IEC 62196

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Logo of the German Institute for Standardization DIN EN 62196
Area Electric vehicles
title Plugs, sockets, vehicle couplings and vehicle plugs - Conductive charging of electric vehicles - Part 1: General requirements, Part 2: Requirements and main dimensions for the compatibility and interchangeability of male and female plug and socket devices for alternating current, Part 3: Requirements for and main dimensions for pins and sockets for the interchangeability of vehicle connectors for dedicated charging with direct current and as a combined version for charging with alternating current / direct current
Brief description: Plug types and charging modes for electric vehicles
Latest edition 2012-11, 2012-07 (part 2, 3)
ISO IEC 62196

The IEC 62196 is an international standard for a number of connector types and charging modes for electric vehicles and is maintained by the International Electrotechnical Commission (IEC). The standard is valid in Germany as DIN standard DIN EN 62196. It consists of several parts that have been adopted one after the other. The third part was published in June 2014. The standardization process for part 4 (plug connections for light electric vehicles ) began in June 2015 .

The standard adopts the IEC-61851 definition for a signal pin that switches the charging current - the charging station remains de-energized until an electric vehicle is connected. The vehicle cannot then be operated during the charging process.

The Part 1 definitions for the signal pin and its IEC-62196-1 charging connector have found their way into other technical regulations. In addition to the IEC 60309 "CEEform" three-phase plugs , the charging modes have also been developed for the SAE-J1772 connection in North America (designed by Yazaki ), for the CHAdeMO plug in Japan and for the Mennekes plug (VDE-AR-E 2623-2 -2) adopted in Europe. Each of these connections forms the basis for a network of public charging stations operated by energy providers.

Loading modes

IEC 62196-1 relates to connectors (plugs), sockets , sockets and pre-assembled cables for electric vehicles that are used for wired charging systems. A range of

  • 690 V AC , with 50 to 60  Hz , with a rated current of up to 250 A;
  • 600 V DC voltage , with a nominal current of up to 400 A.

The charging modes are based on the specifications of IEC61851-1:

  • IEC 61851-1 "Mode 1" - slow charging at household sockets with protective contact (Schuko)
  • IEC 61851-1 "Mode 2" - single- to three-phase charging via a signal that is firmly coded on the plug side
  • IEC 61851-1 "Mode 3" - charging with specific charging connector systems for electric vehicles with pilot and control contact
  • IEC 61851-1 "Mode 4" - fast charging with control by an external charger

Mode 1

Class 1 charging modes are designed for single-phase or three-phase alternating current up to 16 amps of current. The cable includes the phase (s), the neutral conductor and the protective earth. A pilot contact to enable the charging process is not absolutely necessary here. Plugs and cables that can withstand less than 16 amps are not reported by a signal, but it is provided that the maximum current levels are recorded on the devices themselves. The use of IEC 60309 industrial plugs is not required, but simpler plug systems such as Schuko can be used.

Mode 2

Class 2 charging modes are designed for device currents up to 32 amps, which are commonly found in both single-phase and three-phase configurations. The signaling to the vehicle is limited to fixed values, the pilot contact for charging release can be bridged by plugging in. The industrial plugs in accordance with IEC 60309 ensure the current-carrying capacity on the network side thanks to the size of the housing; accordingly, different connection adapters for 16 A or 32 A signal this in the vehicle connector. Other industrial plugs with a specification of 32 A and more can also be used. When connected to Schuko, an ICCB in the cable is necessary for high charging power , which ensures class 2 signaling to the vehicle.

Mode 3

Class 3 charging modes are intended for fast charging up to 250 A. Simple plugs with pilot contact according to class 2 can be used, but limit the charging current to 32 A. For higher charging currents, a suitable charging mode must be recognized. The reference to the IEC 60309 standard adopts the physical parameters for a corresponding charging system up to 250 A, such as the cable diameter and the pin diameter in the connector. The maximum permissible charging current or the availability of digital communication is coded using pulse width modulation . The latter forms the basis for controlled charging of electric vehicles in order to specifically influence the charging process.

