IEC 62196-1:2022
(Main)Plugs, socket-outlets, vehicle connectors and vehicle inlets - Conductive charging of electric vehicles - Part 1: General requirements
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
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Standards Content (Sample)
IEC 62196-1 ®
Edition 4.0 2022-05
COMMENTED VERSION
INTERNATIONAL
STANDARD
colour
inside
Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles –
Part 1: General requirements
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IEC 62196-1 ®
Edition 4.0 2022-05
COMMENTED VERSION
INTERNATIONAL
STANDARD
colour
inside
Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles –
Part 1: General requirements
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 29.120.30; 43.120 ISBN 978-2-8322-5217-8
– 2 – IEC 62196-1:2022 CMV © IEC 2022
CONTENTS
FOREWORD .7
INTRODUCTION . 10
1 Scope . 11
2 Normative references . 11
3 Terms and definitions . 13
4 General . 25
4.1 General requirements . 25
4.2 Components . 26
4.2.1 Ratings . 26
4.2.2 Mechanical assembly. 26
4.2.3 Current-carrying parts of incorporated components . 26
4.2.4 Electrical connections . 26
4.3 General notes on tests . 27
5 Ratings . 27
5.1 Preferred rated operating voltage ranges . 27
5.2 Preferred rated currents . 28
5.2.1 General . 28
5.2.2 Rated current for signal or control purposes . 28
5.2.3 Accessories not suitable for making and breaking an electrical circuit
under load . 28
5.2.4 Accessories suitable for, or not suitable for, making and breaking an
electrical circuit under load . 29
6 Connection between the power supply and the electric vehicle . 29
6.1 General .
6.2 Types of vehicle inlets .
6.3 Types of vehicle connectors .
6.4 Universal interface .
6.5 Basic interface.
6.6 D.C. configurations .
6.7 Combined interface.
6.8 Contact sequencing .
6.1 Interfaces . 34
6.2 Basic interface. 35
6.3 DC interface . 35
6.4 Combined interface. 35
7 Classification of accessories . 35
7.1 According to purpose . 35
7.2 According to the method of connecting the conductors . 35
7.3 According to serviceability . 35
7.4 According to electrical operation . 35
7.5 According to interface . 35
7.6 According to use with cable management systems .
7.7 According to the locking and interlock functions: .
7.6 According to locking facilities . 35
7.7 According to interlock facilities . 36
7.8 According to the presence of shutter(s) . 36
8 Marking . 36
9 Dimensions . 38
10 Protection against electric shock . 39
10.1 General . 39
10.2 Accessories with shutters. 41
10.3 Contact sequencing and order of contact insertion and withdrawal . 46
10.4 Misassembly . 47
11 Size and colour of protective earthing and neutral conductors . 47
12 Provisions for protective earthing . 48
13 Terminals. 51
13.1 Common requirements . 51
13.2 Screw type terminals . 53
13.3 Mechanical tests on terminals . 55
14 Interlocks . 59
14.1 Accessories with interlock . 59
14.2 Accessories with integral switching device . 66
14.3 Control circuit devices and switching elements . 66
14.4 Pilot contacts and auxiliary circuits . 67
15 Resistance to ageing of rubber and thermoplastic material . 67
16 General construction . 67
17 Construction of EV socket-outlets – General . 71
17.1 General .
17.2 Contact tubes .
18 Construction of EV plugs and vehicle connectors . 73
19 Construction of vehicle inlets . 74
20 Degrees of protection . 75
21 Insulation resistance and dielectric strength . 76
22 Breaking capacity. 77
23 Normal operation . 81
23.1 Mechanical, electrical, and thermal stresses and contaminants . 81
23.2 Load endurance test . 82
23.3 No-load endurance test . 83
23.4 Lid springs . 84
24 Temperature rise. 84
25 Flexible cables and their connection . 86
25.1 Strain relief . 86
25.2 Requirements for EV plugs and vehicle connectors . 86
25.2.1 Non-rewirable EV plugs and vehicle connectors. 86
25.2.2 Rewirable EV plugs and vehicle connectors. 86
25.3 EV plugs and vehicle connectors provided with a flexible cable . 87
26 Mechanical strength . 90
26.1 General . 90
26.2 Degree of protection Ball impact . 91
26.3 Rewirable plugs and vehicle connectors Drop test . 94
