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BS EN IEC 62196-1:2022

BS EN IEC 62196-1:2022

$215.11

Plugs, socket-outlets, vehicle connectors and vehicle inlets. Conductive charging of electric vehicles – General requirements

Published By Publication Date Number of Pages
BSI 2022 106
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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.

PDF Catalog

PDF Pages PDF Title
2 undefined
8 Annex ZA (normative)Normative references to international publicationswith their corresponding European publications
11 English
CONTENTS
15 FOREWORD
17 INTRODUCTION
18 1 Scope
2 Normative references
20 3 Terms and definitions
21 Figures
Figure 1 – Diagram showing the use of the accessories
25 Figure 2 – Lug terminals
Figure 3 – Mantle terminals
26 Figure 4 – Pillar terminals
27 Figure 5 – Saddle terminals
28 Figure 6 – Screw-type terminals
29 Figure 7 – Stud terminals
30 4 General
4.1 General requirements
4.2 Components
4.2.1 Ratings
4.2.2 Mechanical assembly
4.2.3 Current-carrying parts of incorporated components
4.2.4 Electrical connections
31 4.3 General notes on tests
32 5 Ratings
5.1 Preferred rated operating voltage ranges
5.2 Preferred rated currents
5.2.1 General
33 5.2.2 Rated current for signal or control purposes
5.2.3 Accessories not suitable for making and breaking an electrical circuit under load
5.2.4 Accessories suitable for, or not suitable for, making and breaking an electrical circuit under load
6 Connection between the power supply and the electric vehicle
6.1 Interfaces
6.2 Basic interface
6.3 DC interface
6.4 Combined interface
34 7 Classification of accessories
7.1 According to purpose
7.2 According to the method of connecting the conductors
7.3 According to serviceability
7.4 According to electrical operation
7.5 According to interface
7.6 According to locking facilities
7.7 According to interlock facilities
7.8 According to the presence of shutter(s)
8 Marking
37 9 Dimensions
Figure 8 – Test piston
38 10 Protection against electric shock
10.1 General
10.2 Accessories with shutters
40 Figure 9 – Gauge “A” for checking shutters
41 10.3 Contact sequencing and order of contact insertion and withdrawal
Figure 10 – Gauge “B” for checking shutters
42 10.4 Misassembly
11 Size and colour of protective earthing and neutral conductors
43 12 Provisions for earthing
Tables
Table 1 – Size for conductors
44 Table 2 – Short-time test currents
45 13 Terminals
13.1 Common requirements
47 13.2 Screw type terminals
48 Figure 11 – Gauges for testing insertability of round unprepared conductor shaving the maximum specified cross-section
49 13.3 Mechanical tests on terminals
50 Figure 12 – Equipment test arrangement
51 Table 3 – Values for flexing under mechanical load test
52 14 Interlocks
14.1 Accessories with interlock
Table 4 – Value for terminal pull test
55 Figure 13 – Apparatus for checking the withdrawal force
56 Figure 14 – Verification of the latching device
Table 5 – Withdrawal force with respect to ratings
57 14.2 Accessories with integral switching device
14.3 Control circuit devices and switching elements
14.4 Pilot contacts and auxiliary circuits
15 Resistance to ageing of rubber and thermoplastic material
58 16 General construction
59 Table 6 – Cable length used to determine pull force on retaining means
62 17 Construction of EV socket-outlets – General
18 Construction of EV plugs and vehicle connectors
63 19 Construction of vehicle inlets
20 Degrees of protection
65 21 Insulation resistance and dielectric strength
66 22 Breaking capacity
Table 7 – Test voltage for dielectric strength test
68 Figure 15 – Circuit diagrams for breaking capacity and normal operation tests
69 23 Normal operation
23.1 Mechanical, electrical, and thermal stresses and contaminants
23.2 Load endurance test
Table 8 – Breaking capacity
70 23.3 No-load endurance test
Table 9 – Normal operation
71 23.4 Lid springs
24 Temperature rise
72 Table 10 – Test current and nominal cross-sectional areas of copper conductors for temperature rise test
73 25 Flexible cables and their connection
25.1 Strain relief
25.2 Requirements for EV plugs and vehicle connectors
25.2.1 Non-rewirable EV plugs and vehicle connectors
25.2.2 Rewirable EV plugs and vehicle connectors
Figure 16 – Points of measurement
74 25.3 EV plugs and vehicle connectors provided with a flexible cable
75 Figure 17 – Apparatus for testing the cable anchorage
76 26 Mechanical strength
26.1 General
Table 11 – Pull force and torque test values for cable anchorage
Table 12 – Summary of mechanical tests
77 26.2 Ball impact
Figure 18 – Ball impact test
78 26.3 Drop test
Table 13 – Impact energy for ball impact test
79 26.4 Flexing test
Figure 19 – Arrangement for mechanical strength testfor EV plugs and vehicle connectors
80 Table 14 – Mechanical load flexing test
81 26.5 Cable gland test
Figure 20 – Apparatus for flexing test
82 26.6 Shutters
26.7 Insulated end caps
26.7.1 General
Table 15 – Torque test values for glands
83 26.7.2 Insulated end caps – Change of temperature test
26.7.3 Insulated end caps – Pull test
27 Screws, current-carrying parts and connections
Table 16 – Pulling force on insulated end caps
84 Table 17 – Tightening torque for verificationof mechanical strength of screw-type terminals
86 28 Creepage distances, clearances and distances through sealing compound
87 29 Resistance to heat and to fire
88 30 Corrosion and resistance to rusting
89 31 Conditional short-circuit current
31.1 General
31.2 Ratings and test conditions
90 31.3 Test circuit
91 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
92 Figure 22 – Diagram of the test circuit for the verification of short-circuit current withstand of three-pole equipment
93 31.4 Calibration
31.5 Test procedure
Figure 23 – Diagram of the test circuit for the verification ofshort-circuit current withstand of four-pole equipment
94 31.6 Behaviour of the equipment under test
31.7 Acceptance conditions
32 Electromagnetic compatibility
32.1 Immunity
32.2 Emission
33 Vehicle drive over
95 34 Thermal cycling
34.1 General
34.2 Initial temperature rise test
34.3 Thermal cycling test
34.4 Final temperature rise test
96 35 Humidity exposure
35.1 General
35.2 Initial temperature rise test
35.3 Humidity test
35.4 Final temperature rise test
36 Misalignment
36.1 General
97 36.2 Samples
36.3 Misalignment test
98 Figure 24 – Overview of the mechanical load test
Figure 25 – Application of external mechanical load (mounted according to Figure 24)
99 37 Contact endurance test
37.1 Equipment
Figure 26 – Temperature rise criteria under external mechanical load
Figure 27 – Forced-air circulating oven
100 37.2 Test sequence
101 37.3 Compliance
Figure 28 – Thermal cycling
102 Figure 29 – Pass/fail based on temperature rise criteria
103 Bibliography

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BS EN IEC 62196-1:2022
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