Mode 4

Class 4 charging modes are intended for fast charging with direct current up to 400 A. Appropriate signaling allows charging plugs that do not match to remain voltage-free.

Connector types

The IEC 62196-1 part of the standard refers to the connector types in IEC 60309 . These were also widely used as charging plugs for electric vehicles, while the following charging connector systems were created specifically for use in the automotive sector. Efforts are being made to connect the vehicle's battery management to the energy supplier's smart grid .

The IEC 62196-2 part of the standard describes the connector types for connection to alternating current. ETSI and CEN-CENELEC started work in June 2010 in accordance with the order from the European Commission for a uniform charging plug. The commission expected a result by mid-2011. On December 17, 2010, IEC 62196–2 began to circulate with an end date of May 20, 2011. The completed IEC standard was published on October 13, 2011. This schedule became possible because the standard could rely on existing standardizations of charging connection systems.

The following types have been added to the list of charging plugs of the IEC 62196-2 standard:

  • IEC 62196-2 "Type 1" - single phase vehicle coupler - adopts the specification from SAE J1772 / 2009
  • IEC 62196-2 "Type 2" - single and three phase vehicle coupler - adopts the specification from VDE-AR-E 2623-2-2
  • IEC 62196-2 "Type 3" - single and three phase vehicle coupler with shutters - adopts the proposals of the EV Plug Alliance

Other connector types according to IEC 62196-1 were the Framatome connectors from EDF, the SCAME connectors in Italy and the CEEplus connector variants in Switzerland .

adapter

Public charging stations in accordance with IEC 62196 that have a specific connection socket (e.g. SAE J1772 or CEEplus) can also be used with other plug types using an adapter - however, the current is not activated until an IEC 61851-compliant signal pin is present of an electric vehicle reports. In addition, the current is limited to 16 A until an IEC-62196-compliant signal is detected, which enables a charging mode with a higher current intensity.

Type 1: SAE J1772-2009

SAE J1772-2009 coupling

In 2001, the North American SAE International Standards Committee passed a standard for a wired charging system for electric vehicles that complied with the specifications of the Californian emission control authority CARB . The SAE J1772-2001 charging connector was rectangular and based on a design by Avcon . In 2009, a revision of the standard was passed that included a new type of connector based on a design by Yazaki that was now round. This SAE-J1772-2009 charging connector was included in the IEC 62196-2 standard as Type 1 ("Type 1"). The plug type has five plug contacts, namely two contacts for single-phase alternating current, a ground and two signal contacts, which are compatible with IEC 61851-2001 / SAE J1772-2001.

Type 2: EN 62196-2 (VDE-AR-E 2623-2-2)

Type 2 charging connector
Type 2 connection
cable and charging station socket according to EN 62196-2 (VDE-AR-E 2623-2-2), "Mennekes plug"
Type 2 and CCS charging modes

The connector system manufacturer Mennekes has developed a derivative of its three-phase plug-based CEEplus connections according to the requirements of RWE and Daimler. Mennekes summarized the status of charging systems for electric vehicles at the beginning of 2009 and presented its charging connector system. This connector type has been suggested for inclusion in the next part 2 of this standard. The proposal is based on the observation that three-phase plugs according to IEC 60309 are very bulky for higher currents (diameter 68 mm / 16 A to 83 mm / 125 A). To ensure easy handling by the consumer, the plugs have been made smaller (55 mm diameter) and flattened on one side (mechanical protection against polarity reversal ).

Since standardization at the IEC is a lengthy process, the DKE / VDE ( German Commission for Electrical, Electronic and Information Technologies ) temporarily took on the task of standardizing the details of the charging system. The pre-standard included the VDE standard plug for charging stations and was published in November 2009 in VDE-AR-E 2623-2-2 . In contrast to the three-phase current plugs , the VDE charging plug has only a single housing diameter for all supported charging modes, from single-phase 16 A to three-phase 63 A charging mode (corresponding to 3.7 kW to 43.5 kW), i.e. it does not cover the entire range Range of class 3 charging modes from IEC 62196.