26.4 Non-rewirable accessories Flexing test . 95
26.5 Cable gland test . 97
– 4 – IEC 62196-1:2022 CMV © IEC 2022
26.6 Shutters . 98
26.7 Insulated end caps . 98
26.7.1 General . 98
26.7.2 Insulated end caps – Change of temperature test . 99
26.7.3 Insulated end caps – Pull test . 99
27 Screws, current-carrying parts and connections . 99
28 Creepage distances, clearances and distances through sealing compound . 102
29 Resistance to heat, and to fire and to tracking . 103
30 Corrosion and resistance to rusting. 105
31 Conditional short-circuit current withstand test . 105
31.1 General . 105
31.2 Ratings and test conditions . 105
31.3 Test circuit . 106
31.4 Calibration . 112
31.5 Test procedure . 112
31.6 Behaviour of the equipment under test . 113
31.7 Acceptance conditions . 113
32 Electromagnetic compatibility . 113
32.1 Immunity . 113
32.2 Emission . 113
33 Vehicle drive over . 113
34 Thermal cycling . 114
34.1 General . 114
34.2 Initial temperature rise test . 114
34.3 Thermal cycling test . 114
34.4 Final temperature rise test . 114
35 Humidity exposure . 115
35.1 General . 115
35.2 Initial temperature rise test . 115
35.3 Humidity test . 115
35.4 Final temperature rise test . 115
36 Misalignment . 115
36.1 General . 115
36.2 Samples . 116
36.3 Misalignment test . 116
37 Contact endurance test . 118
37.1 Equipment . 118
37.2 Test sequence . 119
37.3 Compliance . 120
Bibliography . 122
List of comments . 124
Figure 1 – Diagram showing the use of the accessories. 15
Figure 2 – Lug terminals . 20
Figure 3 – Standard test finger .
Figure 3 – Mantle terminals . 20
Figure 4 – Pillar terminals . 21
Figure 5 – Saddle terminals . 23
Figure 6 – Screw-type terminals . 23
Figure 7 – Stud terminals . 24
Figure 8 – Test piston . 38
Figure 9 – Gauge "A" for checking shutters . 44
Figure 10 – Gauge "B" for checking shutters . 46
Figure 11 – Gauges for testing insertability of round unprepared conductors having the
maximum specified cross-section. 54
Figure 12 – Equipment test arrangement. 56
Figure 13 – Apparatus for checking the withdrawal force . 63
Figure 14 – Verification of the latching device . 65
Figure 15 – Circuit diagrams for breaking capacity and normal operation tests . 80
Figure 16 – Points of measurement . 85
Figure 17 – Apparatus for testing the cable anchorage . 89
Figure 18 – Ball impact test . 92
Figure 19 – Arrangement for mechanical strength test for EV plugs and vehicle
connectors . 94
Figure 20 – Apparatus for flexing test . 97
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. 108
Figure 22 – Diagram of the test circuit for the verification of short-circuit current
withstand of three-pole equipment . 110
Figure 23 – Diagram of the test circuit for the verification of short-circuit current
withstand of four-pole equipment . 112
Figure 24 – Overview of the mechanical load test . 117
Figure 25 – Application of external mechanical load (mounted according to Figure 24) . 117
Figure 26 – Temperature rise criteria under external mechanical load . 118
Figure 27 – Forced-air circulating oven . 118
Figure 28 – Thermal cycling . 120
Figure 29 – Pass/fail based on temperature rise criteria . 121
Table 1 – Compatibility of mating accessories at vehicle .
Table 2 – Overview of the universal vehicle interface .
Table 3 – Overview of the basic vehicle interface .
Table 4 – Overview of the d.c. vehicle interface .
Table 5 – Overview of the combined a.c./d.c. vehicle interface .
Table 1 – Size for conductors . 48
Table 2 – Short-time test currents . 50
Table 3 – Values for flexing under mechanical load test . 58
Table 4 – Value for terminal pull test . 59
Table 5 – Withdrawal force with respect to ratings . 66
Table 6 – Cable length used to determine pull force on retaining means . 69
Table 7 – Test voltage for dielectric strength test . 77
Table 8 – Breaking capacity . 81
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Table 9 – Normal operation . 83
Table 10 – Test current and nominal cross-sectional areas of copper conductors for
temperature rise test . 85
Table 11 – Pull force and torque test values for cable anchorage . 90
Table 12 – Gauges to measure withdrawal force .
