IEC TS 62196-4:2022
(Main)Plugs, socket-outlets, vehicle connectors and vehicle inlets - Conductive charging of electric vehicles - Part 4: Dimensional compatibility and interchangeability requirements for DC pin and contact-tube accessories for Class II or Class III applications
Plugs, socket-outlets, vehicle connectors and vehicle inlets - Conductive charging of electric vehicles - Part 4: Dimensional compatibility and interchangeability requirements for DC pin and contact-tube accessories for Class II or Class III applications
IEC TS 62196-4:2022(E) is applicable to plugs, socket-outlets, vehicle connectors and vehicle inlets, herein referred to as “accessories”, of standardized configuration for DC power supply of electric road vehicles, where the protection against electric shocks relies on double or reinforced insulation between all AC and DC inputs and outputs of the EV supply equipment, intended for use in conductive power supply systems which can incorporate control means, with a maximum operating voltage up to 120 V DC, not exceeding 60 A.
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IEC TS 62196-4
®
Edition 1.0 2022-10
TECHNICAL
SPECIFICATION
Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles –
Part 4: Dimensional compatibility and interchangeability requirements for DC pin
and contact-tube accessories for Class II or Class III applications
IEC TS 62196-4:2022-10(en)
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IEC TS 62196-4
®
Edition 1.0 2022-10
TECHNICAL
SPECIFICATION
Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles –
Part 4: Dimensional compatibility and interchangeability requirements for DC pin
and contact-tube accessories for Class II or Class III applications
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 29.120.30; 43.120 ISBN 978-2-8322-5370-0
Warning! Make sure that you obtained this publication from an authorized distributor.
® Registered trademark of the International Electrotechnical Commission
---------------------- Page: 3 ----------------------
– 2 – IEC TS 62196-4:2022 © IEC 2022
CONTENTS
FOREWORD . 3
INTRODUCTION . 5
1 Scope . 6
2 Normative references . 6
3 Terms and definitions . 7
4 General . 7
5 Ratings . 7
6 Connection between the power supply and the electric vehicle . 8
7 Classification of accessories . 10
8 Marking . 10
9 Dimensions. 10
10 Protection against electric shock . 10
11 Size and colour of protective earthing conductors . 11
12 Provisions for protective earthing. 11
13 Terminals . 12
14 Interlocks . 12
15 Resistance to ageing of rubber and thermoplastic material . 12
16 General construction . 12
17 Construction of socket-outlets . 12
18 Construction of plugs and of vehicle connectors . 13
19 Construction of vehicle inlets . 13
20 Degrees of protection . 13
21 Insulation resistance and dielectric strength . 13
22 Breaking capacity . 14
23 Normal operation . 14
24 Temperature rise . 14
25 Flexible cables and their connection . 14
26 Mechanical strength . 14
27 Screws, current-carrying parts and connections . 15
28 Creepage distances, clearances and distances . 15
29 Resistance to heat, to fire and to tracking . 15
30 Corrosion and resistance to rusting . 15
31 Conditional short-circuit current withstand test . 15
32 Electromagnetic compatibility . 15
33 Vehicle driveover . 15
STANDARD SHEETS 4-I . 16
STANDARD SHEETS 4-II . 24
STANDARD SHEETS 4-III . 37
STANDARD SHEETS 4-IV . 45
Bibliography . 56
Table 401 – Overview of the rated voltages and currents . 8
Table 402 – Overview of the DC vehicle coupler . 9
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IEC TS 62196-4:2022 © IEC 2022 – 3 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
PLUGS, SOCKET-OUTLETS, VEHICLE CONNECTORS AND VEHICLE
INLETS – CONDUCTIVE CHARGING OF ELECTRIC VEHICLES –
Part 4: Dimensional compatibility and interchangeability requirements for
DC pin and contact-tube accessories for Class II or Class III applications
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 this end and
in addition to other activities, IEC publishes International Standards, Technical Specifications, Technical Reports,
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preparation is entrusted to technical committees; any IEC National Committee interested in the subject dealt with
may participate in this preparatory work. International, governmental and non-governmental organizations liaising
with the IEC also participate in this preparation. IEC collaborates closely with the International Organization for
Standardization (ISO) in accordance with conditions determined by agreement between the two organizations.
