Low-voltage docking connectors for removable energy storage units

IEC TS 63066:2017(E) applies to docking connectors (hereinafter referred to as accessories) incorporated in or fixed to electrical equipment, intended to connect removable energy storage units to a dedicated electric power conversion unit, to an energy consuming unit or to another energy storage unit.

General Information

Status
Published
Publication Date
21-Mar-2017
Current Stage
PPUB - Publication issued
Start Date
22-Mar-2017
Completion Date
22-Mar-2017
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IEC TS 63066
Edition 1.0 2017-03
TECHNICAL
SPECIFICATION
Low-voltage docking connectors for removable energy storage units
IEC TS 63066:2017-03(en)
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IEC TS 63066
Edition 1.0 2017-03
TECHNICAL
SPECIFICATION
Low-voltage docking connectors for removable energy storage units
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 29.120.30 ISBN 978-2-8322-4124-0

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

® Registered trademark of the International Electrotechnical Commission
---------------------- Page: 3 ----------------------
– 2 – IEC TS 63066:2017 © IEC 2017
CONTENTS

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

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

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

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

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

4 General ......................................................................................................................... 11

4.1 General requirements ........................................................................................... 11

4.2 General notes on tests .......................................................................................... 11

4.3 General construction ............................................................................................. 11

4.4 Visual examination tests ....................................................................................... 12

4.5 Cable to be used ................................................................................................... 12

4.6 Voltage and current for test purposes ................................................................... 12

4.7 Type of accessories .............................................................................................. 12

5 Standard ratings ............................................................................................................ 13

6 Classification of accessories .......................................................................................... 13

7 Marking ......................................................................................................................... 15

8 Dimensions.................................................................................................................... 16

9 Protection against electric shock ................................................................................... 16

10 Provision for earthing .................................................................................................... 17

11 Terminals and terminations ............................................................................................ 18

12 Interlocks ....................................................................................................................... 18

13 Resistance to ageing of rubber and thermoplastic material ............................................ 19

14 General construction ..................................................................................................... 19

15 Construction of accessories ........................................................................................... 19

16 Degrees of protection .................................................................................................... 19

17 Insulation resistance and dielectric strength .................................................................. 19

18 Mechanical endurance ................................................................................................... 19

19 Temperature rise ........................................................................................................... 20

20 Mechanical strength ...................................................................................................... 20

21 Screws, current-carrying parts and connections ............................................................. 20

22 Creepage distances, clearances and distances through sealing compound .................... 20

23 Resistance to heat, to fire and to tracking ...................................................................... 21

24 Conditional short-circuit current withstand test ............................................................... 21

25 Electromagnetic compatibility ........................................................................................ 21

26 Dynamic mechanical severities ...................................................................................... 21

26.1 Minimum degree of dynamic mechanical severities ............................................... 21

26.2 Appropriate functionality ....................................................................................... 22

27 Electrical endurance ...................................................................................................... 22

27.1 General requirements for accessories ................................................................... 22

27.2 Temperature burden for accessories ..................................................................... 22

27.3 Damp heat for accessories .................................................................................... 23

27.4 Contact resistance ................................................................................................ 23

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IEC TS 63066:2017 © IEC 2017 – 3 –

28 Climatic endurance for contacts ..................................................................................... 23

28.1 General requirements for contacts ........................................................................ 23

28.2 Thermal change for contacts ................................................................................. 24

28.3 Dry heat for contacts ............................................................................................. 24

28.4 Corrosion resistance for contacts .......................................................................... 24

28.5 Damp heat for contacts ......................................................................................... 24

28.6 Functionality for contacts ...................................................................................... 24

28.7 Shocks for contacts .............................................................................................. 24

29 Climatic endurance for bodies ....................................................................................... 25

29.1 General requirements for bodies ........................................................................... 25

29.2 Dry heat for bodies ............................................................................................... 25

29.3 Cold resistance for bodies..................................................................................... 25

29.4 Cold temperatures for bodies ................................................................................ 25

30 Salt stress endurance .................................................................................................... 26

30.1 General requirements for accessories ................................................................... 26

30.2 Salt stress resistance ............................................................................................ 26

31 Operation with misalignments ........................................................................................ 26

31.1 Misalignment at normal operation ......................................................................... 26

31.2 Misalignment after unmating ................................................................................. 30

31.3 Misalignment by terminated wires ......................................................................... 30

31.4 Mating process effected by misalignment .............................................................. 30

32 Environmental conditions ............................................................................................... 31

Annex A (normative) Test cycle electric endurance .............................................................. 33

Annex B (informative) Environmental performance classes for vehicles ............................... 34

Annex C (informative) Examples for accessories on the market ........................................... 35

C.1 General ................................................................................................................. 35

C.2 Accessory example 1 ............................................................................................ 35

C.3 Accessory example 2 ............................................................................................ 38

C.4 Accessory example 3 ............................................................................................ 42

C.5 Accessory example 4 ............................................................................................ 44

C.6 Accessory example 5 ............................................................................................ 46

