IEC 62196-1:2011

Plugs, socket-outlets, vehicle connectors and vehicle inlets - Conductive charging of electric vehicles - Part 1: General requirements

IEC 62196-1:2011 is applicable to plugs, socket-outlets, connectors, inlets and cable assemblies for electric vehicles (EV), herein referred to as "accessories", intended for use in conductive charging systems which incorporate control means, with a rated operating voltage not exceeding:
- 690 V a.c. 50 Hz - 60 Hz, at a rated current not exceeding 250 A,
- 1 500 V d.c. at a rated current not exceeding 400 A. This second edition cancels and replaces the first edition published in 2003 and constitutes a technical revision. The main changes from the previous edition are as follows:
- increase in d.c.voltage for accessories;
- permitted use of accessories with vehicles complying with Subclause 7.2.3.1 of 61851-1:2010;
- minor changes to definitions; - additional voltage and current ratings (Clause 5) and test values (Clause 12, 13,);
- removal of markings to identify generic types of vehicle inlets and connectors;
- addition of a "high power d.c." to the type of accessories covered by the Standard;
- modification of the description of "universal" and "basic" interfaces based on changes to 61851-1:2010;
- simplification of the marking requirements (Clause 8);
- additional requirements for accessories with shutters;
- division of Clause 9 to create Clauses 9 and 11;
- Clause 9: specific requirements for inlet, plug and socket-outlet;
- Clause 11: EVSE (Electric Vehicle Supply Equipment) requirements: the basic generic requirements for charging stations;
- renumbering of annexes.

Fiches, socles de prise de courant, prises mobiles et socles de connecteur de véhicule - Charge conductive des véhicules électriques - Partie 1: Règles générales

La CEI 62196-1:2011 est applicable aux fiches, aux socles de prise de courant, aux prises mobiles, aux socles de connecteur de véhicules et aux câbles de charge pour les véhicules électriques (VE), ci-après dénommé "appareils", destinés à être utilisés dans les systèmes de charge conductive, qui comprennent des moyens de contrôle, avec une tension d'emploi assignée n'excédant pas:
- 690 V en courant alternatif, 50 Hz - 60 Hz, à un courant assigné n'excédant pas 250 A,
- 1 500 V en courant continu, à un courant assigné n'excédant pas 400 A. Cette deuxième édition annule et remplace la première édition parue en 2003 et constitue une révision technique. Les principales modifications de l'édition précédente sont les suivantes:
- augmentation de la tension des appareils en courant continu;
- permission d'utilisation des appareils avec les véhicules conformes au paragraphe 7.2.3.1 de la 61851;
- modifications mineures dans les définitions;
- calibres de tension et de courant supplémentaires (Article 5) et valeurs d'essai supplémentaires (Articles 12 et 13);
- suppression des marquages d'identification des types génériques de socles de connecteur de véhicule et de prises mobiles;
- ajout d'un type "haute puissance c.c." aux appareils couverts par la norme;
- modification de la description des interfaces "universelle" et "de base" suivant les changements de la 61851-1:2010;
- simplification des exigences de marquage (Article 8);
- exigences supplémentaires pour les appareils avec obturateurs;
- division de l'Article 9 et création des Articles 9 et 11;
- Article 9: exigences particulières pour les socles de connecteur, et fiches et les socles de prise;
- Article 11: exigences des SAVE (Système d'Alimentation pour Véhicule Électrique): exigences génériques de base pour les stations de charge;
- renumérotation des annexes.

General Information

• Status: Published
• Publication Date: 12-Oct-2011
• ICS: 29.120.30 - Plugs, socket-outlets, couplers
• ICS: 43.120 - Electric road vehicles
• Technical Committee: SC 23H - Plugs, Socket-outlets and Couplers for industrial and similar applications, and for Electric Vehicles
• Drafting Committee: MT 8 - TC 23/SC 23H/MT 8
• Current Stage: DELPUB - Deleted Publication
• Completion Date: 19-Jun-2014

Relations

• Revised: IEC 62196-1:2014 - Plugs, socket-outlets, vehicle connectors and vehicle inlets - Conductive charging of electric vehicles - Part 1: General requirements
• Effective Date: 05-Sep-2023

Standards Content (Sample)

IEC 62196-1


®


Edition 2.0 2011-10



INTERNATIONAL



STANDARD



NORME
INTERNATIONALE


Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles –
Part 1: General requirements

Fiches, socles de prise de courant, prises mobiles et socles de connecteur de
véhicule – Charge conductive des véhicules électriques –
Partie 1: Règles générales


IEC 62196-1:2011

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---------------------- Page: 2 ----------------------
IEC 62196-1


