AS/NZS 62196.1:2023 Plugs, socket-outlets, vehicle connectors and vehicle inlets - Conductive charging of electric vehicles General requirements (IEC 62196-1:2022, MOD)
CONTENTS
FOREWORD
INTRODUCTION
1 Scope
2 Normative references
3 Terms and definitions
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
4.3 General notes on tests
5 Ratings
5.1 Preferred rated operating voltage ranges
5.2 Preferred rated currents
5.2.1 General
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
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
9 Dimensions
10 Protection against electric shock
10.1 General
10.2 Accessories with shutters
10.3 Contact sequencing and order of contact insertion and withdrawal
10.4 Misassembly
11 Size and colour of protective earthing and neutral conductors
12 Provisions for earthing
13 Terminals
13.1 Common requirements
13.2 Screw type terminals
13.3 Mechanical tests on terminals
14 Interlocks
14.1 Accessories with interlock
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
16 General construction
17 Construction of EV socket-outlets – General
18 Construction of EV plugs and vehicle connectors
19 Construction of vehicle inlets
20 Degrees of protection
21 Insulation resistance and dielectric strength
22 Breaking capacity
23 Normal operation
23.1 Mechanical, electrical, and thermal stresses and contaminants
23.2 Load endurance test
23.3 No-load endurance test
23.4 Lid springs
24 Temperature rise
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
25.3 EV plugs and vehicle connectors provided with a flexible cable
26 Mechanical strength
26.1 General
26.2 Ball impact
26.3 Drop test
26.4 Flexing test
26.5 Cable gland test
26.6 Shutters
26.7 Insulated end caps
26.7.1 General
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
28 Creepage distances, clearances and distances through sealing compound
29 Resistance to heat and to fire
30 Corrosion and resistance to rusting
31 Conditional short-circuit current
31.1 General
31.2 Ratings and test conditions
31.3 Test circuit
31.4 Calibration
31.5 Test procedure
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
34 Thermal cycling
34.1 General
34.2 Initial temperature rise test
34.3 Thermal cycling test
34.4 Final temperature rise test
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
36.2 Samples
36.3 Misalignment test
37 Contact endurance test
37.1 Equipment
37.2 Test sequence
37.3 Compliance
Bibliography
Figures
Figure 1 – Diagram showing the use of the accessories
Figure 2 – Lug terminals
Figure 3 – Mantle terminals
Figure 4 – Pillar terminals
Figure 5 – Saddle terminals
Figure 6 – Screw-type terminals
Figure 7 – Stud terminals
Figure 8 – Test piston
Figure 9 – Gauge "A" for checking shutters
Figure 10 – Gauge "B" for checking shutters
Figure 11 – Gauges for testing insertability of round unprepared conductor shaving the maximum specified cross-section
Figure 12 – Equipment test arrangement
Figure 13 – Apparatus for checking the withdrawal force
Figure 14 – Verification of the latching device
Figure 15 – Circuit diagrams for breaking capacity and normal operation tests
Figure 16 – Points of measurement
Figure 17 – Apparatus for testing the cable anchorage
Figure€18 – Ball impact test
Figure 19 – Arrangement for mechanical strength testfor EV plugs and vehicle connectors
Figure€20 – Apparatus for flexing test
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
Figure 22 – Diagram of the test circuit for the verification of short-circuit current withstand of three-pole equipment
Figure 23 – Diagram of the test circuit for the verification ofshort-circuit current withstand of four-pole equipment
Figure 24 – Overview of the mechanical load test
Figure 25 – Application of external mechanical load (mounted according to Figure 24)
Figure 26 – Temperature rise criteria under external mechanical load
Figure 27 – Forced-air circulating oven
Figure 28 – Thermal cycling
Figure 29 – Pass/fail based on temperature rise criteria
Tables
Table 1 – Size for conductors
Table 2 – Short-time test currents
Table 3 – Values for flexing under mechanical load test
Table 4 – Value for terminal pull test
Table 5 – Withdrawal force with respect to ratings
Table 6 – Cable length used to determine pull force on retaining means
Table 7 – Test voltage for dielectric strength test
Table 8 – Breaking capacity
Table€9 – Normal operation
Table 10 – Test current and nominal cross-sectional areas of copper conductors for temperature rise test
Table 11 – Pull force and torque test values for cable anchorage
Table 12 – Summary of mechanical tests
Table€13 – Impact energy for ball impact test
Table€14 – Mechanical load flexing test
Table 15 – Torque test values for glands
Table 16 – Pulling force on insulated end caps
Table 17 – Tightening torque for verificationof mechanical strength of screw-type terminals
