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

IEC 62196-1:2022 is applicable to EV plugs, EV socket-outlets, vehicle connectors, vehicle inlets, herein referred to as "accessories", and to cable assemblies for electric vehicles (EV) intended for use in conductive charging systems which incorporate control means, with a rated operating voltage not exceeding:
690 V AC 50 Hz to 60 Hz, at a rated current not exceeding 250 A;
1 500 V DC at a rated current not exceeding 800 A.  This fourth edition cancels and replaces the third edition published in 2014. This edition constitutes a technical revision.
This edition includes the following significant technical changes with respect to the previous edition:  
deletion of references to universal AC and DC interfaces;
additional requirements for contact materials and plating;
changes to the temperature rise test to include additional points of measurement;
additional tests for accessories to address thermal stresses and stability, mechanical wear and abuse, and exposure to contaminants;
relocation of information and requirements for DC charging to IEC 62196-3.

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

L’IEC 62196-1:2022 s’applique aux fiches VE, socles de prise de courant VE, prises mobiles de véhicule, socles de connecteur de véhicules, ci-après désignés par le terme "appareils", et aux câbles de charge pour véhicules électriques (VE) destinés à être utilisés dans les systèmes de charge conductive qui comprennent des moyens de contrôle, avec une tension assignée d’emploi n’excédant pas:
690 V 50 Hz à 60 Hz, à un courant alternatif assigné n’excédant pas 250 A;
1 500 V, à un courant continu assigné n’excédant pas 800 A.  Cette quatrième édition annule et remplace la troisième édition parue en 2014. Cette édition constitue une révision technique.
Cette édition inclut les modifications techniques majeures suivantes par rapport à l’édition précédente:  
suppression des références aux interfaces universelles en courant alternatif et en courant continu;
exigences supplémentaires pour les matériaux de contact et la métallisation;
modification de l’essai d’échauffement pour inclure des points de mesure supplémentaires;
essais supplémentaires pour examiner les contraintes et la stabilité thermique, l’usure mécanique et une mauvaise utilisation des appareils, ainsi que leur exposition à des contaminants;
déplacement des informations et exigences concernant la charge en courant continu dans l’IEC 62196-3.  La version française de la norme n’a pas été soumise au vote.

General Information

Status
Published
Publication Date
02-May-2022
Current Stage
PPUB - Publication issued
Completion Date
03-May-2022
Ref Project

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IEC 62196-1
Edition 4.0 2022-05
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
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 de véhicule et socles de
connecteurs de véhicule – Charge conductive des véhicules électriques –
Partie 1: Exigences générales
IEC 62196-1:2022-05(en-fr)
---------------------- Page: 1 ----------------------
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---------------------- Page: 2 ----------------------
IEC 62196-1
Edition 4.0 2022-05
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
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 de véhicule et socles de
connecteurs de véhicule – Charge conductive des véhicules électriques –
Partie 1: Exigences générales
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 29.120.30; 43.120 ISBN 978-2-8322-1101-1

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

Attention! Veuillez vous assurer que vous avez obtenu cette publication via un distributeur agréé.

® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale
---------------------- Page: 3 ----------------------
– 2 – IEC 62196-1:2022 © IEC 2022
CONTENTS

FOREWORD ........................................................................................................................... 6

INTRODUCTION ..................................................................................................................... 8

1 Scope .............................................................................................................................. 9

2 Normative references ...................................................................................................... 9

3 Terms and definitions .................................................................................................... 11

4 General ......................................................................................................................... 21

4.1 General requirements ........................................................................................... 21

4.2 Components ......................................................................................................... 21

4.2.1 Ratings .......................................................................................................... 21

4.2.2 Mechanical assembly ..................................................................................... 21

4.2.3 Current-carrying parts of incorporated components ........................................ 21

4.2.4 Electrical connections .................................................................................... 21

4.3 General notes on tests .......................................................................................... 22

5 Ratings .......................................................................................................................... 23

5.1 Preferred rated operating voltage ranges .............................................................. 23

5.2 Preferred rated currents ........................................................................................ 23

5.2.1 General ......................................................................................................... 23

5.2.2 Rated current for signal or control purposes .................................................. 24

5.2.3 Accessories not suitable for making and breaking an electrical circuit

under load ..................................................................................................... 24

5.2.4 Accessories suitable for, or not suitable for, making and breaking an

electrical circuit under load ............................................................................ 24

6 Connection between the power supply and the electric vehicle ...................................... 24

6.1 Interfaces .............................................................................................................. 24

6.2 Basic interface ...................................................................................................... 24

6.3 DC interface .......................................................................................................... 24

6.4 Combined interface ............................................................................................... 24

7 Classification of accessories .......................................................................................... 25