®


Edition 2.0 2011-10



INTERNATIONAL



STANDARD



NORME
INTERNATIONALE


Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles –
Part 1: General requirements

Fiches, socles de prise de courant, prises mobiles et socles de connecteur de
véhicule – Charge conductive des véhicules électriques –
Partie 1: Règles générales

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
CODE PRIX XC
ICS 29.120.30; 43.120 ISBN 978-2-88912-724-5

® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale

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– 2 – 62196-1 © IEC:2011



CONTENTS

FOREWORD . 4


INTRODUCTION . 6

1 Scope . 7

2 Normative references . 7


3 Terms and definitions . 9

4 General . 13

5 Ratings . 14

6 Connection between the power supply and the electric vehicle . 15
7 Classification of accessories . 17
8 Marking . 18
9 Dimensions . 20
10 Protection against electric shock . 20
11 Size and colour of earthing conductors . 22
12 Provision for earthing . 22
13 Terminals . 24
14 Interlocks . 29
15 Resistance to ageing of rubber and thermoplastic material . 29
16 General construction . 30
17 Construction of socket-outlets . 33
18 Construction of plugs and vehicle connectors . 35
19 Construction of vehicle inlets . 36
20 Degrees of protection . 37
21 Insulation resistance and dielectric strength . 38
22 Breaking capacity . 39
23 Normal operation . 41
24 Temperature rise . 42
25 Flexible cables and their connection . 43
26 Mechanical strength . 45
27 Screws, current-carrying parts and connections . 49

28 Creepage distances, clearances and distances . 51
29 Resistance to heat, to fire and to tracking . 53
30 Corrosion and resistance to rusting . 54
31 Conditional short-circuit current withstand test . 55
32 Electromagnetic compatibility . 57
33 Vehicle driveover . 57
Annex A (informative) EV charging modes and type of connection . 72
Bibliography . 74

Figure 1 – Diagram showing the use of the accessories . 58
Figure 2 – Standard test finger. 59
Figure 3 – Circuit diagrams for breaking capacity and normal operation tests . 60

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62196-1 © IEC:2011 – 3 –


Figure 4 – Apparatus for testing the cable anchorage . 61

Figure 5 – Ball Impact test . 61


Figure 6 – Arrangement for mechanical strength test for plugs and vehicle connectors . 62

Figure 7 – Apparatus for flexing test . 62

Figure 8 – Gauges for testing insertability of round unprepared conductors having the

maximum specified cross-section . 63


Figure 9 – Examples of terminals . 65

Figure 10 – Equipment test arrangement . 65

Figure 11 – Diagram of the test circuit for the verification of short-circuit current

withstand of a two-pole equipment on a single-phase a.c. or d.c. . 66
Figure 12 – Diagram of the test circuit for the verification of short-circuit current
withstand of a three-pole equipment . 67
Figure 13 – Diagram of the test circuit for the verification of short-circuit current
withstand of a four-pole equipment . 68
Figure 14 – Gauge “A” for checking shutters . 69
Figure 15 – Gauge “B” for checking shutters . 70
Figure 16 – Apparatus for checking the withdrawal force . 71

Table 1 – Compatibility of mating devices at vehicle . 16
Table 2 – Overview of the universal vehicle interface . 16
Table 3 – Overview of the basic vehicle interface . 17
Table 4 – Overview of the d.c. vehicle interface . 17
Table 5 – Short-time test currents . 23
Table 6 – Size for conductors . 24
Table 7 – Value for flexing under mechanical load test . 28
Table 8 – Value for terminal pull test . 29
Table 9 – Cable length used to determine pull force on latch assembly . 31
Table 10 – Gauges to measure withdrawal force . 34
Table 11 – Diameter of pins of the test plug . 35
Table 12 – Maximum withdrawal force . 35
Table 13 – Test voltage for dielectric strength test . 39
Table 14 – Breaking capacity . 40

Table 15 – Normal operation . 42
Table 16 – Test current and nominal cross-sectional areas of copper conductors for
temperature rise test . 43
Table 17 – Pull force and torque test values for cable anchorages . 45
Table 18 – Impact energy for ball impact test . 46
Table 19 – Mechanical load flexing test . 48
Table 20 – Torque test values for glands . 48
Table 21 – Tightening torque for verification of mechanical strength of screw-type
terminals . 50

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INTERNATIONAL ELECTROTECHNICAL COMMISSION

____________



PLUGS, SOCKET-OUTLETS,

VEHICLE CONNECTORS AND VEHICLE INLETS –

CONDUCTIVE CHARGING OF ELECTRIC VEHICLES –



Part 1: General requirements


FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
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8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is
indispensable for the correct application of this publication.