2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international
consensus of opinion on the relevant subjects since each technical committee has representation from all
interested IEC National Committees.
3) IEC Publications have the form of recommendations for international use and are accepted by IEC National
Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC
Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any
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4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications
transparently to the maximum extent possible in their national and regional publications. Any divergence between
any IEC Publication and the corresponding national or regional publication shall be clearly indicated in the latter.
5) IEC itself does not provide any attestation of conformity. Independent certification bodies provide conformity
assessment services and, in some areas, access to IEC marks of conformity. IEC is not responsible for any
services carried out by independent certification bodies.
6) All users should ensure that they have the latest edition of this publication.
7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and
members of its technical committees and IEC National Committees for any personal injury, property damage or
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expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC
Publications.
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.
IEC TS 62196-4 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. It is a Technical Specification.
The text of this Technical Specification is based on the following documents:
Draft Report on voting
23H/382/DTS 23H/385B/RVDTS
23H/385A/RVDTS
23H/385/RVDTS
Full information on the voting for its approval can be found in the report on voting indicated in
the above table.
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– 4 – IEC TS 62196-4:2022 © IEC 2022
The language used for the development of this Technical Specification is English.
This document was drafted in accordance with ISO/IEC Directives, Part 2, and developed in
accordance with ISO/IEC Directives, Part 1 and ISO/IEC Directives, IEC Supplement, available
at www.iec.ch/members_experts/refdocs. The main document types developed by IEC are
described in greater detail at www.iec.ch/publications.
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.
This part of IEC 62196 is to be read in conjunction with IEC 62196-1:2014. The clauses of the
particular requirements in Part 4 supplement or modify the corresponding clauses in Part 1.
Where the text 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.
Subclauses, figures, tables or notes which are additional to those in IEC 62196-1 are numbered
starting from 401.
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 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.
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IEC TS 62196-4:2022 © IEC 2022 – 5 –
INTRODUCTION
IEC 62196 (all parts) specifies the requirements for plugs, socket-outlets, vehicle connectors,
vehicle inlets and cable assemblies as described in IEC 61851 (all parts).
Some conductive transfer of electric power can be achieved by direct connection from an
electric vehicle to common mains socket-outlets.
IEC 62196-4 covers the mechanical, electrical and performance requirements for dedicated
accessories for conductive transfer of electric power between the supply network and a light
electric road vehicle according to IEC TS 61851-3 (all parts).
IEC 62196 is divided into several parts:
• Part 1: General requirements, comprising clauses of a general character;
• Part 2: Dimensional compatibility and interchangeability requirements for AC pin and
contact-tube accessories;
• Part 3: Dimensional compatibility and interchangeability requirements for DC and AC/DC
pin and contact-tube vehicle couplers;
• Part 4: Dimensional compatibility and interchangeability requirements for dedicated DC pin
and contact-tube accessories for Class II or Class III applications.
The International Electrotechnical Commission (IEC) draws attention to the fact that it is claimed
that compliance with this document may involve the use of a patent no. EP1537632 B1
concerning Standard sheets 4-I.
IEC takes no position concerning the evidence, validity and scope of this patent right.
The holder of this patent right has assured the IEC that he/she is willing to negotiate licences
under reasonable and non-discriminatory terms and conditions with applicants throughout the
world. In this respect, the statement of the holder of this patent right is registered with IEC.
Information may be obtained from:
Rosenberger Hochfrequenztechnik GmbH & Co. KG
Hauptstraße 1, 83413 Fridolfing, Germany
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– 6 – IEC TS 62196-4:2022 © IEC 2022
PLUGS, SOCKET-OUTLETS, VEHICLE CONNECTORS AND VEHICLE
INLETS – CONDUCTIVE CHARGING OF ELECTRIC VEHICLES –
Part 4: Dimensional compatibility and interchangeability requirements for
DC pin and contact-tube accessories for Class II or Class III applications
1 Scope
This part of IEC 62196 is applicable to plugs, socket-outlets, vehicle connectors and vehicle
inlets, herein referred to as “accessories”, of standardized configuration for DC power supply
of electric road vehicles, where the protection against electric shocks relies on double or
reinforced insulation between all AC and DC inputs and outputs of the EV supply equipment,
intended for use in conductive power supply systems which can incorporate control means, with
a maximum operating voltage up to 120 V DC, not exceeding 60 A.
