Product Specification

108-94323
01 FEB 16 Rev A

The product described in this document has not been fully tested to ensure conformance to the requirements outlined below. Therefore, TE Connectivity (TE)
makes no representation or warranty, express or implied, that the product will comply with these requirements. Further, TE may change these requirements
based on the results of additional testing and evaluation. Contact TE Engineering for further details.

IEC 62196 Electric Vehicle Charge Connector Assembly (Type 2

for Mode 2 and 3)

1. SCOPE
1.1. Content
This specification covers performance, tests and quality requirements for the TE Connectivity (TE) IEC
62196 EV Connector & Plug Assemblies. The Connector & Plug assemblies are designed to perform in
accordance with “Plugs, Socket Outlets and Vehicle Inlets – Conductive Charging of Electric Vehicles”,
IEC 62196. Although cable diameters and assembly current ratings may vary, the mechanical and
environmental requirements contained in this specification apply to all.
1.2. Qualification
When tests are performed on the subject product line, procedures specified in Figure 1 shall be used. All
inspections shall be performed using the applicable inspection plan and product drawing.
1.3. Qualification Test Results
Successful qualification testing on the subject product line has been completed. The Qualification Test
Report number will be issued upon successful qualification testing.
1.4. Terms and definitions

Socket – outlet
Part of a plug and a socket-outlet intended to be installed with the fixed wiring.

Station Side Plug

Station Side Plug is intended to connect with the Socket – Outlet and is part of the supply cable and
contains pin contacts.

Car Side / Vehicle Connector

Car Side Connector is intended to connect with the Vehicle inlet and is part of the supply cable.

Vehicle inlet
Vehicle inlet is assembled on the electrical vehicle and contains pin contacts.
2. DESCRIPTION

The enclosure of plugs and vehicle connectors completely encloses the terminals and the ends of the
flexible cable. (IEC 62196-1, 18.1)
2.1. HOUSINGS
2.1.1. A One Phase
2.1.2. Car-side Connector

© 2016 TE Connectivity family of companies This controlled document is subject to change. 1 of 22

All Rights Reserved For latest revision and Regional Customer Service, visit our website at www.te.com
| Indicates Change PRODUCT INFORMATION 1-800-522-6752
*Trademark. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
 108-94323

The Connector-housing contains one phase lines L1, one ground line (PE), one neutral line (N), one
proximity pilot (PP) and one control pilot (CP).
All contacts are receptacle contacts.

2.1.3. Station-side plug

The plug-housing contains one phase lines L1, one ground line (PE), one neutral line (N), one proximity
pilot (PP) and one control pilot (CP).
All contacts are pin contacts.

2.1.4. Three Phase

The Three-Phase Plug is the same as the one-Phase Plug, with the L2 and L3 Phases line in place.

2.2. SOCKET CONTACTS

2.2.1. Power Socket and neutral pin contacts

Power receptacle contacts are mated in the Connector housing.

Pin diameter compatibility: 6 mm IEC 62196-2, Standard Sheet 2-IIb
Max wire range: See section 4.2.4
Raw material: Brass with Ag finish
Power pins must have an insulation cap at the end of the pin
Cable: see 4.2.3

Rev A 2 of 22
 108-94323

2.2.2. Ground pin contact

Earth power receptacle contact is mated in the Connector housing

Pin diameter compatibility: 6 mm IEC 62196-2, Standard Sheet 2-IIb
Max wire range: See section 4.2.4
Raw material: Brass with Ag finish.
Cable: see 4.2.3

2.2.3. Signal pin contacts

Signal receptacle contact is mated in the Connector housing.

Pin diameter compatibility: 3 mm IEC 62196-2, Standard Sheet 2-IIb
Wire range: See section 4.2.4
Raw material: Brass with Ag finish
Cable: see 4.2.3

2.3. Pin CONTACTS

2.3.1. Power socket and neutral socket contacts

Power receptacle contacts are mated in the plug housing.

Pin diameter: 6 mm IEC 62196-2, Standard Sheet 2-IIb
Max wire range: See section 4.2.4
Raw material: Brass with Ag finish
Power pins must have an insulation cap at the end of the pin
Cable: see 4.2.3

2.3.2. Earth power receptacle contact

Earth power receptacle contact is mated in the plug housing

Pin diameter: 6 mm IEC 62196-2, Standard Sheet 2-IIb
Max wire range: See section 4.2.4
Raw material: Brass with Ag finish
Cable: see 4.2.3

2.3.3. Signal receptacle contacts

Signal receptacle contact is mated in the plug housing.

