Plugs, socket-outlets, vehicle connectors and vehicle inlets - Conductive charging of electric vehicles - Part 3-1: Vehicle connector, vehicle inlet and cable assembly for DC charging intended to be used with a thermal management system

IEC TS 62196-3-1:2020(E) applies to accessories and cable assemblies with the same configuration as specified in IEC 62196-3:2014 with rated operating voltage not exceeding 1 500 V DC and a rated current not exceeding 500 A that employ
- thermal sensing, or
- thermal transport and thermal sensing with the system architecture described in 4.101.
These accessories and cable assemblies are intended to be used in conductive charging systems for circuits specified in IEC 61851-23.
NOTE Edition 2 of IEC 61851-23 is under development.
The accessories covered by this document are intended to be used in charging mode 4 according to IEC 61851-1. These accessories are intended to be connected to cables according to the IEC 62893 series for DC cables.

General Information

Status
Published
Publication Date
25-Mar-2020
Current Stage
PPUB - Publication issued
Completion Date
26-Mar-2020
Ref Project

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Technical specification
IEC TS 62196-3-1:2020 - Plugs, socket-outlets, vehicle connectors and vehicle inlets - Conductive charging of electric vehicles - Part 3-1: Vehicle connector, vehicle inlet and cable assembly for DC charging intended to be used with a thermal management system
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IEC TS 62196-3-1
Edition 1.0 2020-03
TECHNICAL
SPECIFICATION
colour
inside
Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles –
Part 3-1: Vehicle connector, vehicle inlet and cable assembly for DC charging
intended to be used with a thermal management system
IEC TS 62196-3-1:2020-03(en)
---------------------- Page: 1 ----------------------
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---------------------- Page: 2 ----------------------
IEC TS 62196-3-1
Edition 1.0 2020-03
TECHNICAL
SPECIFICATION
colour
inside
Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles –
Part 3-1: Vehicle connector, vehicle inlet and cable assembly for DC charging
intended to be used with a thermal management system
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 29.120.30; 43.120 ISBN 978-2-8322-8022-5

Warning! Make sure that you obtained this publication from an authorized distributor.

® Registered trademark of the International Electrotechnical Commission
---------------------- Page: 3 ----------------------
– 2 – IEC TS 62196-3-1:2020 © IEC 2020
CONTENTS

FOREWORD ........................................................................................................................... 5

INTRODUCTION ..................................................................................................................... 7

1 Scope .............................................................................................................................. 8

2 Normative references ...................................................................................................... 8

3 Terms and definitions ...................................................................................................... 9

4 General ......................................................................................................................... 10

5 Ratings .......................................................................................................................... 18

6 Connection between the power supply and the electric vehicle ...................................... 19

7 Classification of accessories .......................................................................................... 20

8 Marking ......................................................................................................................... 21

9 Dimensions.................................................................................................................... 21

10 Protection against electric shock ................................................................................... 21

11 Size and colour of protective earthing conductors .......................................................... 21

12 Provision for protective earthing .................................................................................... 22

13 Terminals ...................................................................................................................... 22

14 Interlocks ....................................................................................................................... 22

15 Resistance to ageing of rubber and thermoplastic material ............................................ 22

16 General construction ..................................................................................................... 22

17 Construction of socket-outlets ....................................................................................... 25

18 Construction of plugs and vehicle connectors ................................................................ 25

19 Construction of vehicle inlets ......................................................................................... 26

20 Degrees of protection .................................................................................................... 26

21 Insulation resistance and dielectric strength .................................................................. 26

22 Breaking capacity .......................................................................................................... 26

23 Normal operation ........................................................................................................... 26

24 Temperature rise ........................................................................................................... 26

25 Flexible cables and their connection .............................................................................. 31

26 Mechanical strength ...................................................................................................... 32

27 Screws, current-carrying parts and connections ............................................................. 33

28 Creepage distances, clearances and distances ............................................................. 33

29 Resistance to heat, to fire and to tracking ...................................................................... 33

30 Corrosion and resistance to rusting ............................................................................... 33

31 Conditional short-circuit current withstand test ............................................................... 33

32 Electromagnetic compatibility ........................................................................................ 33

33 Vehicle driveover ........................................................................................................... 33

101 Liquid coolants ............................................................................................................. 34

Annex A (normative) Specific information for configuration AA ............................................. 36

Annex B (informative) Specific information for configuration BB ........................................... 44

Annex C (normative) Specific information for configuration EE ............................................. 45

Annex D (normative) Specific information for configuration FF ............................................. 53