These accessories are intended to be used for circuits specified in IEC 61851-3 (all parts).
The accessories covered by this part of IEC 62196 are intended to be used only with electric
vehicles that provide a vehicle power supply circuit with double or reinforced insulation or
battery systems covered by IEC 61851-3 (all parts).
These accessories and cable assemblies are intended to be used in an ambient temperature of
between −30 °C and +50 °C.
These accessories are intended to be connected only to cables with copper or copper-alloy
conductors.
2 Normative references
Clause 2 of IEC 62196-1:2014 applies except as follows:
Addition:
NOTE All EMC related standard references are given in IEC 61851-21-1 and IEC 61851-21-2.
1
IEC TS 61851-3-1:– , Electric vehicle conductive charging system – Part 3-1: DC EV supply
equipment where protection relies on double or reinforced insulation – General rules and
requirements for stationary equipment
2
IEC TS 61851-3-2:– , Electric vehicle conductive charging system – Part 3-2: DC EV supply
equipment where protection relies on double or reinforced insulation – Particular requirements
for portable and mobile equipment
3
IEC TS 61851-3-4:– , Electric vehicle conductive charging system – Part 3-4: DC EV supply
equipment where protection relies on double or reinforced insulation – General definitions and
requirements for CANopen communication
___________
1
Under preparation. Stage at the time of publication: IEC DTS 61851-3-1:2022.
2
Under preparation. Stage at the time of publication: IEC DTS 61851-3-2:2022.
3 Under preparation. Stage at the time of publication: IEC TS 61851-3-4:2022.
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IEC TS 62196-4:2022 © IEC 2022 – 7 –
IEC 61851-21-1, Electric vehicle conductive charging system – Part 21-1 Electric vehicle on-
board charger EMC requirements for conductive connection to AC/DC supply
ISO 17409, Electrically propelled road vehicles – Connection to an external electric power
supply – Safety requirements
3 Terms and definitions
Clause 3 of IEC 62196-1:2014 applies except as follows:
Addition:
3.401
communication contact
auxiliary electric contact for use in a communication and its power supply, if any
4 General
Clause 4 of IEC 62196-1:2014 applies except as follows:
4.1 General requirements
Replacement:
The accessories covered by this document shall only be used with electric vehicles that provide
a vehicle power supply circuit with double or reinforced insulation or battery systems that
comply with the requirements of IEC 61851-3 (all parts).
Accessories shall be so designed and constructed that in normal use their performance is
reliable and minimises the risk of danger to the user or surroundings.
Compliance is checked by meeting all of the relevant requirements and tests specified.
Accessories shall be so designed and constructed that it is not possible to make a cord
extension set. The plug and the vehicle connector shall not be compatible.
Compliance is checked by a manual test.
5 Ratings
Clause 5 of IEC 62196-1:2014 is not applicable.
Replacement:
For voltage and corresponding rated currents, see Table 401.
Voltage classes shall be according to ISO 17409.
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– 8 – IEC TS 62196-4:2022 © IEC 2022
Table 401 – Overview of the rated voltages and currents
Rated volt Rated current DC ISO voltage-class Sheet
V A
60 5 X A 4-I
60 60 X A 4-IIa/4-IIc
120 60 X B 4-IIa/4-IIb
60/120 60 X A/B 4-IIa
(only socket-outlet)
60 60 X A 4-III
120 60 X B 4-IV
NOTE 1 Communication contacts (if any) are rated for 15 V and 2 A DC.
NOTE 2 Nominal system output voltages, see IEC TS 61851-3-1.
An accessory rated above 60 V DC and above 5 A shall be classified as not suitable for making
and breaking an electrical circuit under load.
NOTE In Canada, "not suitable for making and breaking an electric circuit under load" is considered "disconnect
use only".
6 Connection between the power supply and the electric vehicle
Clause 6 of IEC 62196-1:2014 is not applicable.