The national VDE guideline VDE-AR-E 2623-2-2 has meanwhile been incorporated into the international IEC standard and replaced by EN 62196-2: 2012-11. In the run-up to this standard, DKE / VDE worked closely with IEC and CENELEC for the entire process of charging electric vehicles. In June 2010, ETSI and CEN - CENELEC received the order to develop a European standard for charging points for electric vehicles. Meanwhile, Peugeot criticized the VDE standard plug for charging stations as too expensive compared to conventional IEC 60309 plugs. During field tests in France and Great Britain, the already widely used camping plugs (CEE blue, 230 V, 16 A) were used.

In March 2011, the ACEA recommended the use of Type 2 Mode 3 in its second position paper; from 2017 this should be used as a uniform solution in the EU and also be used for direct current charging in the form of the Combo2 plug. The European Commission followed the lobbying work and in January 2013 defined Type 2 for implementation as a common standard in Europe in order to end the previous uncertainties. A uniform standard for charging stations in Europe is to be introduced by December 2015. Since mechanical contact protection (“shutter”) is required for electrical connections in some countries, an optional extension is offered for this, based on a German-Italian compromise proposal from May 2013.

Type 3: EV Plug Alliance

On March 28, 2010 the "EV Plug Alliance" consortium was founded under the leadership of French ( Schneider Electric , Legrand ) and Italian ( Scame ) companies. The proposed charging connector could be based on the experience with the Scame charging connectors, which were already used for light vehicles (especially e-bikes ). The recorded type 3A largely corresponds to the Scame plug, while the type 3C has been expanded to include additional plug contacts that allow charging with three-phase current. In contrast to type 2, only a maximum charge of 32 amperes is specified; on the other hand, an extended contact protection in the form of mechanical shutters is added to prevent direct contact with live contacts. Because of its origins, this connector was also called Scame Type 3 .

Other manufacturers joined the "EV Plug Alliance" on May 31, 2010, including Gimelec , Gewiss , Marechal Electric , Radiall , Vimar , Weidmüller France and Yazaki Europe.

A statement from the European Automobile Manufacturers Association ACEA in June 2010 made it clear that it excludes type 1 due to the lack of three-phase contacts, but prefers type 2 in the choice of type 2 and type 3. The contact protection in mode 3, which is intended for public charging stations, is provided, since the power contacts are voltage-free in the absence of a pilot signal, and it is expected that the shutter will only contain one additional source of error. France decided to use type 3 with reference to the shutter, whereupon Mennekes presented an optional shutter solution for their type 2 plug in October 2012, pointing out that other countries that require child safety devices on household sockets should still use charging stations have set to type 2 (Sweden, Finland, Spain, Italy, UK). In November 2012, the European Commission reaffirmed the need for a uniform charging infrastructure across Europe and announced that it would adopt a statutory regulation in the course of 2013 in the event of market failure. This was done in January 2013 with the definition of type 2. At a hearing in the TRAN Committee in June 2013, the EV Plug Alliance called for the type 2 variant with shutters to be included in the upcoming regulation (making the VDE / Mennekes plug a variant of a Implementation of the IEC Type 3 requirements). The Mennekes proposal for the shutter had been examined by the Italian CEI (a country in which mechanical protection is mandatory) and was proposed by the German and Italian partners for adoption in the CENELEC standardization for charging plugs in May 2013.