Pin diameter: 3 mm IEC 62196-2, Standard Sheet 2-IIb
Wire range: See section 4.2.4
Raw material: Brass with Ag finish
Cable: see 4.2.3

Rev A 3 of 22
 108-94323

3. APPLICABLE DOCUMENTS AND FORMS

The following documents and forms constitute a part of this specification to the extent specified herein.
Unless otherwise indicated, the latest edition of the document applies.


3.1. TE Documents


108-94348 EV Charger round crimp specification


108-94375 EV Charger round contact system


108-94348 EV Charge Round Contact Crimp System
108-94390 EV Charger Cable Strain Relief overmolded, with crimped Rivet


3.2. Industry Documents
ISO 20653:2013-02 Road vehicles; degrees of protection (IP-code); protection against foreign


objects; water and contact; electrical equipment
IEC 60352-2:2014-04 Solderless connections – Part 2: Crimp connections - General requirements,


test methods and practical guidance


IEC 60529:2001-02: International Standard, Degrees of Protection Provided by Enclosure (IP Code)
IEC 61851-1 Edition 2.0 2010-11: Electric vehicle conductive charging system, Part 1: General


requirements
DIN EN 60068-2-14:2010-04 Environmental testing - Part 2-14: Tests - Test N: Change of


temperature
DIN EN 60068-2-30:2006-06 Environmental testing - Part 2-30: Tests - Test Db: Damp heat, cyclic


(12 h + 12 h cycle)
DIN EN 60068-2-38:2010-06 Environmental testing - Part 2-38: Tests - Test Z/AD: Composite


temperature/humidity cyclic test
DIN EN 60068-2-64:2009-04 Environmental testing - Part 2-64: Tests - Test Fh: Vibration,


broadband random and guidance
DIN EN 60068-2-78: Environmental testing - Part 2-78: Tests; Test Cab: Damp heat, steady state


German comments on IEC 62196-2-x: German Proposal 20090430.doc


DIN EN 61984:2009: Connectors- Safety requirements and tests
IEC 60664-1:2007 Insulation coordination for equipment within low-voltage systems - Part 1:


Principles, requirements and tests
IEC 60664-3:2003 Insulation coordination for equipment within low-voltage systems - Part 3: Use of


coating, potting or moulding for protection against pollution


LV124 March 2010: vehicle connector evaluation instruction


LV214 March 2010: vehicle connector evaluation instruction
IEC 62196-1 Edition 2.0 2011-10: Plugs, socket-outlets, vehicle couplers and vehicle inlets –


Conductive charging of electric vehicles – Part 1: General Requirements
IEC 62196-2 Edition 1.0 2011-10: 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
IEC 62196-3 Edition 1.0 2011-10: Plugs, socket-outlets, vehicle connectors and vehicle inlets –
conductive charging of electric vehicles


3.3. Reference Document
109-197 Test Specification (TE Test Specification vs EIA and IEC Test Methods)

Rev A 4 of 22
 108-94323

4. REQUIREMENTS
4.1. Technical Requirements

4.1.1. Current and Voltage Ratings

TABLE 4-1: RATINGS OF CURRENTS AND VOLTAGES (IEC 62196-2, Table 102 & IEC 62196-1, 5.2)

Function Current rating Voltage rating

AC Power 20A up to three phases 250 VAC
Neutral 32A one phase, (three phases optional)
Equipment Ground Rated for fault
Control Pilot 2A 30 V
Proximity Detection 2A 30 V

4.1.2. Ambient temperature

In operation: IEC 62196-1, 1 Site 9

Continuous ambient temperatures in the range of –30 °C to + 50 °C when supplied with the EVSE or
installed in the EV/PHEV

4.1.3. Temperature rise

Maximum temperature rise of terminals does not exceed 50 K, TE intern 35K. IEC 62196-1, 24
Test procedure is described in 4.7.

4.1.4. Touch temperature

The maximum permissible temperature does not exceed the temperatures shown in TABLE 4-2 when
tested at an ambient temperature of 40°C. IEC 62196-1, 16.5

TABLE 4-2: MAXIMUM SURFACE TEMPERATURES (IEC 62196-1, 16.5)

Location Composition of surfacea

Metal Nonmetallic
parts of the plug and the vehicle connector that can be
50°C 60°C
grasped during operation
(122°F) (140°F)
Parts which may be touched but not grasped
60°C 85°C
(140°F) (185°F)

Test procedure is described in 4.7.

