Plugs, socket-outlets, vehicle connectors and vehicle inlets - Conductive charging of electric vehicles - Part 6: Dimensional compatibility requirements for DC pin and contact-tube vehicle couplers intended to be used for DC EV supply equipment where protection relies on electrical separation

IEC 62196-6:2022 is applicable to vehicle connectors, vehicle inlets and cable assemblies for electric vehicle (EV), intended for use in conductive charging systems which incorporate control means, with a rated operating voltage up to 120 V DC and rated current up to 100 A.
These accessories are intended to be used for a DC interface of the conductive charging system according to IEC 61851-25:2020.

Fiches, socles de prise de courant, prises mobiles de véhicule et socles de connecteur de véhicule - Charge conductive des véhicules électriques - Partie 6: Exigences dimensionnelles de compatibilité pour les connecteurs de véhicules à broches et alvéoles à courant continu pour système d’alimentation pour véhicules électriques en courant continu lorsque la protection est réalisée par séparation électrique

L’IEC 62196-6:2022 s’applique aux prises mobiles de véhicule, socles de connecteur de véhicules et 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 120 V en courant continu et un courant assigné n’excédant pas 100 A.
Ces appareils sont destinés à être utilisés pour une interface en courant continu du système de charge conductive conformément à l’IEC 61851-25:2020.
La version française de la norme n’a pas été soumise au vote.

General Information

Status
Published
Publication Date
21-Apr-2022
Current Stage
PPUB - Publication issued
Completion Date
22-Apr-2022
Ref Project

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IEC 62196-6:2022 - Plugs, socket-outlets, vehicle connectors and vehicle inlets - Conductive charging of electric vehicles - Part 6: Dimensional compatibility requirements for DC pin and contact-tube vehicle couplers intended to be used for DC EV supply equipment where protection relies on electrical separation
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IEC 62196-6
Edition 1.0 2022-04
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles –
Part 6: Dimensional compatibility requirements for DC pin and contact-tube
vehicle couplers intended to be used for DC EV supply equipment where
protection relies on electrical separation
Fiches, socles de prise de courant, prises mobiles de véhicule et socles de
connecteurs de véhicule – Charge conductive des véhicules électriques –
Partie 6: Exigences dimensionnelles de compatibilité pour les prises de courant
de véhicules à broches et alvéoles à courant continu pour système
d’alimentation pour véhicules électriques en courant continu lorsque la
protection est réalisée par séparation électrique
IEC 62196-6:2022-04(en-fr)
---------------------- Page: 1 ----------------------
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---------------------- Page: 2 ----------------------
IEC 62196-6
Edition 1.0 2022-04
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles –
Part 6: Dimensional compatibility requirements for DC pin and contact-tube
vehicle couplers intended to be used for DC EV supply equipment where
protection relies on electrical separation
Fiches, socles de prise de courant, prises mobiles de véhicule et socles de
connecteurs de véhicule – Charge conductive des véhicules électriques –
Partie 6: Exigences dimensionnelles de compatibilité pour les prises de courant
de véhicules à broches et alvéoles à courant continu pour système
d’alimentation pour véhicules électriques en courant continu lorsque la
protection est réalisée par séparation électrique
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 29.120.30; 43.120 ISBN 978-2-8322-1101-4

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 62196-6:2022 © IEC 2022
CONTENTS

FOREWORD ........................................................................................................................... 4

INTRODUCTION ..................................................................................................................... 6

1 Scope .............................................................................................................................. 7

2 Normative references ...................................................................................................... 7

3 Terms and definitions ...................................................................................................... 7

4 General ........................................................................................................................... 7

5 Ratings ............................................................................................................................ 8

6 Connection between the power supply and the electric vehicle ........................................ 8

7 Classification of accessories............................................................................................ 9

8 Marking ........................................................................................................................... 9

9 Dimensions ..................................................................................................................... 9

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

11 Size and colour of protective earthing and neutral conductors ....................................... 10

12 Provisions for earthing ................................................................................................... 10

13 Terminals ...................................................................................................................... 10

14 Interlocks....................................................................................................................... 11

15 Resistance to ageing of rubber and thermoplastic material ............................................ 12

16 General construction ..................................................................................................... 12

17 Construction of EV socket-outlets .................................................................................. 13

18 Construction of EV 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 .......................................................................................................... 13