7.1 According to purpose ............................................................................................ 25

7.2 According to the method of connecting the conductors .......................................... 25

7.3 According to serviceability .................................................................................... 25

7.4 According to electrical operation ........................................................................... 25

7.5 According to interface ........................................................................................... 25

7.6 According to locking facilities ................................................................................ 25

7.7 According to interlock facilities .............................................................................. 25

7.8 According to the presence of shutter(s) ................................................................. 25

8 Marking ......................................................................................................................... 25

9 Dimensions.................................................................................................................... 28

10 Protection against electric shock ................................................................................... 29

10.1 General ................................................................................................................. 29

10.2 Accessories with shutters...................................................................................... 29

10.3 Contact sequencing and order of contact insertion and withdrawal ........................ 32

10.4 Misassembly ......................................................................................................... 33

11 Size and colour of protective earthing and neutral conductors ....................................... 33

12 Provisions for earthing ................................................................................................... 34

---------------------- Page: 4 ----------------------
IEC 62196-1:2022 © IEC 2022 – 3 –

13 Terminals ...................................................................................................................... 36

13.1 Common requirements .......................................................................................... 36

13.2 Screw type terminals ............................................................................................. 38

13.3 Mechanical tests on terminals ............................................................................... 40

14 Interlocks ....................................................................................................................... 43

14.1 Accessories with interlock ..................................................................................... 43

14.2 Accessories with integral switching device ............................................................ 48

14.3 Control circuit devices and switching elements ..................................................... 48

14.4 Pilot contacts and auxiliary circuits ....................................................................... 48

15 Resistance to ageing of rubber and thermoplastic material ............................................ 48

16 General construction ..................................................................................................... 49

17 Construction of EV socket-outlets – General .................................................................. 53

18 Construction of EV plugs and vehicle connectors ........................................................... 53

19 Construction of vehicle inlets ......................................................................................... 54

20 Degrees of protection .................................................................................................... 54

21 Insulation resistance and dielectric strength .................................................................. 56

22 Breaking capacity .......................................................................................................... 57

23 Normal operation ........................................................................................................... 60

23.1 Mechanical, electrical, and thermal stresses and contaminants ............................. 60

23.2 Load endurance test ............................................................................................. 60

23.3 No-load endurance test ......................................................................................... 61

23.4 Lid springs ............................................................................................................ 62

24 Temperature rise ........................................................................................................... 62

25 Flexible cables and their connection .............................................................................. 64

25.1 Strain relief ........................................................................................................... 64

25.2 Requirements for EV plugs and vehicle connectors ............................................... 64

25.2.1 Non-rewirable EV plugs and vehicle connectors............................................. 64

25.2.2 Rewirable EV plugs and vehicle connectors ................................................... 64

25.3 EV plugs and vehicle connectors provided with a flexible cable ............................. 65

26 Mechanical strength ...................................................................................................... 67

26.1 General ................................................................................................................. 67

26.2 Ball impact ............................................................................................................ 68

26.3 Drop test ............................................................................................................... 69

26.4 Flexing test ........................................................................................................... 70

26.5 Cable gland test .................................................................................................... 72

26.6 Shutters ................................................................................................................ 73

26.7 Insulated end caps ................................................................................................ 73

26.7.1 General ......................................................................................................... 73

26.7.2 Insulated end caps – Change of temperature test .......................................... 74

26.7.3 Insulated end caps – Pull test ........................................................................ 74

27 Screws, current-carrying parts and connections ............................................................. 74

28 Creepage distances, clearances and distances through sealing compound .................... 77

29 Resistance to heat and to fire ........................................................................................ 78

30 Corrosion and resistance to rusting ............................................................................... 79

31 Conditional short-circuit current ..................................................................................... 80

31.1 General ................................................................................................................. 80

---------------------- Page: 5 ----------------------
– 4 – IEC 62196-1:2022 © IEC 2022

31.2 Ratings and test conditions ................................................................................... 80

31.3 Test circuit ............................................................................................................ 81

31.4 Calibration ............................................................................................................ 84

31.5 Test procedure ...................................................................................................... 84

31.6 Behaviour of the equipment under test .................................................................. 85

31.7 Acceptance conditions .......................................................................................... 85

32 Electromagnetic compatibility ........................................................................................ 85

32.1 Immunity ............................................................................................................... 85

32.2 Emission ............................................................................................................... 85

33 Vehicle drive over .......................................................................................................... 85

34 Thermal cycling ............................................................................................................. 86

34.1 General ................................................................................................................. 86

34.2 Initial temperature rise test ................................................................................... 86

34.3 Thermal cycling test .............................................................................................. 86