Rev A 5 of 22
 108-94323

4.1.5. Clearance- and Creepage Distances

4.1.6. Clearance Distances

TABLE 4-3: Clearance Distance, Single Phase (DIN EN 60664-1)

Voltage Category 4 (Table F.1) 4000V

Dirt Category 3, heterogeneous field (Table F.2) 3 mm
Consideration of Height (5500m, Table A.2) 1,59
Resulting clearance distance Min. 4,77 mm
Measured Value (Car/Station):
Min 13,8 mm

TABLE 4-4: Clearance Distance, Three Phases (DIN EN 60664-1)

Voltage Category 4 (Table F.1) 6000V

Dirt Category 3, heterogeneous field (Table F.2) 5,5mm
Consideration of Height (5500m, Table A.2) 1,59
Resulting clearance distance Min. 8,75 mm
Measured Value (Car/Station):
Min 13,8 mm
4.1.7. Creepage Distance

TABLE 4-5: Creepage Distance Single Phase (DIN EN 60664-1, Table F.4)

Voltage effective Value (Table F.3) 250 V

Dirt Category 3 and Insulating Material Group 3 4mm (7,9 mm1)
(Table F.4)
Measured Value (Car/Station):
Min 20 mm

TABLE 4-6: Creepage Distance Three Phase (DIN EN 60664-1, Table F.4)

Voltage effective Value (Table F.3) 500 V

Dirt Category 3 and Insulating Material Group 3 8mm (7,9 mm1)
(Table F.4)
Measured Value (Car/Station):
Min 20 mm

1when a rib is used

Rev A 6 of 22
 108-94323

4.1.8. Proximity Detection and Current Rating

Vehicle connectors and plugs using the proximity contact for simultaneous proximity detection and
current capability coding of the cable assembly set have a resistor electrically placed between proximity
contact and Protective Earthing contact with a value as indicated in
TABLE 4-7. The resistor is coded to the maximum current capability of the cable assembly. The EVSE
interrupts the current supply if the current capability of the cable is exceeded as detected by the
measurement of the Rc, as defined by the values for the recommended interpretation range in
TABLE 4-7.

The resistor is also used for proximity detection. IEC 61851-22, ANNEX B

TABLE 4-7: RESISTOR CODING FOR PLUGS (IEC 61851-22, ANNEX B)

Current capability of the Nominal resistance of Rc Recommended interpretation

cable assembly Tolerance +/- 3% range by the EVSE
13 A 1.5 kΩ / 0,5 W > 1 k Ω - 2.7 kΩ
20 A 680 Ω / 0,5 W 330 Ω – 1 kΩ
32 A 220 Ω / 0,5 W 150 Ω - 330 Ω
The power dissipation of the resistor caused by the detection circuit does not exceed the value given
above. The value of the pull-up resistor is chosen accordingly.

Figure 1: Diagram for current capability coding of 2 the cable assembly (IEC 61851-22, Annex B)

4.1.9. Electromagnetic Compatibility

Immunity: The operation of accessories within the scope of this standard in normal use is not affected by
electromagnetic disturbances. IEC 62196-1, 32.1
Emission: Accessories within the scope of this standard are intended for continuous use. In normal use,
they do not generate electromagnetic disturbances. IEC 62196-1, 32.2

4.1.10. Mating Cycles

10.000 times of mechanical operation without load and 50 times with load IEC 62196-1, Table 17

Rev A 7 of 22
 108-94323

4.1.11. Mating / unmating forces

The force to insert and withdraw a plug or a vehicle connector is less than 100 N. This force is
necessary to enable a translatory movement parallel to the areas of the friction pairings.
IEC 62196-1, 16.15
4.2. Design requirements
4.2.1. Interlocking Device

The vehicle connector and/or the plug may include a means to allow engagement of an optional locking
mechanism to reduce the likelihood of tampering or unauthorized removal. The minimum force, which it
withstands, is 753 ± 1 N for 60s. IEC 62196-1 Table 10 / Sheet 49 and IEC 62196-3 26.302 table 306

4.2.2. Contact system

See 2.2 for dimensions.

The contact system complies with all parameters of this specification. Furthermore, it provides a secure
fastening which guarantees a solid connection between contacts and enclosures. The contact system is
crimpable.

4.2.3. Type of wire

TABLE 4-8 List of usable cables

Producer ID-No. VDE-Clearance-No.