C.7 Accessory example 6 ............................................................................................ 48

Bibliography .......................................................................................................................... 50

Figure 1 – Diagram showing the use of the accessories ........................................................ 11

Figure 2 – Orthogonal misalignment – front view ................................................................... 27

Figure 3 – Angular misalignment – side view ........................................................................ 27

Figure 4 – Angular misalignment – top view .......................................................................... 27

Figure C.1 – Layout of accessory example 1 ......................................................................... 36

Figure C.2 – Accessory example 1 Type A ............................................................................ 37

Figure C.3 – Accessory example 1 Type B ............................................................................ 38

Figure C.4 – Layout of accessory example 2 ......................................................................... 39

Figure C.5 – Accessory example 2 Type A ............................................................................ 40

Figure C.6 – Accessory example 2 Type B ............................................................................ 41

Figure C.7 – Accessory example 3 Type A ............................................................................ 43

Figure C.8 – Accessory example 3 Type B ............................................................................ 44

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– 4 – IEC TS 63066:2017 © IEC 2017

Figure C.9 – Drawings for accessory example 4 Type A ........................................................ 45

Figure C.10 – Drawings for accessory example 4 Type B ...................................................... 46

Figure C.11 – Drawings for accessory example 5 Type A ...................................................... 47

Figure C.12 – Drawings for accessory example 5 Type B ...................................................... 48

Figure C.13 – Drawings for accessory example 6 Type A ...................................................... 49

Figure C. 14 – Drawings for accessory example 6 Type B ..................................................... 49

Table 1 – General design and usage of accessories ............................................................. 12

Table 2 – Preferred rated currents ........................................................................................ 13

Table 3 – Short-time test currents ......................................................................................... 18

Table 4 – Mechanical endurance .......................................................................................... 20

Table 5 – Dimensions of misalignments ................................................................................ 28

Table 6 – Combinations of misalignments ............................................................................. 29

Table 7 – Environmental performance classes ...................................................................... 31

Table 8 – Severities for environmental performance classes ................................................. 32

Table B.1 – Severities for environmental performance classes for vehicles ........................... 34

Table C.1 – Parameters for accessory example 1 ................................................................. 36

Table C.2 – Parameters for accessory example 2 ................................................................. 39

Table C.3 – Parameters for accessory example 3 ................................................................. 42

Table C.4 – Parameters for accessory example 4 ................................................................. 45

Table C.5 – Parameters for accessory example 5 ................................................................. 47

Table C.6 – Parameters for accessory example 6 ................................................................. 48

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IEC TS 63066:2017 © IEC 2017 – 5 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
LOW-VOLTAGE DOCKING CONNECTORS
FOR REMOVABLE ENERGY STORAGE UNITS
FOREWORD

1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising

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2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international

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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.

IEC TS 63066, 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 23: Electrical accessories.
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– 6 – IEC TS 63066:2017 © IEC 2017
The text of this technical specification is based on the following documents:
Enquiry draft Report on voting
23H/372/DTS 23H/361/RVC

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.

In this document, the following print types are used:
• requirements proper: in roman type;
• test specifications: in italic type;
• explanatory matter: 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
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
A bilingual version of this publication may be issued at a later date.
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IEC TS 63066:2017 © IEC 2017 – 7 –
INTRODUCTION

Pluggable energy storage technology has a large demand and perspective in certain areas.

With the advent of electric vehicles, energy storage units for renewable energy and other

applications, guidance is needed to ensure safe and reliable operation, interoperability,

environmental protection and energy efficiency. The industry needs such a document to

promote the technology development and popularization of pluggable energy storage

technology.

Compared to other accessories, several specific items are considered. The mating process

may not have haptic support by the operator to find the correct position between the two parts

of the connector. The mating process may have a mechanical feed which precludes the

finding of the correct position between the two parts of the connector. To overcome these

issues, the design of the accessories may consist partly of moveable parts to compensate a

mechanical feed and tolerances.
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– 8 – IEC TS 63066:2017 © IEC 2017
LOW-VOLTAGE DOCKING CONNECTORS
FOR REMOVABLE ENERGY STORAGE UNITS
1 Scope

This document applies to docking connectors (hereinafter referred to as accessories)

incorporated in or fixed to electrical equipment, intended to connect removable energy

storage units to a dedicated electric power conversion unit, to an energy consuming unit or to

another energy storage unit.

These accessories are intended for DC and may include an earth contact and/or optional

auxiliary contacts for signaling and data. These accessories have a rated current of up to

800 A and rated operating voltages not exceeding 1 000 V DC.

These accessories are not suitable for mating or unmating under load. These accessories are

intended to be installed by instructed persons (IEC 60050-195:1998, 195-04-02) or skilled

persons (IEC 60050-195:1998, 195-04-01) only.
The list of preferred ratings is not intended to exclude other ratings.

This document applies to accessories for use under environmental conditions as described in

Clause 32.

These accessories are intended to be connected to current carrying parts in copper or copper

alloy only, plated or not plated.