9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 62196-1 has been prepared by IEC subcommittee 23H: Industrial
plugs and socket-outlets, of IEC technical committee 23: Electrical accessories.
This second edition cancels and replaces the first edition published in 2003 and constitutes a
technical revision. The main changes from the previous edition are as follows:
– increase in d.c.voltage for accessories;
– permitted use of accessories with vehicles complying with Subclause 7.2.3.1 of
61851-1:2010;
– minor changes to definitions;
– additional voltage and current ratings (Clause 5) and test values (Clause 12, 13,) ;
– removal of markings to identify generic types of vehicle inlets and connectors;
– addition of a “high power d.c.” to the type of accessories covered by the Standard;

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62196-1 © IEC:2011 – 5 –


– modification of the description of “universal” and “basic” interfaces based on changes

to 61851-1:2010;

– simplification of the marking requirements (Clause 8);


– additional requirements for accessories with shutters;

– division of Clause 9 to create Clauses 9 and 11;

– Clause 9: specific requirements for inlet, plug and socket–outlet;


– Clause 11: EVSE (Electric Vehicle Supply Equipment) requirements: the basic generic
requirements for charging stations;


– renumbering of annexes.

The text of this standard is based on the following documents:
FDIS Report on voting
23H/266/FDIS 23H/269/RVD

Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
A list of all the parts in the IEC 62196 series, under the general title Plugs, socket-outlets,
vehicle connectors and vehicle inlets – Conductive charging of electric vehicles, can be found
on the IEC website.
In this standard, the following print types are used:
- compliance statements: in italic type.
The committee has decided that the contents of this publication will remain unchanged until
the stability date indicated on the IEC web site under "http://webstore.iec.ch" in the data
related to the specific publication. At this date, the publication will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.

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– 6 – 62196-1 © IEC:2011


INTRODUCTION


IEC 61851-1:2010 specifies Electric Vehicle Conductive Charging Equipment. This

International Standard, referred to as IEC 62196 series in IEC 61851-1:2010, specifies the

requirements for plugs, socket-outlets, vehicle connectors, vehicle inlets and cable

assemblies as described in IEC 61851-1:2010. Some charging can be achieved by direct

connection from an electric vehicle to common mains socket-outlets. Some modes of charging

require a dedicated supply and charging equipment incorporating control and communication

circuits. This standard covers the mechanical, electrical and performance requirements for

dedicated plugs, socket outlets, vehicle connectors and vehicle inlets for interfacing between

such dedicated charging equipment and the electric vehicle.

This standard may be divided into several parts as necessary, as follows:
– Part 1: General requirements, comprising clauses of a general character.
Subsequent parts: Particular requirements dealing with particular types of accessories. The
clauses of these particular requirements supplement or modify the corresponding clauses in
Part 1. Where the text of subsequent parts indicates an "addition" to or a "replacement" of the
relevant requirement, test specification or explanation of Part 1, these changes are made to
the relevant text of Part 1, which then becomes part of the standard. Where no change is
necessary, the words "This clause of Part 1 is applicable" are used.
– Part 2: Dimensional compatibility and interchangeability requirements for a.c. pin and
contact-tube accessories.
– Part 3: Dimensional compatibility and interchangeability requirements for pin and contact-
tube accessories for dedicated d.c. charging or for combined a.c./d.c. charging (under
consideration)

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62196-1 © IEC:2011 – 7 –


PLUGS, SOCKET-OUTLETS,

VEHICLE CONNECTORS AND VEHICLE INLETS –

CONDUCTIVE CHARGING OF ELECTRIC VEHICLES –



Part 1: General requirements








1 Scope

This part of IEC 62196 is applicable to plugs, socket-outlets, connectors, inlets and cable
assemblies for electric vehicles (EV), herein referred to as “accessories”, intended for use in
conductive charging systems which incorporate control means, with a rated operating voltage
not exceeding
– 690 V a.c. 50 Hz – 60 Hz, at a rated current not exceeding 250 A,
– 1 500 V d.c. at a rated current not exceeding 400 A.
These accessories and cable assemblies are intended to be used for circuits specified in
IEC 61851-1:2010 which operate at different voltages and frequencies and which may include
ELV and communication signals.
The accessories covered by this standard are intended only to be used with vehicles that
comply with the requirements of 7.2.3.1 of IEC 61851-1:2010.
These accessories and cable assemblies are to be used in an ambient temperature of
between –30 °C and +50 °C.
NOTE In some countries, other requirements may apply.
These accessories are intended to be connected only to cables with copper or copper-alloy
conductors.
The accessories covered by this standard are for use in certain modes of charging EVs.
These modes are defined in IEC 61851-1:2010. These definitions and a description of the
types of connection (cases A, B and C), also described in IEC 61851-1:2010, are reproduced
herein as Annex A.
NOTE In the following country, Mode 1 will not be allowed: UK.
This standard does not apply to those standardised accessories used in charging systems