34.4 Final temperature rise test .................................................................................... 86

35 Humidity exposure ......................................................................................................... 87

35.1 General ................................................................................................................. 87

35.2 Initial temperature rise test ................................................................................... 87

35.3 Humidity test ......................................................................................................... 87

35.4 Final temperature rise test .................................................................................... 87

36 Misalignment ................................................................................................................. 87

36.1 General ................................................................................................................. 87

36.2 Samples................................................................................................................ 88

36.3 Misalignment test .................................................................................................. 88

37 Contact endurance test .................................................................................................. 90

37.1 Equipment ............................................................................................................ 90

37.2 Test sequence ...................................................................................................... 91

37.3 Compliance ........................................................................................................... 92

Bibliography .......................................................................................................................... 94

Figure 1 – Diagram showing the use of the accessories ........................................................ 12

Figure 2 – Lug terminals ....................................................................................................... 16

Figure 3 – Mantle terminals................................................................................................... 16

Figure 4 – Pillar terminals ..................................................................................................... 17

Figure 5 – Saddle terminals .................................................................................................. 18

Figure 6 – Screw-type terminals ............................................................................................ 19

Figure 7 – Stud terminals ...................................................................................................... 20

Figure 8 – Test piston ........................................................................................................... 28

Figure 9 – Gauge "A" for checking shutters ........................................................................... 31

Figure 10 – Gauge "B" for checking shutters ......................................................................... 32

Figure 11 – Gauges for testing insertability of round unprepared conductors having the

maximum specified cross-section .......................................................................................... 39

Figure 12 – Equipment test arrangement .............................................................................. 41

Figure 13 – Apparatus for checking the withdrawal force....................................................... 46

Figure 14 – Verification of the latching device ....................................................................... 47

Figure 15 – Circuit diagrams for breaking capacity and normal operation tests ..................... 59

---------------------- Page: 6 ----------------------
IEC 62196-1:2022 © IEC 2022 – 5 –

Figure 16 – Points of measurement....................................................................................... 64

Figure 17 – Apparatus for testing the cable anchorage ......................................................... 66

Figure 18 – Ball impact test .................................................................................................. 68

Figure 19 – Arrangement for mechanical strength test for EV plugs and vehicle

connectors ............................................................................................................................ 70

Figure 20 – Apparatus for flexing test ................................................................................... 72

Figure 21 – Diagram of the test circuit for the verification of short-circuit current

withstand of two-pole equipment on a single-phase AC or DC ............................................... 82

Figure 22 – Diagram of the test circuit for the verification of short-circuit current

withstand of three-pole equipment ........................................................................................ 83

Figure 23 – Diagram of the test circuit for the verification of short-circuit current

withstand of four-pole equipment .......................................................................................... 84

Figure 24 – Overview of the mechanical load test ................................................................. 89

Figure 25 – Application of external mechanical load (mounted according to Figure 24) ......... 89

Figure 26 – Temperature rise criteria under external mechanical load ................................... 90

Figure 27 – Forced-air circulating oven ................................................................................. 90

Figure 28 – Thermal cycling .................................................................................................. 92

Figure 29 – Pass/fail based on temperature rise criteria ........................................................ 93

Table 1 – Size for conductors ............................................................................................... 34

Table 2 – Short-time test currents ......................................................................................... 35

Table 3 – Values for flexing under mechanical load test ........................................................ 42

Table 4 – Value for terminal pull test ..................................................................................... 43

Table 5 – Withdrawal force with respect to ratings ................................................................ 47

Table 6 – Cable length used to determine pull force on retaining means ............................... 50

Table 7 – Test voltage for dielectric strength test .................................................................. 57

Table 8 – Breaking capacity .................................................................................................. 60

Table 9 – Normal operation ................................................................................................... 61

Table 10 – Test current and nominal cross-sectional areas of copper conductors for

temperature rise test ............................................................................................................. 63

Table 11 – Pull force and torque test values for cable anchorage .......................................... 67

Table 12 – Summary of mechanical tests .............................................................................. 67

Table 13 – Impact energy for ball impact test ........................................................................ 69

Table 14 – Mechanical load flexing test ................................................................................ 71

Table 15 – Torque test values for glands .............................................................................. 73

Table 16 – Pulling force on insulated end caps ..................................................................... 74

Table 17 – Tightening torque for verification of mechanical strength of screw-type

terminals ............................................................................................................................... 75

---------------------- Page: 7 ----------------------
– 6 – IEC 62196-1:2022 © IEC 2022
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
PLUGS, SOCKET-OUTLETS, VEHICLE CONNECTORS AND VEHICLE
INLETS – CONDUCTIVE CHARGING OF ELECTRIC VEHICLES –
Part 1: General requirements
FOREWORD

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