Coroplast S05BQ-F 3 G 2,5 mm² + 0,5 mm² VDE REG.-NR. 8491 [JJ/KW] CE
Coroplast S05BQ-F 3 G 6 mm² + 0,5 mm² VDE REG.-NR. 8491 [JJ/KW] CE

4.2.4. Wire Sizes

Non-rewireable accessories are provided with soldered, welded, crimped or equally effective permanent
connections (terminations). The accessory is constructed that the cable or wiring cannot be separated
from the accessory without making it permanently useless
IEC 62196-1, 25.2.2

TABLE 4-9: SUMMARY OF WIRE SIZES IN FUNCTION OF DEVICE RATINGS (IEC 62196-1, 13.1.2)

Device rating Wire Gauge (mm2)

Signal Line 2A 0,5 mm2

Earth & Power Line ≤ 20A 2,5 mm2

≤ 32 A 6 mm2

Rev A 8 of 22
 108-94323

4.2.5. Strain Relief

Rewirable accessories are provided with a strain relief means designed to prevent the twisting of the
cable that may occur. IEC 62196-1, 25.2.2
Non-rewirable plugs and vehicle connectors shall be provided with a suitable flexible cable appropriate
for the rating of the plug and vehicle connector and as specified by the manufacturer.
Non-rewirable plugs and vehicle connectors shall be tested as a cable assembly. IEC 62196-1, 25.2.1

4.2.6. Contact crimping area

See the areas in 4.2.4. => 108-94348

4.2.7. Insulating Material

Insulating parts supporting live parts are of material resistant to tracking. IEC 62196-1, 29.6

4.2.8. Protection against Manipulation

Protected against manipulation acc. to 62196-1, 16. 16.9 See 4.5.1.

4.2.9. Sealing of Interface-contact Area

The sealing area is free of shrinkage, toolcuts and ejectors according to Standard Sheets 2-IIb and 2IIc.
IEC 62196-2, Standard Sheet 2-IIb & Standard Sheet 2-IIe

4.2.10. Other design requirements

None

4.3. Features (Form, Fit, Function, Material Requirements)

4.3.1. Dimensional constraints: Dimensions max L/W/H/Diameter

See IEC 62196/2011-07-22 Standard sheets 2-II.

4.4. Reliability

4.4.1. Fluid Resistance

The plug is resistant to the following chemicals. The functionality is not negatively influenced. All the
specifications of this document are met after the plug has been in contact with the chemicals.

Rev A 9 of 22
 108-94323

Following Table also see LV 214:2010-03 PG 22A att. E

Pouring over: Min. 100 ml (acc. to DIN EN ISO 175
min. 8 ml / cm² surface)
rubbing: impregnated cotton cloth
spraying: ca. 1 s each side

TABLE 4-10: OVERVIEW OF CHEMICALS AGAINST WHICH THE PLUG SHALL BE RESISTANT

TE Spezifikation 108-94323, angelehnt an LV 214 PG 22

ID Chemikalie Beschreibung PG Temperatur Dauer
1 Diesel DIN EN 590 22 B T RT 22 h
2 Bio Diesel EN 14214 22 B T RT 22 h
3 FAM Test Fuel handelsüblich 22 B T RT 10 min
4 Motoröl Multigrade Oil SAE 0W40, API 22 B 50 22 h
SL-CF
5 Servolenkungsöl handelsüblich 22 B 50 22 h

6 Automatic transmission oil ATF Full synthetic 22 B 50 22 h

7 Schmierfett Heisslagerfett 22 A 50 22 h
8 Batteriesäure verdünnte Schwefelsäure; Dichte 22 B 50 22h
1,28 g/ml
9 Bremsflüssigkeit DOT4-DOT5 22 B 50 22 h
10 Frostschutzmittel Ethylen Glycol für -40°C 22 B 50 22 h
11 AdBlue wässrige ISO 22241-1 22 B TRT 22h
Harnstofflösung
12 Windschutzscheibenreiniger, handelsüblich, unverdünnt 22 A 50 2h
Winter
13 Innenreiniger, Cockpitspray handelsüblich 22 A 50 2h
14 Motor- und Kaltreiniger handelsüblich, z.B. Caramba 22 A 50 22 h
605415
15 Schweiß DIN 53160 T RT 22 h
16 Kosmetische Produkte z.B. z.B. Nivea, Kenzo T RT 22 h
Creme
17 Tausalzlösung 3 % Salzlösung 22 B 50 22 h
18 Isopropanol handelsüblich 22 A T RT 22 h

Compliance is to be checked by the Fluid resistance test in section Error! Reference source not
found..
4.5. Requirements concerning Serviceability
4.5.1. Requirements concerning Maintainability

The housing of the plug consists of two parts: the cover and the plug-housing. Inside the plug-housing
all components are assembled and at the end the cover is welded to the housing. Due to the welding,
maintaining work is made impossible and defect plugs have to be disposed.