23 Normal operation ........................................................................................................... 13

24 Temperature rise ........................................................................................................... 14

25 Flexible cables and their connection .............................................................................. 14

26 Mechanical strength ...................................................................................................... 15

27 Screws, current-carrying parts and connections ............................................................. 15

28 Creepage distances, clearances and distances ............................................................. 15

29 Resistance to heat and fire ............................................................................................ 15

30 Corrosion and resistance to rusting ............................................................................... 15

31 Conditional short-circuit current ..................................................................................... 15

32 Electromagnetic compatibility ........................................................................................ 15

33 Vehicle driveover ........................................................................................................... 15

34 Thermal cycling ............................................................................................................. 15

35 Humidity exposure ......................................................................................................... 15

36 Misalignment ................................................................................................................. 15

37 Contact endurance test .................................................................................................. 16

STANDARD SHEETS............................................................................................................ 17

Bibliography .......................................................................................................................... 27

---------------------- Page: 4 ----------------------
IEC 62196-6:2022 © IEC 2022 – 3 –

Table 601 – Overview of the DC vehicle interface ................................................................... 9

Table 1 – Size for conductors ............................................................................................... 11

Table 9 – Normal operation ................................................................................................... 14

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

temperature rise test ............................................................................................................. 14

Table 11 – Pull force and torque test values for cable anchorage.......................................... 14

---------------------- Page: 5 ----------------------
– 4 – IEC 62196-6:2022 © IEC 2022
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
PLUGS, SOCKET-OUTLETS, VEHICLE CONNECTORS AND VEHICLE
INLETS – CONDUCTIVE CHARGING OF ELECTRIC VEHICLES –
Part 6: Dimensional compatibility requirements for DC pin and
contact-tube vehicle couplers intended to be used for DC EV supply
equipment where protection relies on electrical separation
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

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preparation is entrusted to technical committees; any IEC National Committee interested in the subject dealt with

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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

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8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is

indispensable for the correct application of this publication.

9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of patent

rights. IEC shall not be held responsible for identifying any or all such patent rights.

International Standard IEC 62196-6 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.
The text of this International Standard is based on the following documents:
Draft Report on voting
23H/501/FDIS 23H/505/RVD

Full information on the voting for its approval can be found in the report on voting indicated in

the above table.
The language used for the development of this International Standard is English.
---------------------- Page: 6 ----------------------
IEC 62196-6:2022 © IEC 2022 – 5 –

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/standardsdev/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 document is to be read in conjunction with IEC 62196-1:2022. The clauses of the particular

requirements in Part 6 supplement or modify the corresponding clauses in Part 1. Where the

text indicates "addition" to or "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 this standard. Where no change is necessary, the words "Clause X of

IEC 62196-1:2022 is applicable" are used.

Subclauses, figures or tables which are additional to those in IEC 62196-1:2022 are numbered

starting from 601.
In this standard, 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.
---------------------- Page: 7 ----------------------
– 6 – IEC 62196-6:2022 © IEC 2022
INTRODUCTION

With the continued development and expansion of the use of electric power into other classes

of electric vehicles (EV) and hybrid electric vehicles, the introduction and commercialization of

electric powered two or three wheelers (hereafter e-PTWs) are being accelerated in the global

market and responding to the global concerns on CO reduction and energy saving.

In comparison with the passenger cars, e-PTWs have a shorter range per charge and need

more charging possibilities, especially public DC charging stations. This document provides

general and basic requirements for a compact interface for small sized DC EV supply equipment,

which could be installed in various places such as convenience stores, newspaper stands,

lottery shops, etc., and could help the diffusion of e-PTWs.
---------------------- Page: 8 ----------------------
IEC 62196-6:2022 © IEC 2022 – 7 –
PLUGS, SOCKET-OUTLETS, VEHICLE CONNECTORS AND VEHICLE
INLETS – CONDUCTIVE CHARGING OF ELECTRIC VEHICLES –
Part 6: Dimensional compatibility requirements for DC pin and
contact-tube vehicle couplers intended to be used for DC EV supply
equipment where protection relies on electrical separation
1 Scope

This part of IEC 62196 is applicable to vehicle connectors, vehicle inlets and cable assemblies

for electric vehicle (EV), intended for use in conductive charging systems which incorporate

control means, with a rated operating voltage up to 120 V DC and rated current up to 100 A.

