What is the IEC 62196 Plugs, socket-outlets, vehicle connectors and vehicle inlets ?

IEC 62196 Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive charging of electric vehicles is a series of international standards that define requirements and tests for plugs, socket-outlets, vehicle connectors and vehicle inlets for conductive charging of electric vehicles and is maintained by the technical subcommittee SC 23H "Plugs, Socket-outlets and Couplers for industrial and similar applications, and for Electric Vehicles" of the International Electrotechnical Commission (IEC).

Plugs, socket-outlets, vehicle connectors and vehicle inlets according to this series of standards are used in EV supply equipment according to IEC 61851 series or IEC 62752 and in electric vehicles according to ISO 17409 or ISO 18246.

Most plugs, socket-outlets, vehicle connectors and vehicle inlets according to this series of standards provide additional contacts that support specific functions that are relevant for charging of electric vehicles, e.g. power is not supplied unless a vehicle is connected and the vehicle is immobilized while still connected.

Several parts of this series of standards have been published as European standards (EN 62196 series) which in turn have been published as British standards (BS EN 62196 series). Similar requirements are contained in SAE J1772 which is widely applied in the US.

Parts
The following parts of IEC 62196 series have been published:

    *IEC 62196-1 Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive charging of electric vehicles – Part 1: General requirements[1]
    *IEC 62196-2 Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive charging of electric vehicles – Part 2: Dimensional compatibility and interchangeability requirements for A.C. pin and contact-tube accessories[2]
   *IEC 62196-3 Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive charging of electric vehicles – Part 3: Dimensional compatibility and interchangeability requirements for D.C. and A.C./D.C. pin and contact-tube vehicle couplers[3]
    *IEC TS 62196-3-1 Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive charging of electric vehicles – Part 3-1: Vehicle connector, vehicle inlet and cable assembly intended to be used with a thermal management system for DC charging[4]

Additional parts of IEC 62196 are under preparation (as of September 2021):[5]

    *IEC TS 62196-4 Plugs, socket-outlets, vehicle connectors and vehicles inlet – Conductive charging of electric vehicles – Part 4: Dimensional compatibility and interchangeability requirements for DC pin and contact-tube accessories for class II or class III applications
    *IEC 62196-6 Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive charging of electric vehicles – Part 6: Dimensional compatibility and interchangeability requirements for DC pin and contact-tube vehicle couplers for DC EV supply equipment where protection relies on electrical separation
    *IEC TS 62196-7 Plugs, socket-outlets, vehicle connectors and vehicle inlets - Conductive charging of electric vehicles - Part 7: Vehicle adapter

IEC 62196-1
Contents

IEC 62196-1 provides a general description of the interface between an electric vehicle and a charging station as well as general mechanical and electrical requirements and tests for plugs, socket-outlets, vehicle connectors and vehicle inlets that are intended to be used for EV charging. It does not describe specific designs, which can be found in the other parts of the standard.
History

The first edition, IEC 62196-1:2003,[6] was published in 2003. This edition was applicable to plugs, socket-outlets, connectors, inlets and cable assemblies for AC and DC charging of electric vehicles with rated voltages and rated currents as follows:

    AC: up to 690 V, up to 250 A
    DC: up to 600 V, up to 400 A.

Typical connectors and inlets that were built according to this edition of the standard used spring-loaded butt contacts and were made by Avcon and Maréchal Electric.

The second edition, IEC 62196-1:2011,[7] was published in 2011. One significant change was the increase of the maximum voltage of connectors, inlets and cable assemblies for DC charging to 1500 V. The development of this edition was coordinated with the first edition of IEC 62196-2, which describes several configurations of pin-and-sleeve contacts for AC charging.

The third edition, IEC 62196-1:2014, was published in 2014. One significant addition was the general description of a "combined interface" as used by the Combined Charging System. The development of this edition was coordinated with the first edition of IEC 62196-3, which describes connectors and inlets for DC charging.

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IEC 62196-2
Contents

IEC 62196-2 extends IEC 62196-1 and describes specific designs of plugs, socket-outlets, vehicle connectors and vehicle inlets that are intended to be used for AC charging of electric vehicles in the modes 1, 2 and 3 as described by IEC 61851-1. The specific designs are grouped into three configurations.

The designs are described with sufficient detail to allow compatibility between products of different manufacturers.

Configurations



Notes

    In India, "low-power" vehicles with traction battery voltages less than 100 V DC use the Bharat EV Charger standards. For AC charging (230 V, 15 A / 10 kW maximum), the Bharat EV Charger AC-001 standard endorses the IEC 60309 three-pin connector. For DC charging (48–72+ V, 200 A / 15 kW maximum), the corresponding Bharat EV Charger DC-001 standard endorses the same connector used in China (GB/T 20234.3).[8] For high-power vehicles, India has largely adopted global standards: IEC 62196 Type 2 connector for AC charging (≥22 kW) and CHAdeMO and CCS Combo 2 for DC charging (≥50 kW).[9]










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IEC 62196-3
Contents

IEC 62196-3 extends IEC 62196-1 and describes specific designs of vehicle connectors and vehicle inlets that are intended to be used for DC charging of electric vehicles in mode 4 as described by IEC 61851-1 and IEC 61851-23. The specific designs are grouped into several configurations.