Rev A 10 of 22
 108-94323

4.6. Safety requirements

4.6.1. Accessibility of live parts

Accessories are so designed that live parts of socket-outlets and vehicle connectors, when they are
wired as in normal use, and live parts of plugs and vehicle inlets, when they are in partial or complete
engagement with the complementary accessories, are not accessible.

This can be tested by means of a test finger. But already design of the plug is regulated in that way, that
access of live parts with the test finger should be impossible. Thus a further testing seems to be
superfluous. IEC 62196-1, 10.1
4.6.2. Contacting Sequence

The connections shall be made accordingly with TABLE 4-11 (IEC 62196-1, 6.8 and 10.3)

TABLE 4-11: SEQUENCE OF CONNECTIONS

Inserting the plug Step 1

Step 2a

Step 3a

Rev A 11 of 22
 108-94323

Step 4b

Charging
Withdrawing the Plug Step 1c

Step 2a

Step 3a

Rev A 12 of 22
 108-94323

Step 4

a Can be made/braked simultaneously.

b Proximity connection can be made before the control connection.
c Proximity connection can be braked before the control connection.

4.6.3. Protection degrees

Live parts of socket-outlets and vehicle connectors, when they are wired as in normal use, and live parts
of plugs and vehicle inlets, when they are in partial or complete engagement with the complementary
accessories, are not accessible.
IEC 62196-1, 10.1

Plugs incorporate means for ensuring the marked degree of protection when in complete engagement
with the complementary accessory.
IEC 62196-1, 18.3

The parts of the vehicle connector shall be fixed together that they will not work loose in normal use.
Dismantle without tools shall be impossible.
IEC 62196-1, 18.2

Vehicle connectors are totally enclosed when fitted with a flexible cable as in normal use and when not
in engagement with the vehicle inlet. In addition, they incorporate means for ensuring the marked
degree of protection when in complete engagement with the vehicle inlet.
IEC 62196-1, 18.4
TABLE 4-12: PROTECTION DEGREE ON PRODUCTS (acc. IEC 61851-1, 11.3.1)

State CAR-side STATION-side

Connector Plug

Mated IP 44 IP 44

Unmated (with cap) IP 24 IP 24

Unmated IP 20 IP 20

4.7. Performances and descriptions

General note 1: Tables and figures named in this section can be found in ANNEX A if there is not a
reference to another section.
General note 2: CR means Customer Request, the, to the code (Customer X) corresponding, costumer
is defined in a separate document.

Rev A 13 of 22
 108-94323

4.7.1. Test Requirements and Procedures Summary

Unless otherwise specified, all tests shall be performed at ambient environmental conditions.
TEST DESCRIPTION REQUIREMENT PROCEDURE
Visual examination of product Meets requirements of product
drawing and Meets visual
requirements
ELECTRICAL
Measurement of contact resistance Contact 108-94375
Crimp 108-94348

Insulation resistance Test The insulation resistance shall be IEC 62196-1, 21.1; 21.2
not less than 5 MΩ.

Comparative Tracking Index Test The material under test shall pass at IEC 62196-1 29.6 / IEC 60112
a proof tracking index of 175 V
A flat surface at least 15 mm –
15 mm and 3 mm thick is placed
in the horizontal position on the
apparatus.
Test solution A with an interval
between drops of 30 s ± 5 s

Flammability glow-wire test No flame or glowing of the IEC 62196-1, 29.5

specimen or the surroundings
extinguish within 30 s after
removal of the glow-wire, and the
surrounding parts have not
burned away completely.
There shall be no ignition of the
tissue paper or scorching of the
board.
Dielectric Strength 1 minute hold with no breakdown or IEC 62196-1, 21.3
flashover, no deformation that effects
mating polarization or proper Subject 3 unmated specimens
functioning of specimen between live parts of opposite
polarity, secondary circuits and
ground, and secondary circuits
and live parts to 2000Vac at 50 –
60Hz, uniformly and rapidly
applied, beginning at ½ the
voltage.
Number of samples: at least 6