These accessories are intended to be used for a DC interface of the conductive charging system

according to IEC 61851-25:2020.

This document applies to accessories and cable assemblies to be used in an ambient

temperature of between –30 °C and +40 °C.

The vehicle connector and vehicle inlets are intended to be connected only to cables with

copper or copper-alloy conductors.
2 Normative references
Clause 2 of IEC 62196-1:2022 applies, except as follows:
Addition:

IEC 61851-25:2020, Electric vehicle conductive charging system – Part 25: DC EV supply

equipment where protection relies on electrical separation

IEC 62196-1:2022, Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive

charging of electric vehicles – Part 1: General requirements
3 Terms and definitions
Clause 3 of IEC 62196-1:2022 applies.
4 General
Clause 4 of IEC 62196-1:2022 applies, except as follows:
4.1 General requirements
Replacement of the first paragraph:

The accessories covered by this document shall only be used with DC EV supply equipment

that complies with the requirements of IEC 61851-25.
---------------------- Page: 9 ----------------------
– 8 – IEC 62196-6:2022 © IEC 2022
5 Ratings
Clause 5 of IEC 62196-1:2022 applies, except as follows:
Replacement:
5.1 Preferred rated operating voltage ranges
The preferred rated operating voltage ranges are:
0 V to 30 V (signal or control purposes only)
120 V DC
5.2 Preferred rated currents
5.2.1 General
The DC rated current for vehicle coupler is 100 A.
The DC rated currents for cable assembly are:
16 A
20 A
50 A
70 A
100 A
6 Connection between the power supply and the electric vehicle
Clause 6 of IEC 62196-1:2022 applies, except as follows:
6.1 Interfaces
Replacement:

This clause provides a description of the physical conductive electrical interface requirements

between the vehicle and the power supply for the DC interface.
6.2 Basic interface
Not applicable.
6.3 DC interface
Replacement:

The DC interface may contain up to 7 (power or signal) contacts, with only one physical

configuration of contact positions. The electrical ratings and their function are described in

Table 601. They shall be used in a system according to IEC 61851-25.
---------------------- Page: 10 ----------------------
IEC 62196-6:2022 © IEC 2022 – 9 –
Table 601 – Overview of the DC vehicle interface
U I
max max
Position
Symbol Function
number
V A
1 120 100 DC + DC +
2 120 100 DC – DC –
3 30 2 Control pilot
CPW
4 30 2 CAN HI Communication (CAN) (+)
5 30 2 CAN LO Communication (CAN) (−)
6 30 2 +12V Auxiliary power supply (+)
7 30 2 0V Auxiliary power supply (−)

Position number does not refer to the location and/or identification of the contact in the accessory.

CPW stands for "control pilot wire".
6.4 Combined interface
Not applicable.
7 Classification of accessories
Clause 7 of IEC 62196-1:2022 applies, except as follows:
7.1 According to purpose
Replacement:
– vehicle connectors,
– vehicle inlets,
– cable assemblies.
7.5 According to interface
Replacement:
– DC
8 Marking
Clause 8 of IEC 62196-1:2022 applies.
9 Dimensions
Clause 9 of IEC 62196-1:2022 applies, except as follows:
Replacement of the first paragraph:

The vehicle connector and vehicle inlet shall comply with configuration shown in Standard

Sheet 6.
---------------------- Page: 11 ----------------------
– 10 – IEC 62196-6:2022 © IEC 2022
10 Protection against electric shock
Clause 10 of IEC 62196-1:2022 applies, except as follows:
10.3 Contact sequencing and order of contact insertion and withdrawal
Replacement:
The contact sequence during the connection process shall be:
– DC power contacts

– Control pilot and other contacts (i.e. auxiliary power supply and communication)