Annex E (informative) Recommended data .......................................................................... 61

Bibliography .......................................................................................................................... 62

---------------------- Page: 4 ----------------------
IEC TS 62196-3-1:2020 © IEC 2020 – 3 –

Figure 101 – DC EV supply equipment with thermal sensing ................................................. 17

Figure 102 – DC EV supply equipment with thermal sensing, thermal transport and

thermal exchange ................................................................................................................. 18

Figure A.1 – Reference device AA_0 .................................................................................... 36

Figure A.2 – Test setup AA_0 ............................................................................................... 37

Figure A.3 – Test setup AA_1 ............................................................................................... 38

Figure A.4 – Test setup AA_2 ............................................................................................... 39

Figure A.5 – Reference device AA_1 .................................................................................... 39

Figure A.6 – Test setup AA_3 ............................................................................................... 40

Figure A.7 – Reference device AA_2 .................................................................................... 41

Figure A.8 – Test setup AA_4 ............................................................................................... 42

Figure A.9 – General test setup for temperature rise tests and thermal sensing device

tests (configuration AA) ........................................................................................................ 42

Figure A.10 – Plating of contacts for configuration AA ........................................................... 43

Figure C.1 – Reference device EE_0 .................................................................................... 46

Figure C.2 – Test setup EE_0 ............................................................................................... 47

Figure C.3 – Test setup EE_1 ............................................................................................... 47

Figure C.4 – Test setup EE_2 ............................................................................................... 48

Figure C.5 – Reference device EE_1 .................................................................................... 48

Figure C.6 – Test setup EE_3 ............................................................................................... 49

Figure C.7 – Reference device EE_2 .................................................................................... 49

Figure C.8 – Test setup EE_4 ............................................................................................... 50

Figure C.9 – General test setup for temperature rise tests and thermal sensing device

tests (configuration EE) ........................................................................................................ 50

Figure C.10 – Plating of contacts for configuration EE .......................................................... 52

Figure D.1 – Reference device FF_0 ..................................................................................... 54

Figure D.2 – Test setup FF_0 ............................................................................................... 55

Figure D.3 – Test setup FF_1 ............................................................................................... 55

Figure D.4 – Test setup FF_2 ............................................................................................... 56

Figure D.5 – Reference device FF_1 ..................................................................................... 57

Figure D.6 – Test setup FF_3 ............................................................................................... 57

Figure D.7 – Reference device FF_2 ..................................................................................... 58

Figure D.8 – Test setup FF_4 ............................................................................................... 58

Figure D.9 – General test setup for temperature rise tests and thermal sensing device

tests (configuration FF) ......................................................................................................... 59

Figure D.10 – Plating of contacts for configuration FF ........................................................... 60

Table 101 – Overview of applicable tests for different classifications of accessories ............. 11

Table 102 – Test sequence A ............................................................................................... 15

Table 103 – Test sequence B ............................................................................................... 15

Table 104 – Test sequence C ............................................................................................... 16

Table 105 – Test sequence D ............................................................................................... 16

Table 106 – Overview of the DC vehicle interface ................................................................. 19

Table 107 – Overview of the combined AC/DC vehicle interface ........................................... 20

---------------------- Page: 5 ----------------------
– 4 – IEC TS 62196-3-1:2020 © IEC 2020

Table 108 – Interface overview ............................................................................................. 21

Table 109 – Short-time test currents ..................................................................................... 22

Table 110 – Properties of DC accessory contact plating for pin ............................................. 25

Table 111 – Normal operation ............................................................................................... 26

Table 112 – Pull force and torque test values for cable anchorage ........................................ 31

Table 113 – Impact energy for ball impact test ...................................................................... 32

Table 114 – Mechanical load flexing test .............................................................................. 33

Table A.1 – Maximum contact resistances and dimensions of reference device AA_0 ........... 37

Table A.2 – Dimensions for reference device conductor ........................................................ 43

Table C.1 – Contact resistances and dimensions of reference device EE_0 .......................... 46

Table C.2 – Dimensions for reference device conductor (configuration EE) ........................... 51

Table D.1 – Contact resistances and dimensions of reference device FF_0 .......................... 54

Table D.2 – Dimensions for reference device conductor (configuration FF) ........................... 59

---------------------- Page: 6 ----------------------
IEC TS 62196-3-1:2020 © IEC 2020 – 5 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
___________
PLUGS, SOCKET-OUTLETS, VEHICLE CONNECTORS AND VEHICLE
INLETS – CONDUCTIVE CHARGING OF ELECTRIC VEHICLES –
Part 3-1: Vehicle connector, vehicle inlet and cable assembly for
DC charging intended to be used with a thermal management system
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

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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.