Current Load Cyclic Temperature Rise < 35 K TE internal

Change of Resistance acc. to 108- 16 Amps, DC load 120 min ON.,
94348 Table: contact resistance 60 min OFF, 25 cycles
overview: initial and after aging
70°C ambient temperature
Use testing-device for fixation
of plugs with continuity check of
temperature and resistance.
Temperature Rise Test The temperature rise of terminals IEC 62196-1, 24.1 The test
shall not exceed 50 K. current is an alternating current
of the value shown in IEC
62196-1, table 18.
For the purpose of this test, a
length of at least 2 m of the

Rev A 14 of 22
 108-94323

cable shall be connected to the

terminals.
High Voltage
Contact Resistance and Temperature
1 GOhm VDE 0623 Part 5 and VDE – AR-
Monitoring E 2623-2-2
Low Voltage: PM 348 E 2010-06-18
Limit for Connection test: 100
Ohm High Voltage:
Limit for short circuit test: 20 kOhm Testing Voltage: 1500V DC
(ISO)
Testing Voltage: 2000V AC
(Dielectric Withstanding Test)
Duration: 1s
Low Voltage
Testing Voltage: 20V
Derating temp rise contact temperature rise < 50K after IEC 60512-5-2 16 A
1 hour test duration

Breaking capacity An accessory classified "Not IEC62196-1,22.3

suitable for making and breaking
an electrical circuit under load"
shall have sufficient breaking
capacity to interrupt the circuit in
case of a fault, without any
indication of a fire or shock
hazard. The accessory need not
remain functional after the
completion of the test. It shall not
be used for any further tests.
Compliance is checked by testing
the mating accessories in
accordance with 22.2 for up to
three making and breaking
operations, if the accessory
permits, under the indicated load.
Following the test, the accessories
shall comply with a dielectric test in
accordance to 21.3

MECHANICAL

Polarization Integrity Test The devices shall not be able DIN EN 61984:2009, 6.9.1
to mate in any manner that (TE-Intern)
would energize the
grounding feature of the Compliance with the
device. requirements specified in shall
be determined by using each
The force required to mate of three devices assembled in
the devices shall not exceed its intended housing with the
180 N (40 lbf). polarization feature removed.
Cable Pull Test / Torque Test During the tests, the cable IEC 62196-1, 25.3
shall not be damaged. The cable is then subjected 100
times to a pull of the value shown
in IEC 62196-1, table 19. Each pull
is applied without jerks and has a
duration of 1 s.

Drop test No defect adversely affecting IEC 62196-1, 26.3

correct operation
Plug (and socket) samples are
preconditioned at (-30±2)°C for
16 hours

Rev A 15 of 22
 108-94323

Drop height 1m on concrete

floor
2.25 m fixed to a wall and
rotated through 45° each time
Vehicle drive over There shall be no severe IEC 62196-1, 33
Part 1 & Part 2 cracking, breakage, or
deformation.
Ball pressure test at temperature Mark diameter must be smaller IEC 62196-1, 29.3 The surface
than 2 mm of the part to be tested is placed
in the horizontal position and a
steel ball of
5 mm diameter is pressed
against this surface by a force
of 20 N.
The test is made in a heating
cabinet at a temperature of:
– (125 ± 5) °C for parts
supporting live parts of
rewireable accessories;
- (80 ± 3) °C for other parts.
Duration 1 hour
Cable flexing test No defect adversely affecting IEC 62196-1, 26.4
correct operation
A current equal to the rated
current of the accessory is
passed through the
conductors, the voltage
between them being the rated
voltage. The oscillating
member is moved backwards
and forwards through an angle
of 90° (45° on either side of the
vertical), the number of flexing
being 20 000 and the rate of
flexing 60 per minute.
Torque Test values for glands After the test, the glands and the IEC 62196-1, 26.5
enclosures of the samples shall
show no damage within the The glands are then tightened
meaning of this standard. by means of a suitable spanner,
the force shown in IEC 62196-
1, 25.3 being applied to the
spanner for 1 min, at a point 25
cm from the axis of the gland.
Vibration Test The sample must be fully LV124 PG 17,
functional before, during and
after the test, and all parameters This test simulated the
must meet the specifications vibrational load of the
component during driving
operation. The test serves to
verify the resistance of the part
to faults, such as component
displacement or material
fatigue.
Number of samples: 6
Random:10–1000 Hz, 19,7m/s²
Temperature: -40 – 105°C
Shock: 30g/6ms 2x3x1000