This document also applies to accessories intended to be used at extra-low voltage.

In locations where special conditions prevail, for example on board vehicles, additional

requirements may apply.
These accessories are intended to be used with a specific charging system.

NOTE For conditions other than operation, additional requirements could be applicable, for instance IEC 62133

and the UN Recommendations on the Transport of Dangerous Goods section 38.338.3.
2 Normative references
Clause 3 of IEC 60309-1:1999, IEC 60309-1:1999/AMD1:2005 and
IEC 60309-1:1999/AMD2:2012 applies, except as follows:
Addition of the following new references:
IEC 60068-2-1, Environmental testing – Part 2-1: Tests – Test A: Cold
IEC 60068-2-2, Environmental testing – Part 2-2: Tests – Test B: Dry heat

IEC 60068-2-14, Environmental testing – Part 2-14: Tests – Test N: Change of temperature

—————————
In some countries, the term ground is used instead of earth.
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IEC TS 63066:2017 © IEC 2017 – 9 –

IEC 60068-2-30, Environmental testing – Part 2-30: Tests – Test Db: Damp heat, cyclic

(12 h + 12 h cycle)
IEC 60068-2-38, Environmental testing – Part 2-38: Tests – Test Z/AD: Composite
temperature/humidity cyclic test

IEC 60068-2-52, Environmental testing – Part 2: Tests – Test Kb: Salt mist, cyclic (sodium

chloride solution)

IEC 60068-2-60, Environmental testing – Part 2-60: Tests – Test Ke: Flowing mixed gas

corrosion test

IEC 60309-1:1999, Plugs, socket-outlets and couplers for industrial purposes – Part 1:

General requirements
IEC 60309-1:1999/AMD1:2005
IEC 60309-1:1999/AMD2:2012
IEC 60352 (all parts), Solderless connections

IEC 60417, Graphical symbols for use on equipment (available at http://www.graphical-

symbols.info/equipment)

IEC 61140:2016, Protection against electric shock – Common aspects for installation and

equipment

IEC 61373:2010, Railway applications – Rolling stock equipment – Shock and vibration tests

ISO/IEC TR 29106:2007, Information technology – Generic cabling – Introduction to the MICE

environmental classification
ISO/IEC TR 29106:2007/AMD1:2012
3 Terms and definitions
Clause 2 of IEC 60309-1:1999, IEC 60309-1:1999/AMD1:2005 and
IEC 60309-1:1999/AMD2:2012 applies, except as follows:
Addition of the following new terms and definitions:
3.1
docking connector

accessory where the two complementary accessories are equipped with guiding means

allowing their connection without the haptic support of an operator
3.2
unmated condition
position of the accessory without any contact between both parts
3.3
mated condition

service condition and position where the two parts of the accessory are in a position as

described in the relevant standard sheet
3.4
guiding means

mechanical structure intended to ensure the proper alignment of the two complementary

accessories before their mating
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– 10 – IEC TS 63066:2017 © IEC 2017
3.5
energy storage unit

unit, which includes accessories, multiple batteries or other chargeable cells arranged in a

way to store electrical energy

Note 1 to entry: This may also include supporting means for charging, storage, interlocking and discharging.

3.6
removable energy storage unit

energy storage unit, which can be easily detached and inserted into a rack to establish the

electrical connection with an accessory
3.7
rack

mechanical structure intended to incorporate one or more removable energy storage units

3.8
electric power conversion unit

device converting electric energy from one form to another, converting between AC and DC,

or changing the voltage or frequency, or a combination of these
3.9
shutter

movable part incorporated into an accessory arranged to automatically shield at least the live

contacts when the complementary accessory is withdrawn

[SOURCE: IEC 60884-1:2002/AMD2:2013, 3.27, modified – 'socket-outlet' and 'plug' are

replaced by 'accessory', 'automatically' is deleted and 'complementary' is added]

3.10
superordinate system

overall technical system as a set of components or systems with relationships between the

components or systems and between their attributes
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IEC TS 63066:2017 © IEC 2017 – 11 –
IEC
Key
A docking accessories type A
B complementary docking accessories type B
C removable energy storage units
D rack
E guiding means
Figure 1 – Diagram showing the use of the accessories
4 General
Clause 4 of IEC 60309-1:1999, IEC 60309-1:1999/AMD1:2005 and
IEC 60309-1:1999/AMD2:2012 applies, except as follows:
4.1 General requirements
Replacement of the fourth paragraph with:

Accessories shall have a minimum degree of protection as indicated in Table 8, test variable

TV1.
4.2 General notes on tests
Subclause 4.2 of IEC 60309-1:1999, IEC 60309-1:1999/AMD1:2005 and
IEC 60309-1:1999/AMD2:2012 applies.
4.3 General construction

Different possibilities for the movement, adjustment and mating of components and

accessories are stated in Table 1.
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– 12 – IEC TS 63066:2017 © IEC 2017
Table 1 – General design and usage of accessories
Case Accessory Type A Accessory Type B Removabl
...

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