Table 13 – Diameter of pins of the test plug .
Table 14 – Maximum withdrawal force .
Table 12 – Summary of mechanical tests . 90
Table 13 – Impact energy for ball impact test . 93
Table 14 – Mechanical load flexing test. 95
Table 15 – Torque test values for glands . 98
Table 16 – Pulling force on insulated end caps. 99
Table 17 – Tightening torque for verification of mechanical strength of screw-type
terminals . 100
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
PLUGS, SOCKET-OUTLETS, VEHICLE CONNECTORS AND VEHICLE
INLETS – CONDUCTIVE CHARGING OF ELECTRIC VEHICLES –
Part 1: General requirements
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
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6) All users should ensure that they have the latest edition of this publication.
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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.
This commented version (CMV) of the official standard IEC 62196-1:2022 edition 4.0
allows the user to identify the changes made to the previous IEC 62196-1:2014
edition 3.0. Futhermore, comments from IEC SC 23H experts are provided to explain the
reasons of the most relevant changes.
A vertical bar appears in the margin wherever a change has been made. Additions are in
green text, deletions are in strikethrough red text. Experts' comments are identified by a
blue-background number. Mouse over a number to display a pop-up note with the
comment.
This publication contains the CMV and the official standard. The full list of comments is
available at the end of the CMV.
– 8 – IEC 62196-1:2022 CMV © IEC 2022
IEC 62196-1 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 an International Standard.
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:
a) deletion of references to universal AC and DC interfaces;
b) additional requirements for contact materials and plating;
c) changes to the temperature rise test to include additional points of measurement;
d) additional tests for accessories to address thermal stresses and stability, mechanical wear
and abuse, and exposure to contaminants;
e) relocation of information and requirements for DC charging to IEC 62196-3.
The text of this International Standard is based on the following documents:
Draft Report on voting
23H/499/FDIS 23H/503/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.
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 parts in the IEC 62196 series, published under the general title Plugs, socket-outlets,
vehicle connectors and vehicle inlets – Conductive charging of electric vehicles, can be found
on the IEC website.
Subsequent parts of IEC 62196 deal with the requirements of particular types of accessories.
The clauses of those particular requirements supplement or modify the corresponding clauses
in this document.
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.
IMPORTANT – The "colour inside" logo on the cover page of this document indicates that it
contains colours which are considered to be useful for the correct understanding of its
contents. Users should therefore print this document using a colour printer.
– 10 – IEC 62196-1:2022 CMV © IEC 2022
INTRODUCTION
IEC 61851-1 (all parts) specifies requirements for electric vehicle (EV) conductive charging
equipment systems.
IEC 62196 (all parts) specifies the requirements for plugs, socket-outlets, vehicle connectors,
vehicle inlets and cable assemblies as described in the IEC 61851-1 series.
Some charging can be achieved by direct connection from an electric vehicle to common mains
standard socket-outlets connected to a supply network (mains or electrical grid).
Some modes of charging require a dedicated supply and charging equipment incorporating
control and communication circuits.
IEC 62196 (all parts) covers the mechanical, electrical and performance requirements for
dedicated plugs, socket-outlets, vehicle connectors and vehicle inlets for interfacing between
such dedicated charging the connection between the EV supply equipment and the electric
vehicle.
The IEC 62196 series consists of the following 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 3-1: Vehicle connector, vehicle inlet and cable assembly intended to be used with a
thermal management system for DC charging.
– Part 4 : Dimensional compatibility and interchangeability requirements for DC pin and
contact-tube accessories for Class II or Class III applications.
– Part 6: Dimensional compatibility and interchangeability requirements for DC pin and
contact-tube couplers for applications using a system of protective electrical separation.
____________
To be published
Pending publication.
PLUGS, SOCKET-OUTLETS, VEHICLE CONNECTORS AND VEHICLE
INLETS – CONDUCTIVE CHARGING OF ELECTRIC VEHICLES –
Part 1: General requirements
1 Scope
This part of IEC 62196 is applicable to EV plugs, EV 1 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 400 800 A 2.