Rev A 16 of 22
 108-94323

Retention force of the plug in the socket VDE § 16 The plug shall not be IEC 62196-1, 16.8 With the
with latching mechanism released latching mechanism in place,
the mating accessory shall be
pulled with a force F equal to
the weight of the accessory
and a 4m length of the
maximum size cable or cable
assembly used with the
accessory.
Insertion and withdraw force of the Operating speed : TBD different IEC 62196-1, 16.15 VDE § 16
connector, plug in the socket from 62196-1
100 N max
Touch temperature test The maximum permissible IEC 62196-1, 16.5
temperature of those parts of the
plug and the vehicle Parts are loaded with maximum
rated current at ambient
temperature of (25±5) °C
Test is checked by
Temperature rise.
10.000 mating/unmating cycles – no wear impairing the further IEC 62196-1, 23
use of the accessory or of its
interlock, if any Speed of mating-unmating
cycles : 0.8±0.1m/s
– no deterioration of enclosures
or barriers Maximum number of cycles/mn
: 7.5 cycles/mn
– no damage to the entry holes
for the plug contacts that might Durability : 10000 cycles with
impair proper working no load

– no loosening of electrical or Durability : 50 cycles with load

mechanical connections; If load, samples are loaded with
– no seepage of sealing rated current at rated voltage
compound products are connected using
Figure 3 – Circuit diagrams for
– the continuity between mating breaking capacity and normal
signal and pilot contacts are operation tests – IEC 62196-1
maintained.
The samples shall then withstand
a dielectric strength test, the
test voltage, however, being
decreased by 500 V.
ENVIRONMENTAL
Enclosure Test: IEC 62196-1, 20.1/20.2 IEC
compliance of IP-Code In general, if any water has 60529, 14.2.5, 14.3( VDE +
entered, it shall not: TE Intern)
- be sufficient to interfere with the IP 44
correct operation of the
equipment or impair safety; The test is made by spraying
the enclosure from all
- deposit on insulation parts practicable directions with a
where it could lead to tracking stream of water from a standard
along the creepage distances; test nozzle defined in IEC
- reach live parts or windings not 62196. The conditions to be
designed to operate when wet; observed are as follows:
- accumulate near the cable end - internal diameter of the
or enter the cable if any. nozzle: 6,3 mm;
If the enclosure is provided with - delivery rate: 12,5 l/min ± 5 %;
drain-holes, it should be proved by

Rev A 17 of 22
 108-94323

inspection that any water which

enters - water pressure: to be adjusted
to achieve the specified delivery
rate;
- core of the substantial stream:
circle of approximately 40 mm
diameter at 2,5 m distance from
nozzle;
- test duration per square meter
of enclosure surface area likely
to be sprayed: 1 min;
- minimum test duration: 3 min
- distance from nozzle to
enclosure surface: between 2,5
m and 3 m.
After this test, the dielectric
withstand test shall be
conducted on the probes.
Minimum degrees of protection
as required in IEC 61851-1.

IPXY Min. Protection Degree: ISO20653 (VDE)

X: Protection against ingress of foreign Mated: X=4 Unmated: X=2
objects
IPXY Min. Protection Degree: IEC 62196-1, 10.1 (VDE)
Y: Protection against water Mated: Y=4 Unmated: Y=4 ISO 20653

Protection against electrical shock No electrical contact established IEC 62196-1, 10.1
between test finger and pilot line
contacts, power lines and neutral Test finger definition : see
line contact 62196-1 fig 2 Umin = 40 V

Humidity treatment After this treatment, the samples IEC 62196-1, 20.3
shall show no damage within the
meaning of the standard. Samples are introduced in the
cabinet at a temperature of T to
T+4 °C stabilized.
Pre-conditioning : Relative
humidity : 91 % to 95 %
Temperature : T=(25 ± 5) °C
Duration : 168h (7 days)
Immediately after pre-
conditioning Insulation
resistance and Dielectric
strength are performed.
ENDURANCE

Min. Max Temperature storage All sample parameters must meet LV 124 , K-01
the specifications.
24 hours (12h each), between -
40 - +85 °C , 2 cycles
Resistance to heat No defect adversely affecting IEC 62196-1, 29.1
correct operation
IEC 62196-1, 29.2

Rev A 18 of 22
 108-94323

The samples are kept for 1 h in

a heating cabinet at a
temperature of (110 ± 5) °C.
Rapid Change of Temperature The samples must be fully functional DIN EN 60068-2-14
before and after the test, and all
parameters must meet the LV 124, K-016
specifications 300 cycles, -40 °C/ 85 °C by 60
minutes per cycle
Humid heat, (cyclic with frost) Test The samples must be fully functional DIN EN 60068-2-38
before, during and after the test, and
all parameters must meet the LV 124, K-09
specifications. 25 °C/55 °C, 10 days, 95 %
humidity with frost combination
Total test duration: 240 h
Number of cycles: 10

