IEC PAS 63454:2022 PDF

Overview

IEC PAS 63454:2022 provides a Publicly Available Specification for the conductive DC charging vehicle coupler – configuration GG. It defines vehicle couplers with pins and contact-tubes (referred to as “accessories”) intended for use in electric vehicle (EV) conductive charging systems that incorporate control means. The PAS is a pre‑standard document intended to accelerate industry adoption of a new DC vehicle interface (configuration GG) and will be considered for inclusion in future editions of IEC 62196‑3.

Key facts:

• Applicable to DC charging mode 4, case C (IEC 61851‑1).
• Ambient temperature range: −30 °C to +40 °C (note: SE uses −35 °C).
• Cables: only copper or copper‑alloy conductors.
• May contain up to 12 power or signal contacts (power, pilot, communication, PE, isolation monitor, auxiliary, etc.).
• PAS status: interim document (initial validity up to 2 years).

Key topics and technical requirements

The PAS specifies technical requirements and test items relevant to the safe and interoperable use of the GG coupler:

• Contact layout and functions: DC+ / DC− power contacts, Control Pilot(s) (CP, CP2, CP3), communication contacts (COM1, COM2), Isolation Monitor (IM), Protective Earth (PE), Proximity/Connection switch (PP/CS), and auxiliary power contacts.
• Rated voltage ranges: preferred rated operation voltages include signal ranges (0–60 V) and common DC system voltages referenced in IEC 62196‑1 (examples in the PAS: 480 V, 600 V, 750 V, 1 000 V, 1 500 V DC).
• Mechanical and environmental performance: dimensional requirements, misalignment, vehicle driveover, mechanical strength, thermal cycling, humidity, and contact endurance.
• Electrical safety and performance tests: insulation resistance, dielectric strength, breaking capacity, temperature rise, creepage/clearance, short‑circuit and fault ratings, EMC.
• Marking, classification and earthing: accessory classification, marking rules, earthing provisions and conductor colour/size guidance.
• Materials and durability: resistance to ageing of rubber/thermoplastic materials, corrosion resistance, fire and tracking resistance.

Applications and users

IEC PAS 63454 is practical for:

• EV OEMs and vehicle electrical designers specifying a GG vehicle inlet.
• Charging station manufacturers and EVSE designers implementing compatible DC chargers.
• Component suppliers producing couplers, pins, contact tubes and earthing components.
• Test laboratories and certification bodies performing type and conformance testing.
• Standards bodies and regulators assessing interoperability and safety of new DC charging interfaces.

Related standards

• IEC 62196‑1:2022 (general requirements for vehicle couplers)
• IEC 62196‑3:2022 (DC vehicle couplers - existing configurations)
• IEC 61851‑1:2017 (electric vehicle conductive charging - charging modes)
• IEC 61851‑23 (DC charging station requirements - under revision)

Keywords: IEC PAS 63454, configuration GG, DC vehicle coupler, conductive charging, electric vehicle charging, vehicle inlet, DC charging interface, EVSE interoperability.