These accessories and cable assemblies are intended to be installed by instructed persons
(IEV 195-04-02) or skilled persons (IEV 195-04-01) only.
These accessories and cable assemblies are intended to be used for circuits specified in
IEC 61851-1 (all parts), which operate at different voltages and frequencies, and which may
can include extra-low voltage and communication signals.
These accessories and cable assemblies are intended to be used at an ambient temperature
between −30 °C and +50 40 °C 3.
NOTE 1 In some countries, other requirements may can apply.
NOTE 2 In the following country, −35 °C applies: SE.
NOTE 3 The manufacturer can enlarge the temperature range on the condition that the specified range information
is provided.
These accessories are intended to be connected only to cables with copper or copper-alloy
conductors.
The accessories covered by this document are for use in certain modes of charging electric
vehicles intended for use in electric vehicle supply equipment in accordance with IEC 61851
(all parts). These modes are defined in IEC 61851-1. These definitions and a description of the
types of connection (cases A, B and C), are described in IEC 61851-1:2010, 6.2 and 6.3.1.
This document does not apply to those standardised accessories used in charging systems
where the use of such accessories constructed to the requirements of other standards is
permitted (e.g. in mode 1 and mode 2) standard plug and socket-outlets used for mode 1 and
mode 2 according to IEC 61851-1:2017, 6.2. Such standardized accessories may be used for
those situations (mode and case) identified in IEC 61851-1.
NOTE 4 In the following countries, mode 1 will not be is not allowed: UK, US, CA, SG.
This part of IEC 62196 may be used as a guide for accessories with a lesser number of contacts
and lower ratings for use with light duty vehicles.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies.
– 12 – IEC 62196-1:2022 CMV © IEC 2022
For undated references, the latest edition of the referenced document (including any
amendments) applies.
IEC 60068-2-14, Environmental testing – Part 2-14: Tests – Test N: Change of temperature
IEC 60068-2-30, Environmental testing – Part 2-30: Tests – Test Db: Damp heat, cyclic
(12 h + 12 h cycle)
IEC 60112, Method for the determination of the proof and the comparative tracking indices of
solid insulating materials
IEC 60227 (all parts), Polyvinyl chloride insulated cables of rated voltages up to and including
450/750 V
IEC 60228:2004, Conductors of insulated cables
IEC 60245-4, Rubber insulated cables – Rated voltages up to and including 450/750 V – Part 4:
Cords and flexible cables
IEC 60269-1, Low-voltage fuses – Part 1: General requirements
IEC 60269-2, Low-voltage fuses – Part 2: Supplementary requirements for fuses for use by
authorized persons (fuses mainly for industrial application) – Examples of standardized systems
of fuses A to K
IEC 60309-4:20062021, Plugs, fixed or portable socket-outlets and couplers appliance inlets
for industrial purposes – Part 4: Switched socket-outlets and connectors with or without interlock
IEC 60449, Voltage bands for electrical installations of buildings
IEC 60529:1989, Degrees of protection provided by enclosures (IP code)
IEC 60529:1989/AMD1:1999
IEC 60529:1989/AMD2:2013
IEC 60664-1:20072020, Insulation coordination for equipment within low-voltage supply
systems – Part 1: Principles, requirements and tests
IEC 60664-3, Insulation coordination for equipment within low-voltage systems – Part 3: Use of
coating, potting or moulding for protection against pollution
IEC 60695-2-11, Fire hazard testing – Part 2-11: Glowing/hot-wire based test methods –
Glow-wire flammability test method for end-products (GWEPT)
IEC 60695-10-2, Fire hazard testing – Part 10-2: Abnormal heat – Ball pressure test method
IEC 60947-3:2020, Low-voltage switchgear and controlgear – Part 3: Switches, disconnectors,
switch-disconnectors and fuse-combination units
IEC 60947-5-1, Low-voltage switchgear and controlgear – Part 5-1: Control circuit devices and
switching elements – Electromechanical control circuit devices
IEC 61032:1997, Protection of persons and equipment by enclosures – Probes for verification
IEC 61058-1:2016, Switches for appliances – Part 1: General requirements
IEC 61851-1:20102017, Electric vehicle conductive charging system – Part 1: General
requirements
IEC 61851-23:2014— , Electric vehicle conductive charging system – Part 23: DC electric
vehicle charging station supply equipment
IEC 62196-2:2022, Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles – Part 2: Dimensional compatibility requirements for AC pin and
contact-tube accessories
IEC 62196-3:2022, Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles – Part 3: Dimensional compatibility requirements for DC and
AC/DC pin and contact-tube vehicle couplers
ISO 1456, Metallic and other inorganic coatings – Electrodeposited coatings of nickel, nickel
plus chromium, copper plus nickel and of copper plus nickel plus chromium
ISO 2081, Metallic and other inorganic coatings – Electroplated coatings of zinc with
supplementary treatments on iron or steel
ISO 2093, Electroplated coatings of tin – Specification and test methods
ISO 4521:2008, Metallic and other inorganic coatings – Electrodeposited silver and silver alloy
coatings for engineering purposes – Specification and test methods
3 Terms and definitions
For the purposes of this document, the terms and definitions given in IEC 61851-1:2010 as well
as the following terms and definitions apply.