The main task of IEC technical committees is to prepare International Standards. In exceptional

circumstances, a technical committee may propose the publication of a Technical Specification

when

• the required support cannot be obtained for the publication of an International Standard,

despite repeated efforts, or

• the subject is still under technical development or where, for any other reason, there is the

future but no immediate possibility of an agreement on an International Standard.

Technical Specifications are subject to review within three years of publication to decide

whether they can be transformed into International Standards.
---------------------- Page: 7 ----------------------
– 6 – IEC TS 62196-3-1:2020 © IEC 2020

IEC TS 62196-3-1, which is a Technical Specification, has been prepared by subcommittee 23H:

Plugs, Socket-outlets and Couplers for industrial and similar applications, and for Electric

Vehicles, of IEC technical committee TC 23: Electrical accessories.
The text of this Technical Specification is based on the following documents:
Draft TS Report on voting
23H/448/DTS 23H/460/RVDTS

Full information on the voting for the approval of this Technical Specification can be found in

the report on voting indicated in the above table.

This document has been drafted in accordance with the ISO/IEC Directives, Part 2.

A list of all the parts in the IEC 62196 series, published under the general title Plugs,

socket­outlets, vehicle connectors and vehicle inlets – Conductive charging of electrical

vehicles, can be found on the IEC website.

This document is to be read in conjunction with IEC 62196-1:2014 and IEC 62196-3:2014. The

particular requirements in this document supplement or modify the corresponding clauses in

Part 3, which, in turn, is based on Part 1. Where the text indicates an "addition" to or a

"replacement" of the relevant requirement, test specification or explanation of Part 3, these

changes are made to the relevant text of Part 3 or Part 1, which then becomes part of this

document. Where no change is necessary, the words "Clause X of IEC 62196-3:2014 applies"

are used.

Subclauses, figures, tables or notes which are additional to those in IEC 62196-3 are numbered

starting from 101.
In this document, the following print types are used:
– requirements proper: in roman type;
– test specifications: in italic type;
– notes: in smaller roman type.

The committee has decided that the contents of this document will remain unchanged until the

stability date indicated on the IEC website under "http://webstore.iec.ch" in the data related to

the specific document. At this date, the document will be
• transformed into an International Standard,
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.

IMPORTANT – The 'colour inside' logo on the cover page of this publication indicates

that it contains colours which are considered to be useful for the correct understanding

of its contents. Users should therefore print this document using a colour printer.

---------------------- Page: 8 ----------------------
IEC TS 62196-3-1:2020 © IEC 2020 – 7 –
INTRODUCTION

Responding to global challenges of CO reduction and energy safety, the automobile industries

have been accelerating the development and commercialization of electric vehicles (EV) and

hybrid electric vehicles. In addition to the prevailing hybrid electric vehicles, battery electric

vehicles including plug-in hybrid electric vehicles are going to be mass-marketed. To support

the diffusion of such vehicles, this document provides the standard interface configurations of

vehicle couplers and accessories to be used in conductive charging of electric vehicles, taking

the most frequent charging situations into consideration.

To meet the market demand for increased electric vehicle ranges, batteries with larger

capacities need to be integrated. To charge those batteries with larger capacity in similar times

as existing charging times or even faster, the charging power needs to be increased. Besides

increasing the charging voltage, the charging current also needs to be increased to boost the

charging power. The larger charging current implies either larger conductor cross sections for

the cable assembly according to existing standards or additional measures in the cable

assembly.

The large conductor cross sections that are required according to the existing design

requirements and test methods result in significantly thicker and heavier cable assemblies.

These are difficult to handle and thus less desirable for public use. Therefore, to improve the

usability of charging systems this document makes use of thermal management techniques to

enhance the performance of the accessories.

This document provides definitions, requirements, and tests for EV couplers up to rated current

according to IEC 62196-1, which supports backward compatibility to couplers according to

IEC 62196-3:2014.
IEC 62196 is divided into several parts as follows:
– Part 1: General requirements, comprising clauses of a general character.

– Part 2: Dimensional compatibility requirements for AC pin and contact-tube accessories.

– Part 3: Dimensional compatibility requirements for DC and AC/DC pin and contact-tube

vehicle couplers.

– Part 4 : Dimensional compatibility requirements for DC pin and contact-tube accessories for

Class II or Class III applications.

