose an increasingly serious concern.

What to do:

• Employ thermal management systems such as heat sinks, ventilation and active cooling to reduce overheating risks.
• Use materials with low flammability ratings according to established standards like UL 94, the Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances, and IEC 60695, Fire Hazard Testing.
• Evaluate and test products for fire propagation risks to these key safety standards:
  • For North America this would include ANSI/UL 2202, the Standard for DC Charging Equipment for Electric Vehicles, or ANSI/UL 2594, the Standard for Electric Vehicle Supply Equipment (EVSE).

User safety – harging interfaces should be intuitive and user-friendly to promote customer convenience and satisfaction, prevent injuries or damage from misuse, and support safer interactions.

What to do:

• Prioritize user functionality and accessibility in charging station design. Integrate features like:
  • Well-placed disconnect switches.
  • Lockouts or smart connections.
  • Clear, easy-to-follow instructions for safe charging practices to inform interactions.
• In North America, comply with:
  • National Electrical Code (NEC) for the U.S. and Mexico.
  • Canadian Electrical Code (CEC) for Canada.
  • ANSI/UL 2594: Standard for Electric Vehicle Supply Equipment (EVSE) or ANSI/UL 2202: Standard for DC Charging Equipment for Electric Vehicles.
• In Europe and other regions accepting IEC/EN standards, comply with:
  • IEC 60364 series for installation requirements.

These standards support safe user interaction, proper connection and protection from electric shock.

Compatibility matters

EV drivers rely on a consistent and compatible charging experience across geographies and networks. To achieve this, manufacturers of charging stations must navigate a range of regionally adopted connector types and communication protocols.

There is no universal connector standard globally. Instead, connector choices are shaped by regional policy, market preferences, and vehicle integration strategies. For instance, UL was tasked by the Joint Office of the Department of Energy and the Department of Transportation to create a standard for adapters that would be used to convert from one configuration to another.

• In North America, connector types are defined by the Society of Automotive Engineers (SAE):
  • SAE J1772 supports AC charging with the Type 1 connector.
  • CCS1 (Combined Charging System) uses the same vehicle inlet to accommodate either alternating current (AC) or direct current (DC) charging, but not on the same connector. AC and DC charging are delivered through separate connector types using different pins.
  • SAE J3400, also known as North American Charging Standard (NACS), enables both AC and DC charging through a single connector interface and shared pins, simplifying hardware requirements.
• In Europe and countries using IEC/EN standards:
  • IEC 61851 and ISO 15118 define requirements for communication and charging behavior.
  • IEC 62196 defines physical, mechanical and safety aspects of various EV connector types, supporting interoperability between connector and inlet manufacturers but not promoting one connector standard over another. In North America, similar requirements are addressed by UL 2251, which covers plugs, receptacles and couplers for electric vehicles.

What to do:

• Communication protocols like ISO 15118 and Open Charge Point Protocol (OCPP) unlock features such as plug-and-charge capabilities so that users can connect their EVs to a charging station without manual authentication.
• Charging operators can use standards like Open Charge Point Interface (OCPI) to promote roaming capabilities between networks so users can safely and seamlessly charge vehicles across different networks.
• Automakers, manufacturers and operators must be ready to adapt to new or emerging technologies, such as bidirectional charging. Preparing for evolving technologies and standards will help the automobile industry remain competitive.

On the road to customer satisfaction

Getting vehicles, equipment, devices and infrastructure to work harmoniously is essential for system safety and a smooth user experience. Seamless interactions between EVs, charging systems and other connected devices support positive operational outcomes for network and charging station providers and operators.

To avoid customer frustration and reputational risks, EV and charger manufacturers and OEMs should: (1) prioritize interoperability in design and development, and (2) conduct rigorous, third-party reliability and durability testing to help their products comply with the latest standards.

• Interoperable charging services attract customers by providing convenient charging options, leading to higher EV adoption rates.
• Businesses that install interoperable charging systems can serve a broader range of EV users, expanding their potential customer base.
• With a broader network of charging options, charging operators can generate additional revenue by charging fees, through partnerships and by selling subscriptions to charging networks.
• Implementing and routinely evaluating interoperability helps the EV industry prepare for future innovations and evolving standards.
• Aligning with interoperability standards can help stakeholders maintain compliance with regulatory requirements and codes and boost their brand reputation and credibility.

Taking charge of safer, more sustainable EV charging systems

As the EV industry matures, manufacturers, OEMs, service providers and regulators all benefit from keeping pace with evolving standards and best practices. Benefits include:

• Improve safety and reliability – Standards require manufacturers to design charging systems that are safe and reliable, minimizing the risks to grids and users.¹²
• Promote interoperability – Standards allow diverse manufacturers, devices and systems to work together effectively.
• Support market adoption and affordability – When EV products adhere to the same standards, consumers feel more confident purchasing them, knowing their vehicle will charge in most charging stations. Standardization encourages mass production, lowering costs, and making technology more affordable and accessible.
• Encourage accelerated innovation – A common foundation allows manufacturers and OEMs to focus on innovation and accelerate technological advancement.
• Simplify regulatory enforcement – Assessing products against established standards and protocols can help governments and regulatory bodies enforce safety, environmental and energy efficiency and help drive the adoption of clean energy technologies.