where the use of such accessories constructed to the requirements of other standards is
permitted (e.g. in mode 1 and mode 2). Such standardized accessories may be used for those
situations (mode and case) identified in IEC 61851-1:2010.
This standard can be used as a guide for accessories with a lesser number of contacts and
lower ratings for use with light duty vehicles.
2 Normative references
The following referenced documents are indispensable for the application of this document.
For dated references, only the edition cited applies. For undated references, the latest edition
of the referenced document (including any amendments) applies.

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– 8 – 62196-1 © IEC:2011


IEC 60112:2003, Method for the determination of the proof and the comparative tracking

indices of solid insulating materials

1
Amendment1 (2009)


IEC 60227 (all parts), Polyvinyl chloride insulated cables of rated voltages up to and including

450/750 V


IEC 60228:2004, Conductors of insulated cables


IEC 60245-4:1994, Rubber insulated cables of rated voltages up to and including 450/750 V –

Part 4: Cords and flexible cables

Amendment 1 (1997)
2
Amendment 2 (2003)
IEC 60269-1:2006, Low-voltage fuses – Part 1: General requirements
3
Amendment 1 (2009)
IEC 60269-2:2010, Low-voltage fuses – Part 2: Supplementary requirements for fuses for use
by authorised persons (fuses mainly for industrial application) – Examples of standardized
systems of fuses A to J
IEC 60309-4, Plugs, socket-outlets and couplers for industrial purposes – Part 4: Switched
socket-outlets and connectors with or without interlock
IEC 60529:1989, Degrees of protection provided by enclosures (IP code)
4

Amendment 1 (1999)
IEC 60664-1:2007, Insulation coordination for equipment within low-voltage systems – Part 1:
Principles, requirements and tests
IEC 60664-3:2003, Insulation coordination for equipment within low-voltage systems – Part 3:
Use of coating, potting or moulding for protection against pollution
IEC 60695-2-11:2004, Fire hazard testing – Part 2-11: Glowing/hot-wire based test methods –
Glow-wire flammability test method for end-products
IEC 60695-10-2, Fire hazard testing – Part 10-2: Abnormal heat – Ball pressure test
IEC 60947-1, Low-voltage switchgear and controlgear – Part 1: General rules

IEC 60999 -1:1999, Connecting devices – Electrical copper conductors – Safety requirements
for screw-type and screwless-type clamping units – Part 1: General requirements and
2 2
particular requirements for conductors from 0,2 mm up to 35 mm (included)
IEC 60999 -2:2003, Connecting devices – Electrical copper conductors – Safety requirements
for screw-type and screwless-type clamping units – Part 2: Particular requirements for
2 2
clamping units for conductors above 35 mm up to 300 mm (included)
___________
1
 There exists a consolidated edition (2009) that includes IEC 60112 (1993) and its Amendment 1 (2009).
2
 There exists a consolidated edition (2004) that includes IEC 60245-4 (1994) and its Amendments 1 (1997)
and 2 (2003).
3
 There exists a consolidated edition (2009) that includes IEC 60269-1 (2006) and its Amendment 1 (2009).
4
 There exists a consolidated edition (2001) that includes IEC 60529 (1989) and its Amendment 1 (1999).

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62196-1 © IEC:2011 – 9 –


IEC 61851-1:2010, Electric vehicle conductive charging system – Part 1: General requirement


ISO 1456, Metallic and other inorganic coatings – Electrodeposited coatings of nickel, nickel

plus chromium, copper plus nickel and of copper plus nickel plus chromium


ISO 2081, Metallic and other inorganic coatings – Electroplated coatings of zinc with

supplementary treatments on iron or steel


ISO 2093, Electroplated coatings of tin – Specification and test methods



3 Terms and definitions
For the purposes of this document, the terms and definitions in IEC 61851-1:2010 as well as the
following apply.
NOTE 1 Where the terms voltage and current are used, they imply r.m.s. values, unless otherwise specified.
NOTE 2 Throughout this standard, the word «earthing» is used for «protective earthing» unless otherwise
specified.
NOTE 3 The terms «basic interface» and «universal interface» refer to terms described in IEC 61851–1.
NOTE 4 The application of accessories is shown in Figure 1.
3.1
cable assembly
piece of equipment which is used to establish the connection between the electric vehicle and
the electric vehicle supply equipment (EVSE)
...