Replacement:
6.401 General
Clause 6 provides a description of the different types of accessories.
Table 402 gives an overview of the types of accessories.
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IEC TS 62196-4:2022 © IEC 2022 – 9 –
Table 402 – Overview of the DC vehicle coupler
c c
4-IIa 4-IIa
e
4-I 4-III 4-IV
4-IIa
d d
Pos no. Functions
4-IIc 4-IIb
60 V 60 V 120 V 60/120 V 60 V 120 V
1 5 A 60 A -- 60 A 60 A -- DC +60 V
2 -- -- 60 A 60 A -- 60 A DC −120 V
3 5 A 60 A 60 A 60 A 60 A 60 A DC 0 V
a b b b a a
4 CAN Hi
2 A NA NA NA 2 A 2 A
a b b b a a
5 CAN Lo
2 A NA NA NA 2 A 2 A
a b b b a a
6 AUX +12 V
2 A NA NA NA 2 A 2 A
a b b b a a
7 AUX 0 V
2 A NA NA NA 2 A 2 A
a
For contacts 4 to 7, 15 V DC.
b
Communication contacts provided by near field communication (NFC).
c
Socket-outlets/vehicle inlets.
d
Plug/vehicle connectors.
e
Only used for socket-outlets.
6.402 Types of vehicle inlets
There are different types of vehicle inlets:
– 5 A and 60 V DC;
– 60 A and 60 V DC;
– 60 A and 120 V DC.
6.403 Types of vehicle connectors
There are different types of vehicle connectors:
– 5 A and 60 V DC;
– 60 A and 60 V DC;
– 60 A and 120 V DC.
6.404 Types of socket-outlets
There are different types of socket-outlets:
– 5 A and 60 V DC;
– 60 A and 60 V DC;
– 60 A and 120 V DC.
6.405 Types of plugs
There are different types of plugs:
– 5 A and 60 V DC;
– 60 A and 60 V DC;
– 60 A and 120 V DC.
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– 10 – IEC TS 62196-4:2022 © IEC 2022
6.406 Contact sequencing
The contact sequence during the connection process shall be:
– power contacts: “DC 0 V”, “DC +60 V”, “DC −120 V” (if provided);
– communication contacts (if provided);
– proximity detection (if provided).
During disconnection, the order shall be reversed.
7 Classification of accessories
Clause 7 of IEC 62196-1:2014 applies except as follows:
7.5 Not applicable.
8 Marking
Clause 8 of IEC 62196-1:2014 applies except as follows:
8.5 Replacement:
For rewireable accessories, the contacts shall be indicated by the following symbols:
– DC +60 V or +, DC −120 V or −, DC 0 V or 0 V for DC, if any;
– CAN Hi or 4;
– CAN Lo or 5;
– AUX +12 V or 6;
– AUX 0 V or 7.
These symbols shall be placed close to the relevant terminals; they shall not be placed on
screws, removable washers or other removable parts.
If numbers are used, a pin description shall be stated in the documentation.
Compliance is checked by inspection.
9 Dimensions
Clause 9 of IEC 62196-1:2014 applies.
10 Protection against electric shock
Clause 10 of IEC 62196-1:2014 applies except as follows:
10.1 Replacement:
Accessories shall be so designed that hazardous live parts of accessories, when they are wired
as in normal use, are not accessible.
In addition, it shall not be possible to make contact between a live part of a plug or vehicle
connector and a live part of a socket-outlet or vehicle inlet while any live part is accessible.
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IEC TS 62196-4:2022 © IEC 2022 – 11 –
NOTE DC 0 V contacts of vehicle connectors and plugs are deemed to be live parts; communication contacts are
not considered to be live parts.
This does not apply to contacts and conductors used for signal, data, communications and
control circuits.
Compliance is checked by inspection and, if necessary, by a test on the sample wired as in
normal use.
The standard test finger shown in Figure 3 of IEC 62196-1:2014 is applied in every possible
position, an electrical indicator, with a voltage not less than 40 V, being used to show contact
with the relevant part.