ISO and IEC maintain terminological databases for use in standardization at the following
addresses:
• IEC Electropedia: available at http://www.electropedia.org/
• ISO Online browsing platform: available at http://www.iso.org/obp
NOTE 1 Where the terms "voltage" and "current" are used, they imply root mean square (RMS) values, unless
otherwise specified.
NOTE 2 The application of accessories is shown in Figure 1.
____________
on under preparation. Stage at the time of publication: IEC PRVC 61851-23:2022.
Second editi
– 14 – IEC 62196-1:2022 CMV © IEC 2022
Socket-outlet
Plug
Supply
(Mains or EVSE)
Plug and
socket-outlet
In-cable control and protective device (IC-CPD)
Flexible cable
Vehicle
Vehicle coupler
Vehicle connector
Vehicle inlet
IEC 1877/14
Key
1 In-cable control and protective device (IC-CPD)
A Standard socket-outlet or EV socket-outlet
B Standard plug or EV plug
C Vehicle connector
D Vehicle inlet
Figure 1 – Diagram showing the use of the accessories
3.1
auxiliary power
electrical energy provision from an external source used for purposes other than charging of
the electric vehicle propulsion battery
Note 1 to entry: In French, the resulting assembly when a plug is inserted into a socket-outlet is called "prise de
courant".
3.2
cable assembly
piece of equipment that is used to establish the connection between the electric vehicle and the
electric vehicle supply equipment
assembly consisting of flexible cable or cord fitted with a standard plug or EV plug and/or a
vehicle connector, that is used to establish the connection between the EV and the supply
network or an EV charging station
Note 1 to entry: A cable assembly may be either fixed to and included in one of these devices, or detachable. It
includes the flexible cable, the vehicle connector and/or plug that are required for proper connection. A cable
assembly can be detachable or be a part of the EV or of the EV charging station.
Note 2 to entry: A cable assembly may can include one or more cab
...
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
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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
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 29.120.30; 43.120 ISBN 978-2-8322-1101-1
– 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
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
– 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
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
– 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
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
misinterpretation by any end user.
4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications
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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
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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
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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 62196-1 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 an International Standard.
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:
a) deletion of references to universal AC and DC interfaces;
b) additional requirements for contact materials and plating;
c) changes to the temperature rise test to include additional points of measurement;
d) additional tests for accessories to address thermal stresses and stability, mechanical wear
and abuse, and exposure to contaminants;
e) relocation of information and requirements for DC charging to IEC 62196-3.
The text of this International Standard is based on the following documents:
Draft Report on voting
23H/499/FDIS 23H/503/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.
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 parts in the IEC 62196 series, published under the general title Plugs, socket-outlets,
vehicle connectors and vehicle inlets – Conductive charging of electric vehicles, can be found
on the IEC website.
Subsequent parts of IEC 62196 deal with the requirements of particular types of accessories.
The clauses of those particular requirements supplement or modify the corresponding clauses
in this document.
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.
IMPORTANT – The "colour inside" logo on the cover page of this document indicates that it
contains colours which are considered to be useful for the correct understanding of its
contents. Users should therefore print this document using a colour printer.
– 8 – IEC 62196-1:2022 © IEC 2022
INTRODUCTION
IEC 61851 (all parts) specifies requirements for electric vehicle (EV) conductive charging
systems.