While the complexities of standards, regulations and technical requirements may seem daunting, they are necessary to build a safer, more reliable and accessible charging infrastructure. As technology evolves and new risks emerge, standards need to keep pace. Collaboration among manufacturers, OEMs, standard-setting bodies and cross-jurisdictional regulators is key to accelerating the development of standards alongside innovation.

For manufacturers, OEMs and charging network operators, staying ahead of these changes isn't just about compliance — it's about seizing opportunities in a growing market.

Looking ahead: Staying competitive through testing and certification

There are several initiatives underway aimed at aligning the industry on common features for EV charging. These include:

• Unified charging networks – In 2023, seven major automakers announced plans for a unified North American charging network, advancing interoperability goals.¹³
• Standardized charging ports – Automakers are increasingly adopting the NACS charging port standard in order to maximize the amount of existing infrastructure for charging their vehicles.¹⁴
• Cybersecurity initiatives – Organizations with cybersecurity expertise, including the U.S. Department of Energy's Office of Cybersecurity, Energy Security and Emergency Response (CESER) — are working to mitigate cyber threats in EV charging.¹⁵

In the future, new requirements and standards will likely emerge to strengthen the safety and enhance compatibility of EV charging systems. Independent third-party organizations like UL Solutions, with dedicated resources to track and contribute to evolving standards, can help companies stay ahead of the curve.

As competition increases to meet the market’s growing demand for EVs and high-performing bidirectional charging, companies that have rigorously tested their products against robust standards and protocols are positioned for clear advantage. Leveraging safety science and aligning with relevant standards helps accelerate deployment, enhance performance and inspire consumer confidence.

Appendix: Standards and codes for EV charging

Below is a list of standards across various categories of the EV charging landscape that manufacturers, OEMs and other industry stakeholders should know.

Charging standards

• ISO 15118 series – Governs communication between EVs and charging stations for both charging and bidirectional current flow.
• SAE J1772 – Defines the Type 1 and CCS1 electrical vehicle couplers and the communication protocol for AC charging.
• SAE J3400 – Defines the NACS electrical vehicle couplers and the communication protocol for AC and DC charging.
• IEC 61850 – The standard for the communication networks and systems in substations to enhance the management of energy resources in line with EV charging.

Safety standards

• IEC 60364 series – Provides guidelines for electrical installations in Europe.
• ANSI/NFPA 70, the National Electrical Code – Provides guidelines and rules for electrical installations in the US
• CSA C22.1, Canadian Electrical Code
• ANSI/UL 2202 / CSA C22.2 No. 346 / NMX-J-817-ANCE – The Standard for DC Charging Equipment for Electric Vehicles, establishing safety and performance criteria for DC chargers.
• ANSI/UL 2594 / CSA C22.2 No. 280 / NMX-J-677-ANCE – The Standard for Electric Vehicle Supply Equipment (EVSE), focusing on the safety and reliability of EV charging equipment.
• IEC 61851 series – Covers charging equipment requirements for charging systems
• ANSI/UL 2231-1 / CSA C22.2 No. 281.1 / NMX-J-668-1-ANCE – The Standard for Personnel Protection Systems for Electric Vehicle (EV) Supply Circuits; Part 1: General Requirements, covering general requirements for safety.
• UL 2231-2 / CSA C22.2 No. 281.2 / NMX-J-668-2-ANCE – The Standard for Personnel Protection Systems for Electric Vehicle (EV) Supply Circuits: Particular Requirements for Protection Devices for Use in Charging Systems.
• UL 9741 / CSA C22.2 No. 348 – The Standard for Electric Vehicle Power Export Equipment (EVPE), outlining safety guidelines for exporting electric energy from EVs.
• UL 991 – Tests for Safety-Related Controls Employing Solid State Devices.

Connector standards

• IEC 62196 series – Specifies the design and compatibility for EV connectors for Europe.
• UL 2251 / CSA C22.2 No. 282 / NMX-J-678-ANCE – Standard for Plugs, Receptacles and Couplers for Electric Vehicles, covering safety requirements for EV couplers.

Interoperability standards

• Open Charge Point Protocol (OCPP) – A communication protocol that enables interoperability between EV charging stations and central management systems.
• Open Charge Point Interface (OCPI) – Enables roaming between different charging networks, providing real-time access and information on charging stations.

Other protocols

• UL 2750 – Standard for Wireless Power Transfer Equipment for Electric Vehicles.
• ANSI/CAN/UL 3202 – Standard for Mobile Electric Vehicle Charging Systems Integrated with Energy Storage Systems.
• UL 61810-20 – Outline of Investigation for Electric Vehicle Electromechanical Elementary Relays, crucial for control operations in charging systems.