During disconnection the order shall be reversed.
Accessories shall be so designed that

a) when inserting the vehicle connector, the control pilot and other contacts (i.e. auxiliary

power supply and communication) connection are made after DC +/- contacts are made;

b) when withdrawing the vehicle connector, the control pilot and other contacts (i.e. auxiliary

power supply and communication) connection are broken before DC +/- contacts are
broken."
Compliance is checked by inspection and manual test, if required.
11 Size and colour of protective earthing and neutral conductors
Not applicable.
12 Provisions for earthing
Not applicable.
13 Terminals
Clause 13 of IEC 62196-1:2022 applies, except as follows:
---------------------- Page: 12 ----------------------
IEC 62196-6:2022 © IEC 2022 – 11 –
Replacement of Table 1:
Table 1 – Size for conductors
Current rating Internal connection
Flexible cables for vehicle connectors
Current
Solid or stranded cables for vehicle inlets
2 b
mm AWG/MCM
16 to 20 1,0 to 2,5 16 to 14
50 6 to 10 10 to 8
70 10 to 16 8 to 6
100 16 to 25 6 to 4
Classification of conductors: according to IEC 60228.
The nominal cross-sectional areas of conductors are given in square millimeters
2 2
(mm ). AWG/MCM values are considered as equivalent to mm for the purpose of this
document.
Reference IEC 60999-1:1999 (Annex A), IEC 60999-2:2003 (Annex C).
AWG: American Wire Gauge is a system of identifying wires in which the diameters
are found in geometric progression between size 36 and size 0000.
MCM: Mille Circular Mils denotes circle surface unit. 1 MCM = 0,5 067 mm .
14 Interlocks
Clause 14 of IEC 62196-1:2022 applies, except as follows:
Replacement:

14.1.6 The vehicle inlet is fixed to the support of an apparatus as shown in Figure 14 a) so

that the axis of separation is horizontal. With the latching devices holding the vehicle connector

into the vehicle inlet in the engaged position, an axial pull is applied to the cable attached at an

appropriate vehicle connector inserted in the vehicle inlet with interlock.
The contacts are wiped free from grease before test.

The test sample is inserted into and withdrawn from the vehicle inlet ten times. It is then again

inserted with a mass being attached to it by means of a suitable clamp. The total mass of the

vehicle connector, the clamp, the carrier, the principal and the supplementary weight shall exert

a pull force of 750 N. The supplementary weight shall be such that it exerts a force equal to

one-tenth of the withdrawal force. The retaining means, if any, shall be opened.

The principal weight is hung without jolting on the test vehicle connector, and the supplementary

weight is allowed to fall from a height of 5 cm onto the principal weight.
After this test, the total weight shall be maintained for 60 s.

The test of 14.1.6 is repeated three times, rotating the vehicle inlet of 90° on the vertical plane

each time (see Figure 14b))

During the tests of 14.1.6, the vehicle connector shall not come out of the vehicle inlet and the

latching devices holding the vehicle connector in the vehicle inlet shall remain in locked position.

During the test the electrical continuity shall be maintained, and the cable shall not be damaged.

---------------------- Page: 13 ----------------------
– 12 – IEC 62196-6:2022 © IEC 2022

After the test, the vehicle connector with interlock shall show no damage or deformation which

may impair the function of the product. The cable shall not have been displaced by more than

the values indicated in Table 11. For rewirable accessories, the ends of the conductors shall

not have moved noticeably in the terminals; for non-rewirable accessories, there shall be no

break in the electrical connections.

For the measurement of the longitudinal displacement, a mark is made on the cable at a

distance of approximately 2 cm from the end of the sample or the cable anchorage before

starting the tests. If, for non-rewirable accessories, there is no definite end to the sample, an

additional mark is made on the body of the sample.

After the tests, the displacement of the mark on the cable in relation to the sample or the cable

anchorage is measured.
Compliance is checked by inspection and test.
14.4 Pilot contacts and auxiliary circuits
Replacement:

Pilot contacts and auxiliary circuits used for interlocks shall make after the DC+ and DC− are

made.

Pilot contacts and auxiliary circuits used for interlocks shall break before the DC+ and DC− are

broken.
Compliance is checked by inspection and by the test of 14.1.5.
Addition:
14.601 Latching function
The vehicle connector shall be provided with a latching device.
An example of latching device is given in the Standard Sheet 6-d.

The interlock function shall be performed by the proper functioning of the latching device.

A means shall be provided to indicate that the interlock is properly engaged.

Compliance is checked by inspection and manual test in accordance with 14.1.5 and 14.1.6.

15 Resistance to ageing of rubber and thermoplastic material
Clause 15 of IEC 62196-1:2022 applies.
16 General construction
Clause 16 of IEC 62196-1:2022 applies, except as follows:
---------------------- Page: 14 ------------
...

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