Understanding UL Certification for Electric Vehicle (EV) Charging Infrastructure

Underwriters Laboratories (UL) is a global safety certification organization that conducts rigorous testing to evaluate whether products meet established safety and performance standards. In the automotive sector, UL certification is especially relevant for products such as:

EV Batteries and Charging Systems: 

• ANSI/UL 2202, the Standard for DC Charging Equipment for Electric Vehicles

• ANSI/UL 2594, the Standard for Electric Vehicle Supply Equipment (EVSE)

• ANSI/UL 2251, the Standard for Plugs, Receptacles and Couplers for Electric Vehicles

• UL 2252, the Outline of Investigation for Adapters for use with Electric Vehicle Couplers

• UL 9741, the Standard for Electric Vehicle Power Export Equipment (EVPE) 

• UL 2750, the Standard for Wireless Power Transfer Equipment for Electric Vehicles

• ANSI/UL 2231-1, the Standard for Personnel Protection Systems for Electric Vehicle (EV) Supply Circuits; Part 1: General Requirements 

• ANSI/UL 2231-2, the Standard for Personnel Protection Systems for Electric Vehicle Supply Circuits: Particular Requirements for Protective Devices for Use in Charging Systems 

• UL 61810-20, the Outline of Investigation for Electric Vehicle Electromechanical Elementary Relays

• UL 3202, the Outline of Investigation for Mobile Electric Vehicle Charging Systems Integrated with Energy Storage Systems

• UL 1998, the Standard for Software in Programmable Components

• UL 991, the Standard for Test for Safety-Related Controls Employing Solid State Devices

Certification body (CB) scheme certificates

• IEC 61851-1, Electric Vehicle Conductive Charging Systems – General Requirements

• IEC 61851-23, Electric Vehicle Conductive Charging Systems – Part 23: DC Electric Vehicle Charging Station  

• IEC 62752, In-Cable Control and Protection Device for Mode 2 Charging of Electric Road Vehicles

• IEC 62196 series (-1, -2 and -3) Plugs, Socket-Outlets, Vehicle Connectors and Vehicle Inlets – Conductive Charging of Electric Vehicles Supply 

Informative EV charging infrastructure test reports

• IEC 61851-23, Electric Vehicle Conductive Charging Systems – Part 23: DC Electric Vehicle Charging Station

• IEC 61851-21-2, Electric Vehicle Requirements For Conductive Connection to an AC/DC

The UL certification process for automotive applications is a multi-step procedure that involves comprehensive testing, audits, and ongoing surveillance. It typically unfolds in the following stages:

Application and Documentation Review

Manufacturers submit all necessary documentation, including:

• Product specification

• Technical documentation and design schematics

• Power connections and markings. 

• Manufacturing location details. 

• Factory test equipment

to UL for initial evaluation. This step is crucial for identifying potential compliance gaps early in the process.

Preliminary Evaluation

Before formal testing, UL engineers conduct a preliminary review to assess the product’s design and identify possible compliance issues. Engaging UL during the design phase can help manufacturers avoid costly redesigns later.

Product Testing and Compliance Verification

The core of the UL certification process involves subjecting the product to rigorous tests under real-world conditions. Depending on the product type, these tests may include:

• Electrical Safety Testing:

  These tests ensure products are safe for electrical use, including wire sizes, device current handling, and proper construction to prevent hazards. 

• Mechanical Safety Testing:

  The mechanical safety tests are include tensile tests, impact testing, hardness testing, ball drop testing, three-point loading among other test to ensure the integrity and durability of products.

• Environmental Testing:

  UL may conduct tests to evaluate a product's performance and safety under various environmental conditions, like temperature, humidity, and exposure to chemicals. 

• Specific Product Testing:

  Depending on the product type, UL may conduct specialized tests to evaluate specific hazards or performance characteristics, such as fire resistance, flammability, or performance under specific conditions. 

• Durability Testing:

  UL performs durability tests under adverse conditions to ensure products are safe and high-quality, withstanding long-term use. 

• Factory Inspection:

  UL may conduct inspections at the manufacturing facility to ensure consistent production of test design and maintain the integrity of the certification. 

  
  

Certification and UL Mark Approval

Once all tests and audits are successfully completed, UL issues the certification and authorizes the use of the UL Mark on the product. This mark demonstrates compliance and enhances market acceptance.

How Much Does UL Certification Cost for Automotive Products?

The cost of UL certification can vary widely depending on the product’s complexity, testing requirements, and factory inspections.

• Application and Initial Review: $2,000 – $5,000

• Product Testing and Evaluation: $5,000 – $50,000+

  • High-risk or complex systems, such as EV batteries or autonomous systems, often fall on the higher end.

• Factory Audit and Inspection: $3,000 – $10,000 per audit

• Certification and Labeling Fees: $1,500 – $5,000

• Annual Renewal and Surveillance Costs: $2,000 – $10,000 per year

Eternal Lotus is proud to welcome Dr. Cheung as our Executive Advisor to lead our Engineering Compliance Services. With a Ph.D. in Electrical Engineering from MIT and extensive experience in government and national labs, Dr. Cheung’s expertise will help corporations identify compliance gaps early, prevent costly errors, and accelerate project timelines—saving companies hundreds of thousands of dollars while maintaining high standards.For more information and book a consultant session, please contact hello@eternallotus.co