IEC 62196 (all parts) specifies the requirements for plugs, socket-outlets, vehicle connectors,
vehicle inlets and cable assemblies as described in the IEC 61851 series.
Some charging can be achieved by direct connection from an electric vehicle to standard
socket-outlets connected to a supply network (mains or electrical grid).
Some modes of charging require a dedicated supply and charging equipment incorporating
control and communication circuits.
IEC 62196 (all parts) covers the mechanical, electrical and performance requirements for plugs,
socket-outlets, vehicle connectors and vehicle inlets for the connection between the EV supply
equipment and the electric vehicle.
The IEC 62196 series consists of the following 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 3-1: Vehicle connector, vehicle inlet and cable assembly intended to be used with a
thermal management system for DC charging.
– Part 4 : Dimensional compatibility and interchangeability requirements for DC pin and
contact-tube accessories for Class II or Class III applications.
– Part 6: Dimensional compatibility and interchangeability requirements for DC pin and
contact-tube couplers for applications using a system of protective electrical separation.
____________
Pending publication.
PLUGS, SOCKET-OUTLETS, VEHICLE CONNECTORS AND VEHICLE
INLETS – CONDUCTIVE CHARGING OF ELECTRIC VEHICLES –
Part 1: General requirements
1 Scope
This part of IEC 62196 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.
These accessories and cable assemblies are intended to be installed by instructed persons
(IEV 195-04-02) or skilled persons (IEV 195-04-01) only.
These accessories and cable assemblies are intended to be used for circuits specified in
IEC 61851 (all parts), which operate at different voltages and frequencies, and which can
include extra-low voltage and communication signals.
These accessories and cable assemblies are intended to be used at an ambient temperature
between −30 °C and +40 °C.
NOTE 1 In some countries, other requirements can apply.
NOTE 2 In the following country, −35 °C applies: SE.
NOTE 3 The manufacturer can enlarge the temperature range on the condition that the specified range information
is provided.
These accessories are intended to be connected only to cables with copper or copper-alloy
conductors.
The accessories covered by this document are intended for use in electric vehicle supply
equipment in accordance with IEC 61851 (all parts).
This document does not apply to standard plug and socket-outlets used for mode 1 and mode 2
according to IEC 61851-1:2017, 6.2.
NOTE 4 In the following countries, mode 1 is not allowed: UK, US, CA, SG.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies.
For undated references, the latest edition of the referenced document (including any
amendments) applies.
IEC 60068-2-14, Environmental testing – Part 2-14: Tests – Test N: Change of temperature
IEC 60068-2-30, Environmental testing – Part 2-30: Tests – Test Db: Damp heat, cyclic
(12 h + 12 h cycle)
– 10 – IEC 62196-1:2022 © IEC 2022
IEC 60112, Method for the determination of the proof and the comparative tracking indices of
solid insulating materials
IEC 60227 (all parts), Polyvinyl chloride insulated cables of rated voltages up to and including
450/750 V
IEC 60228:2004, Conductors of insulated cables
IEC 60245-4, Rubber insulated cables – Rated voltages up to and including 450/750 V – Part 4:
Cords and flexible cables
IEC 60269-1, Low-voltage fuses – Part 1: General requirements
IEC 60269-2, Low-voltage fuses – Part 2: Supplementary requirements for fuses for use by
authorized persons (fuses mainly for industrial application) – Examples of standardized systems
of fuses A to K
IEC 60309-4:2021, Plugs, fixed or portable socket-outlets and appliance inlets for industrial
purposes – Part 4: Switched socket-outlets with or without interlock
IEC 60529:1989, Degrees of protection provided by enclosures (IP code)
IEC 60529:1989/AMD1:1999
IEC 60529:1989/AMD2:2013
IEC 60664-1:2020, Insulation coordination for equipment within low-voltage supply systems –
Part 1: Principles, requirements and tests
IEC 60664-3, Insulation coordination for equipment within low-voltage systems – Part 3: Use of
coating, potting or moulding for protection against pollution
IEC 60695-2-11, Fire hazard testing – Part 2-11: Glowing/hot-wire based test methods –
Glow-wire flammability test method for end-products (GWEPT)
IEC 60695-10-2, Fire hazard testing – Part 10-2: Abnormal heat – Ball pressure test method
IEC 60947-3:2020, Low-voltage switchgear and controlgear – Part 3: Switches, disconnectors,
switch-disconnectors and fuse-combination units
IEC 60947-5-1, Low-voltage switchgear and controlgear – Part 5-1: Control circuit devices and
switching elements – Electromechanical control circuit devices
IEC 61032:1997, Protection of persons and equipment by enclosures – Probes for verification
IEC 61058-1:2016, Switches for appliances – Part 1: General requirements
IEC 61851-1:2017, Electric vehicle conductive charging system – Part 1: General requirements
IEC 61851-23:— , Electric vehicle conductive charging system – Part 23: DC electric vehicle
supply equipment
____________
Second edition under preparation. Stage at the time of publication: IEC PRVC 61851-23:2022.