– Part 6 : Dimensional compatibility requirements for DC pin and contact-tube couplers for

applications using a system of protective electrical separation.
——————
Under preparation.
Under consideration.
---------------------- Page: 9 ----------------------
– 8 – IEC TS 62196-3-1:2020 © IEC 2020
PLUGS, SOCKET-OUTLETS, VEHICLE CONNECTORS AND VEHICLE
INLETS – CONDUCTIVE CHARGING OF ELECTRIC VEHICLES –
Part 3-1: Vehicle connector, vehicle inlet and cable assembly for
DC charging intended to be used with a thermal management system
1 Scope

This document applies to accessories and cable assemblies with the same configuration as

specified in IEC 62196-3:2014 with rated operating voltage not exceeding 1 500 V DC and a

rated current not exceeding 500 A that employ
– thermal sensing, or
– thermal transport and thermal sensing
with the system architecture described in 4.101.

These accessories and cable assemblies are intended to be used in conductive charging

systems for circuits specified in IEC 61851-23.
NOTE Edition 2 of IEC 61851-23 is under development.

The accessories covered by this document are intended to be used in charging mode 4

according to IEC 61851-1. These accessories are intended to be connected to cables according

to the IEC 62893 series for DC cables.
2 Normative references
Clause 2 of IEC 62196-3:2014 applies, except as follows:
Additional normative references:

IEC 60364-5-54:2011, Low­voltage electrical installations – Part 5­54: Selection and erection

of electrical equipment – Earthing arrangements and protective conductors

IEC 60811-501, Electric and optical fibre cables – Test methods for non­metallic materials –

Part 501: Mechanical tests – Tests for determining the mechanical properties of insulating and

sheathing compounds

IEC 61851-23:— , Electric vehicle conductive charging system – Part 23: DC electric vehicle

supply equipment

IEC 62196-1:2014, Plugs, socket­outlets, vehicle connectors and vehicle inlets – Conductive

charging of electric vehicles – Part 1: General requirements

IEC 62196-2:2016, Plugs, socket­outlets, vehicle connectors and vehicle inlets – Conductive

charging of electric vehicles – Part 2: Dimensional compatibility and interchangeability

requirements for AC pin and contact­tube accessories
——————

Second edition under preparation. Stage at the time of publication: IEC CDV 61851-23:2020.

---------------------- Page: 10 ----------------------
IEC TS 62196-3-1:2020 © IEC 2020 – 9 –

IEC 62196-3:2014, Plugs, socket­outlets, vehicle connectors and vehicle inlets – Conductive

charging of electric vehicles – Part 3: Dimensional compatibility and interchangeability

requirements for DC and AC/DC pin and contact­tube vehicle couplers

IEC 62893-4-1:— , Charging cables for electric vehicles of rated voltages up to and including

0,6/1 kV – Part 4­1: Cables for DC charging according to mode 4 of IEC 61851­1 – DC charging

without use of a thermal management system
ISO 2719:2016, Determination of flash point – Pensky­Martens closed cup method

ISO 17409:2020, Electrically propelled road vehicles – Conductive power transfer – Safety

requirements

ISO 25178-1:2016, Geometrical product specifications (GPS) – Surface texture: Areal – Part 1:

Indication of surface texture

Globally Harmonized System of Classification and Labelling of Chemicals (GHS), Eighth revised

edition, United Nations, 2019

OECD Guidelines for the Testing of Chemicals, Section 3, Test No. 301: Ready Biodegradability,

17 Jul 1992
3 Terms and definitions
Clause 3 of IEC 62196-3:2014 applies, except as follows:
Additional terms and definitions:
3.101
thermal sensing

method for obtaining temperature data of accessories, cable assemblies or parts thereof

3.102
thermal sensing device

means for providing temperature data of accessories, cable assemblies or parts thereof

3.103
thermal transport

method for managing the heat dissipation of accessories, cable assemblies or parts thereof,

independent of changing the current
3.104
thermal transport device

means for managing the heat dissipation of accessories, cable assemblies or parts thereof,

independent of changing the current
3.105
thermal exchange
method for cooling and dissipating thermal energy from the thermal transport
3.106
thermal exchange device
means for cooling and dissipating thermal energy from the thermal transport
——————
Under preparation. Stage at the time of publication: IEC FDIS 62893-4-1:2020.
---------------------- Page: 11 ----------------------
– 10 – IEC TS 62196-3-1:2020 © IEC 2020
3.107
thermal management system

combination of thermal sensing, thermal transport and thermal exchange in order to regulate

temperature
3.108
rated pressure

maximum pressure assigned by the manufacturer to the thermal transport coolant liquid of a

cable assembly under normal and continuous operating c
...

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