10.3 Replacement:
Accessories shall be so designed that:
a) when inserting the plug or the vehicle connector,
1) communication connection, if any, is made after the DC +60 V, DC −120 V, DC 0 V
connections, if any, are made;
2) the proximity contact or the connection switch contact, if any, is made after or at the
same time as the communication connections if any are made.
b) when withdrawing the plug or the vehicle connector,
1) communication connection if any, is broken before the DC +60 V, DC −120 V, DC 0 V
connections, if any, are broken;
2) the proximity contact or connection switch contact, if any, is broken before or at the
same time as the communication connections are broken.
Compliance is checked by inspection and manual test, if required.
10.4 Replacement:
It shall not be possible to inadvertently assemble:
• either the part that carries the contacts of a socket-outlet or of a vehicle inlet into the
enclosure of a plug or of a vehicle connector,
• or the part that carries the contacts of a plug or of a vehicle connector into the enclosure of
a socket-outlet or of a vehicle inlet.
Compliance is checked by inspection and manual test, if required.
11 Size and colour of protective earthing conductors
Clause 11 of IEC 62196-1:2014 is not applicable.
12 Provisions for protective earthing
Clause 12 of IEC 62196-1:2014 is not applicable.
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– 12 – IEC TS 62196-4:2022 © IEC 2022
13 Terminals
Clause 13 of IEC 62196-1:2014 applies except as follows:
13.1.2 Addition:
Add the following lines to Table 7:
5 1 16 N.A. 1 16 N.A.
60 6 to 16 10 to 6 N.A. 6 to 25 10 to 4 N.A.
14 Interlocks
Clause 14 of IEC 62196-1:2014 applies.
15 Resistance to ageing of rubber and thermoplastic material
Clause 15 of IEC 62196-1:2014 applies.
16 General construction
Clause 16 of IEC 62196-1:2014 applies except as follows:
16.8 Replacement:
With the retaining means in place, the mating accessory shall be pulled with a force equal to
the weight of the accessory and a cable of 1,5 m in length with the maximum size conductors
as specified in Table 7 of IEC 62196-1:2014. The retaining means shall not release.
17 Construction of socket-outlets
Clause 17 of IEC 62196-1:2014 applies except as follows:
17.2 Contact tubes
17.2.1 Addition:
Add the following line to Table 12:
4 3,85 2,5
17.2.2 Addition:
Add the following line to Table 13:
4 4,00
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IEC TS 62196-4:2022 © IEC 2022 – 13 –
Add the following lines to Table 14:
up to and including 5 100
from 6 up to and including 60 275
18 Construction of plugs and of vehicle connectors
Clause 18 of IEC 62196-1:2014 applies.
19 Construction of vehicle inlets
Clause 19 of IEC 62196-1:2014 applies except as follows:
19.2 Not applicable.
20 Degrees of protection
Clause 20 of IEC 62196-1:2014 applies except as follows:
20.1 Replacement of the first paragraph:
Accessories shall have the minimum degrees of protection as required in IEC TS 61851-3-1.
21 Insulation resistance and dielectric strength
Clause 21 of IEC 62196-1:2014 applies except as follows:
21.1 Replacement:
Replace the NOTE with the following NOTE:
NOTE For the purpose of these tests, the communications contacts, if any, are connected together and deemed as
one pole.
21.3 Replacement of the second and third paragraphs:
For the parts indicated in 21.2 a) (first dashed item) and 21.2 b) (first dashed item) of
IEC 62196-1:2014, which are used in non-power circuits for energy management system (EMS)
communication according to IEC TS 61851-3-4, each circuit may be tested separately, using a
test voltage based on the highest voltage in the circuit.
For the parts indicated in 21.2 a) (second dashed item) and 21.2 b) (second dashed item) of
IEC 62196-1:2014, which are used in non-power circuits for energy management system (EMS)
communication according to IEC TS 61851-3-4, the test voltage between these circuits and the
power circuits shall be based on the voltage of the power circuit.
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– 14 – IEC TS 62196-4:2022 © IEC 2022
22 Breaking capacity
Clause 22 of IEC 62196-1:2014 applies except as follows:
22.2 Addition:
Add the following lines to Table 16:
5 (DC) 8 1,1 × maximum rat
...
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