DC Charging Connectors and Cables: Key Design Requirements Under IEC 61851-23:2023

For suppliers like NexwayEV, understanding the latest international standards is essential to delivering compliant, reliable, and globally competitive EV charging solutions.

In this article, we analyze the latest IEC 61851-23:2023 standard, focusing on how it reshapes the design, safety, and configuration requirements of DC charging connectors and cables.

1. Temperature Control: A Critical Safety Factor in High-Power Charging

With higher charging currents comes increased heat generation. Managing temperature rise in charging connectors and cables has become a key challenge—especially in hot climates or heavy-duty usage scenarios.

Clear Definition of "Graspable Parts”

The new standard defines:

• Charging connectors
• Charging cables

as graspable components, meaning users may directly touch them during operation.

This removes ambiguity from previous standards and places stricter responsibility on manufacturers to ensure user safety.

Temperature Limits (At 40°C Ambient)

Under standard conditions:

• Metal parts: ≤ 50°C
• Non-metal parts: ≤ 60°C

However, if safety measures are applied (such as warning labels or additional handles), limits can be extended to:

• Metal parts: ≤ 60°C
• Non-metal parts: ≤ 85°C

This provides flexibility in design, but also requires better safety communication and ergonomic considerations.

Certification Mismatch Risk

A common industry issue:

• Charging station certification: -30°C to 50°C
• Some cable certifications (IEC 62196): -30°C to 40°C

This mismatch may lead to:

Components failing to meet real-world operating conditions

For global suppliers, ensuring aligned certification standards is crucial for project reliability.

2. Multi-Connector Charging Systems: Not All Combinations Are Allowed

Different regions adopt different DC charging standards, including:

• CHAdeMO (Japan)
• GB/T (China)
• CCS1 (North America)
• CCS2 (Europe)
• NACS (North American Charging Standard, led by Tesla, formalized as SAE J3400)

IEC Restrictions on Connector Combinations

According to IEC 61851-23:2023 (Annex FF), charging systems are categorized by their power electronics configuration (PEC):

• Single PEC (no simultaneous charging)
• Multiple PEC (simultaneous multi-vehicle charging)

However, only five connector combinations are permitted:

• A + A
• B + B
• C + C
• A + B
• A + C

Not allowed:

• B + C
• A + B + C

Why Are Some Combinations Restricted?

From an industry perspective:

• Market segmentation
  • GB/T (System B): China & parts of Asia
  • CCS (System C): Europe & North America
    → Limited real-world demand for B + C combinations
• Technical and regulatory barriers
  → Helps maintain system compatibility and standard integrity

That said, future revisions may evolve as global charging networks become more interconnected.

3. Often Overlooked Design Requirements

Beyond electrical performance, IEC standards also emphasize usability and accessibility.

Charging Connector Mounting Height

Standard requirement:

• 0.5 m to 1.5 m

In addition, many regions enforce accessibility regulations, such as:

• EU Accessibility Directive (2019/882)
• National standards (UK, Germany, USA, etc.)

These regulations ensure:

• Ease of use for all users, including people with disabilities
• Proper positioning of connectors, screens, and payment systems

For international projects, local compliance is essential.

Cable Length and Management

Requirement:

• If cable length exceeds 7.5 meters
  → A cable management system is mandatory

Purpose:

• Prevent tripping hazards
• Improve usability
• Maintain a clean and organized charging environment

Industry practice:

Most manufacturers limit cable length to ≤ 7.5 m to simplify design

4. Industry Trend: From Performance to User Experience

The latest standards reflect a broader shift in the EV charging industry:

Key priorities:

• Safer (temperature control)
• Easier to use (height & handling)
• More standardized (system design)

5. NexwayEV Perspective: Enabling Global EV Charging Solutions

As a supplier specializing in EV charging connectors and cable assemblies, NexwayEV recognizes that success in global markets depends on:

• Deep understanding of IEC, SAE, and GB standards
• Ability to adapt to regional compliance requirements
• Engineering for both performance and safety
• Enhancing user experience through thoughtful design

Conclusion

As EV adoption accelerates worldwide, charging infrastructure is evolving from basic functionality to high-quality user-centric design.

DC charging connectors and cables are no longer just components—they are critical touchpoints between users and energy systems.

Companies that lead in standard compliance, product design, and global adaptability will be best positioned to succeed in the rapidly growing EV charging market.