The designs are described with sufficient detail to allow compatibility between products of different manufacturers.

The first edition, IEC 62196-3:2014, was published in 2014.









IEC TS 62196-3-1

This IEC technical specification describes how vehicle connectors and vehicle inlets according to IEC 62196-3 can be used with cables with quite small conductor cross section if thermal management is applied. Thermal management uses thermal sensors and adjusts the current to limit the temperature rise of the cable assembly.

The first edition, IEC TS 62196-3-1:2020, was published in 2020.
IEC TS 62196-4

This IEC technical specification extends IEC 62196-1 and describes specific designs of plugs, socket-outlets, vehicle connectors and vehicle inlets that are intended to be used for DC charging through circuits specified in IEC 61851–3 series, where protection against electric shock is ensured by double or reinforced insulation. The maximum operating voltage is 120 V at a nominal current of up to 60 A. One typical application are light electric vehicles.

Preparation of this document is finished (as of July 2018) but the final version has not yet been published.
IEC 62196-6

This IEC technical specification will extend IEC 62196-1 and describe specific designs of plugs, socket-outlets, vehicle connectors and vehicle inlets that are intended to be used for DC charging through circuits that will be specified in IEC 61851-25, where protection against electric shock is ensured by electrical separation. The maximum operating voltage is 120 V at a nominal current of up to 100 A. One typical application will be light electric vehicles.

This document is under preparation (as of July 2018) and the final version has not yet been published.

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1. Overview
The **IEC 62196** series of standards defines the requirements for **plugs, socket outlets, vehicle connectors, and inlets** used in electric vehicle (EV) charging systems. It ensures compatibility, safety, and interoperability across manufacturers and regions.

Key Focus:

• Defines the physical interface (connectors and plugs).
• Covers both **AC (Alternating Current)** and **DC (Direct Current)** charging systems.
• Supports various charging modes for EVs as defined in IEC 61851.

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2. Main Components Covered by IEC 62196

• Plugs and Socket-Outlets: Connect the charger to the power supply (e.g., public charging stations or residential setups).
• Vehicle Connectors and Inlets: Provide the interface between the charging station and the vehicle.
• Charging Modes:
  - Mode 1: Standard household socket charging.
  - Mode 2: Household socket with in-cable protection.
  - Mode 3: Dedicated EV charging station (fast charging).
  - Mode 4: DC fast charging with external equipment.

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3. Types of Connectors Defined in IEC 62196
IEC 62196 specifies connector types for different regions and charging requirements:

• Type 1 (SAE J1772):
  - **Region:** North America and Japan.
  - **Use:** AC charging (single-phase).
  - **Pins:** 5 (Line, Neutral, Ground, and 2 for communication).

• Type 2 (Mennekes):
  - **Region:** Europe.
  - **Use:** AC charging (single-phase or three-phase) and DC charging.
  - **Pins:** 7 (supports three-phase and communication).

• Combined Charging System (CCS):
  - **Region:** Global (CCS1 in North America, CCS2 in Europe and Asia).
  - **Use:** AC and DC fast charging.
  - **Design:** Combines Type 1 or Type 2 connectors with additional DC pins.

• CHAdeMO:
  - **Region:** Japan and some global markets.
  - **Use:** DC fast charging.
  - **Special Feature:** Supports bidirectional charging (vehicle-to-grid or V2G).

• GB/T:
  - **Region:** China.
  - **Use:** Separate standards for AC and DC charging.
  - **Design:** Specific to China's EV standards.

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4. Key Features of IEC 62196 Connectors
Interoperability: Ensures compatibility between EVs and chargers from different manufacturers. 
Safety: Includes provisions for grounding, insulation, and communication for safe operation. 
Durability: Specifies mechanical durability and environmental resistance (e.g., water and dust protection). 
Standardized Communication: Facilitates real-time monitoring and control between the vehicle and charger.

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5. Benefits of IEC 62196

• Global Standardization: Supports the global adoption of EVs with unified charging infrastructure.
• Improved User Experience: Enables seamless charging across different regions and stations.
• Future-Ready: Supports high-power charging and advanced features like bidirectional charging.

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6. Applications
The IEC 62196 standard is applied in:

• Public Charging Stations: Urban areas, highways, and shopping centers.
• Residential Charging: Wall-mounted home chargers or socket outlets compliant with IEC 62196.
• Commercial Fleets: Charging hubs for electric buses, taxis, and delivery vehicles.

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7. Conclusion
The **IEC 62196** standard ensures safe, reliable, and interoperable charging for electric vehicles globally. By defining connector types, performance requirements, and safety measures, it supports the widespread adoption of EVs and charging infrastructure.

Key Points:

• Defines global EV charging connectors and plugs.
• Supports AC and DC charging modes.
• Critical for public, residential, and commercial EV infrastructure.

References: IEC 62196, EV charging standards, and related industry best practices.