The EV Plug Alliance appeared again at a hearing in June 2013. The website was no longer maintained and on October 22nd, 2014 a notice was given about the cessation of operations. Due to the decision at EU level in favor of type 2, a type 2 connection was provided for new projects in France that began in 2015 in order to receive funding. In October 2015 it was announced that Schneider (a founding member of the EV Plug Alliance) only delivers its charging stations with the type 2S connection (type 2 with shutters). In November 2015, it became known that Renault was delivering its vehicles in France with a type 2 charging cable instead of the previously included type 3 cable. The production of the type 3C connector of the EV Plug Alliance was thus finally stopped. The domain was finally deregistered in spring 2016, marking the end of the consortium.

Signal contacts

The function of the signal contacts was described in SAE J1772 : 2001 and included in IEC 61851. All connector types of IEC 62196-2 use the two signal contacts defined therein - the pilot contact CP ( Control Pilot ) and proximity switch PP ( Proximity Pilot ) are added to the normal current contacts ( outer conductor L1 – L3, neutral conductor N, protective conductor PE). The protocol is suitable for doing without digital electronics (in contrast to the CAN bus with CHAdeMO and EnergyBus ).

A public charging station charges the pilot contact CP with a 1 kHz square wave with ± 12 V, which is fed back to the protective conductor PE on the side of the electric vehicle via a resistor and a diode. With an open circuit, public charging stations are basically voltage-free, even if the standard allows power output in mode 1 (maximum 16 amps). The electric vehicle can request a charge release via the resistor - a mode 3-compatible vehicle is reported with 2700 ohms (" vehicle detected ") that has not yet requested a charge. At 880 ohms, the vehicle is ready for a charging current (" ready ") and at 240 ohms, ventilation is also requested (" with ventilation "). The charging station reports the maximum power output to the vehicle via pulse width modulation of the square wave.

The PP proximity switch signals the connection from the wallbox to the car and ensures the maximum load capacity of the cable to the charging station. For this purpose, a resistor is set between PP and PE on the vehicle side. Adapter cables can use a corresponding resistance coding here.

Resistance CP – PE open 2700 Ω 880 Ω 240 Ω
Charge approval A - standby B - vehicle detected C - ready (charging) D - with ventilation
Resistance PP – PE 1500 Ω 680 Ω 220 Ω 100 Ω
Max. Charging current 13 A 20 A 32 A 63 A
Conductor cross-section 1.5 mm² 2.5 mm² 6 mm² 16 mm²

IEC 62196-3: DC charging

The parts of the standard adopted in 2010/11 only cover the charging of electric vehicles with alternating current. After its adoption, the development of the standard part IEC 62196-3 began. In July 2012, a German standard DIN EN 62196-3 was published. The international standard was published in June 2014.

The CHAdeMO specification with up to 500 volts and 125 amperes already existed as a standard, but is based on the JARI level 3 DC plug. This charging connector system is already a de facto standard at existing charging stations in Japan, and stations for fast charging according to CHAdeMo have also been set up in Europe and America. The protocol for the signal pins is not based on IEC 61851, but on a CAN bus , and the connector is also considered to be very unwieldy.

The SAE 1772 working group had been working on a proposal for DC charging since 2010. The major German automobile manufacturers introduced a proposal into the standardization process in which the type 2 connector is used as the basis and provided with an extension for direct current charging. The possibility of data communication via CAN bus or PLC bus was provided.

DC charging with Combo2 coupling (only signal contacts used in type 2 pinout) and Combo2 on the vehicle connector (also suitable for AC charging)

Ultimately, American and European manufacturers have come out in favor of a uniform charging connector system: their proposal was to install the existing Type 1 and Type 2 plugs in a larger housing in which two additional contacts are responsible for direct current charging. Regardless of whether Combo Type 1 ("Combo1" for short) or Combo Type 2 ("Combo2" for short) is used, the DC contacts are plug-compatible. In the second statement from ACEA 2011, the Combo2 connector was proposed as a uniform vehicle connector type. Several car manufacturers (BMW, Daimler, Ford, General Motors and the Volkswagen Group) have agreed to use the "Combined Charging System" in their electric vehicles from mid-2012.