IEC 62196-2:2022, Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles – Part 2: Dimensional compatibility requirements for AC pin and
contact-tube accessories
IEC 62196-3:2022, Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive
charging of electric vehicles – Part 3: Dimensional compatibility requirements for DC and
AC/DC pin and contact-tube vehicle couplers
ISO 1456, Metallic and other inorganic coatings – Electrodeposited coatings of nickel, nickel
plus chromium, copper plus nickel and of copper plus nickel plus chromium
ISO 2081, Metallic and other inorganic coatings – Electroplated coatings of zinc with
supplementary treatments on iron or steel
ISO 2093, Electroplated coatings of tin – Specification and test methods
ISO 4521:2008, Metallic and other inorganic coatings – Electrodeposited silver and silver alloy
coatings for engineering purposes – Specification and test methods
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
ISO and IEC maintain terminological databases for use in standardization at the following
addresses:
• IEC Electropedia: available at http://www.electropedia.org/
• ISO Online browsing platform: available at http://www.iso.org/obp
NOTE 1 Where the terms "voltage" and "curren"t are used, they imply root mean square (RMS) values, unless
otherwise specified.
NOTE 2 The application of accessories is shown in Figure 1.
– 12 – IEC 62196-1:2022 © IEC 2022
Key
1 In-cable control and protective device (IC-CPD)
A Standard socket-outlet or EV socket-outlet
B Standard plug or EV plug
C Vehicle connector
D Vehicle inlet
Figure 1 – Diagram showing the use of the accessories
3.1
auxiliary power
electrical energy provision from an external source used for purposes other than charging of
the electric vehicle propulsion battery
Note 1 to entry: In French, the resulting assembly when a plug is inserted into a socket-outlet is called "prise de
courant".
3.2
cable assembly
assembly consisting of flexible cable or cord fitted with a standard plug or EV plug and/or a
vehicle connector, that is used to establish the connection between the EV and the supply
network or an EV charging station
Note 1 to entry: A cable assembly can be detachable or be a part of the EV or of the EV charging station.
Note 2 to entry: A cable assembly can include one or more cables, with or without a fixed jacket, which can be in a
flexible tube, conduit or wire way.
[SOURCE: IEC 61851-1:2017, 3.5.2, modified – "plug" has been replaced with "standard plug
or EV plug".]
3.3
cap
part separated or attached, which may be used to provide the degree of protection of an EV
plug or vehicle inlet, when it is not engaged with an EV socket-outlet or a vehicle connector
3.4
clamping unit
part of a terminal necessary for the clamping and the electrical connection of the conductor
3.5
compatibility
compatible
ability of accessories to join together and be functional
Note 1 to entry: Non-compatible accessories can physically join together, but not be functional.
3.6
conditional short-circuit current
prospective current that an accessory, protected by a specified short-circuit protective device,
can withstand satisfactorily for the total operating time of that device under specified conditions
of use and behaviour
[SOURCE: IEC 60050-441:1984, 441-17-20, modified – The concept of current-limiting device
has been broadened into a short-circuit protective device, the function of which is not only to
limit the current.]
3.7
conductive part
part that can carry electric current
[SOURCE: IEC 60050-195:2021, 195-01-06]
3.8
connection
single conductive path
3.9
cord extension set
assembly consisting of a flexible cable or cord fitted with an EV plug that is intended to mate
with a vehicle connector as covered by the IEC 62196 series
3.10
control circuit device
electrical device intended for the controlling, signalling, interlocking, etc. of switchgear and
controlgear
...
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