Combined Charging System

Combo2 coupling for DC charging only

The Combined AC / DC Charging System , CCS is a charging connector system for electric vehicles according to IEC 62196 and supports both AC charging ( alternating current ) and DC charging ( direct current ). It was developed by Phoenix Contact in cooperation with German automobile manufacturers ( Volkswagen AG , Daimler AG , BMW Group ) and essentially consists of a socket on the vehicle, the so-called inlet, and the two plugs for AC and DC charging. It was part of the 15th International VDI Congress "Electronics in Motor Vehicles" on 12./13. It was presented in Baden-Baden in October 2011 and was ready for use from mid-2013. The first version of the system for international standardization according to IEC 62196-3 was submitted in January 2011 and the second in June.

Thanks to the universal plug-in system, only one charging interface is required on the side of the vehicle to cover the various charging options such as AC and DC charging. A mechanical lock prevents unauthorized pulling out before the end of the charging process, which protects both people and the vehicle. The signal contacts CP and PP enable communication between the vehicle and the charging station and the charging process is controlled in a targeted manner. Due to the larger dimensioned DC contacts compared to AC charging, currents of up to 200 A are possible, which means that fast charging can be implemented, for example, when on the move. An ergonomically shaped handle and low insertion and removal forces should enable the plug-in connection to be inserted / removed easily with just one hand. Up to 125 A at a nominal voltage of up to 850 V are standardized.

As of March 2014, freely available electric vehicles that use the "Combined Charging System" are the VW e-up! , VW e-Golf , BMW i3 and Chevrolet Spark EV . However, the vehicles only support type 2 charging as standard; the CCS extension for fast direct current charging is, in contrast to vehicles with CHAdeMO, only optional at an additional cost. In series production, vehicles such as the Hyundai Ioniq (up to 100 kW), the Opel Ampera-e (up to 55 kW), the Audi e-tron (up to 150 kW) or the Jaguar I-Pace (up to 110 kW) are equipped with CCS .

The combined charging system competes with the tried and tested CHAdeMO rapid charging system with direct current, which is established in Japan and the USA and has also been introduced in Europe.

The superchargers built by Tesla Motors have been using the IEC-62196-2 type 2 connector in Europe since 2013 for rapid DC charging up to 145 kW, with the two additional pins of the CCS connector being dispensed with.

Type AC part type 2 DC part
Nominal voltage: 480 V 850 V
maximum charging current: 63 A 125 A
IP protection class when plugged in: min. IP44 min. IP44
IP protection class when not plugged in: min. IP 20 / IPXXB min. IP 20 / IPXXB
IP protection class of the inlet when covered (so-called road position): min. IP55 min. IP55
Standardization: IEC 62196–2 & IEC 62196–3 (Draft) IEC 62196–3 (Draft)

The first public CCS charging station with 50 kW direct current was set up in Wolfsburg in June 2013 and thus supported the tests of the VW e-up !, which was optionally equipped with a CCS Combo2 connection. Two weeks later, BMW also inaugurated the first CCS charging station in Munich, with which the tests of the BMW i3 are supported. The BMW i3 also only supports faster charging with direct current for an additional charge.

On the occasion of the second EV World Summit in June 2013, spokesmen for the Chademo Group and the Volkswagen-BMW Group pointed out that competition between the two standards for direct current charging will not be mandatory, since the additional costs for a further charging protocol are just 5% - hence Chademo, Volkswagen and Nissan jointly recommend the establishment of “multi-standard fast chargers” that can be controlled by vehicles with Chademo as well as those with Combo2 connection.

Individual evidence

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  7. VDE-AR-E 2623-2-2 (2009-10) : "Plugs, sockets, vehicle plug devices and vehicle plugs - charging of electric vehicles"; "Part 2-2: Requirements and main dimensions for the interchangeability of male and female connectors"; Issue date 2009-10, Association of Electrical, Electronic and Information Technologies
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