Solar irradiation The part must be fully functional DIN 75220

before, during and after the test, and
all parameters must meet the LV 124, K-17
specifications. Simulation of sun and UV
irradiation. For coverage of the
durability of the component of
material fatigue like cracks,
color change.
Test acc. to DIN 75220:
 Mode I.a
 Profile Z-out, table 2+5
 Duration 25 d, (15 dry, 10
wet)
 Cycles: 1
Dry Temperature Storage Product Requirements shall be IEC-60068-2-2, Bb
maintained during the test. The test 120 hours/ 85°C
is continued with functional test
under normal climate condition.

Fluid Resistance Testing The Tested plug shall be fully See list 4.4.1 based on PG 22 B
functional before and after A, attachment E
the test, and all parameters
The chemical must be applied
shall meet the specifications.
to the test object at TRT. Unless
otherwise defined one of the
following applications has to be
selected.

Accelerated Ageing Test – Rubber No crack visible to the naked eye, IEC 62196-1, 15
compounds nor shall the material have become (70 ± 2) °C and 10 days (240 h),
sticky or greasy. for rubber;

Accelerated Ageing Test – thermoplastic No crack visible to the naked eye, IEC 62196-1, 15
nor shall the material have become (80 ± 2) °C and 7 days (168 h), for
sticky or greasy thermoplastic;

Breaking capacity An accessory classified "Not IEC62196-1,22.3

suitable for making and breaking

Rev A 19 of 22
 108-94323

an electrical circuit under load"

shall have sufficient breaking
capacity to interrupt the circuit in
case of a fault, without any
indication of a fire or shock
hazard. The accessory need not
remain functional after the
completion of the test. It shall not
be used for any further tests.
Compliance is checked by testing
the mating accessories in
accordance with 22.2 for up to
three making and breaking
operations, if the accessory
permits, under the indicated load.
Following the test, the accessories
shall comply with a dielectric test in
accordance to 21.3
NOTE
Shall meet visual requirements, show no physical damage, and meet requirements of additional
tests as specified in the Product Qualification and Requalification Test Sequence shown in
Figure 2.
4.8. Product Qualification and Requalification Test Sequence

TEST GROUP (a)

15
TEST OR EXAMINATION 1 2 3 4 5 6 7 8 9 10 11 12 13 14
(c)

TEST SEQUENCE (b)

Test Sample 3 3 3 6 4 2 3 3 4 3 3 2 2 3 3
Visual examination of product 1, 1, 1,7 1, 1, 1, 1, 1,3, 1, 1, 1, 1, 1,3, 1,4 1,3
10 10 7 5 4 5 5 4 3 3 4 5

Insulation resistance Test 6 7 3 3 3 3

Comparative Tracking Index 3

Flammability glow-wire test 2

Dielectric Strength 7 8

Current Load Cyclic 4

Temperature Rise Test 2

Contact Resistance and 9 9 2,6

Temperature Monitoring

Derating temp rise 3,5

Polarization Integrity Test 2

Cable Pull Test / Torque Test 2

Drop test 8

Vehicle drive over Part 1&2 2

Ball pressure test at 4

temperature

Rev A 20 of 22
 108-94323

Cable flexing test 2

Torque Test values for 2

glands

Vibration Test 2

Retention force of the plug in 2

the socket with latching
mechanism

Insertion and withdraw force 2

of the connector, plug in the
socket

10.000 mating/unmating 4, 6
cycles
Enclosure Test: 2
compliance of IP-Code

IPXY X: Protection 3,
against ingress of foreign 6
objects
IPXY Y: Protection 2 2,
against water 4

Protection against 2
electrical shock
Humidity treatment 2
Min. Max Temperature 2 2 4
storage

Resistance to heat 2

Rapid Change of 4 5
Temperature

Humid heat, (cyclic with frost) 5

Test

Solar irradiation 3

Dry Temperature Storage 3 3 5

Fluid Resistance Testing 2

Accelerated Ageing Test – 4

Rubber compounds

Accelerated Ageing Test – 2

thermoplastic
NOTE

(a) Specimens shall be prepared in accordance with applicable Manufacturing Process

Instructions (MPI) and shall be selected at random from current production. Each test group
shall consist of quantities and design as described in the Procedure
(b) Numbers indicate sequence in which tests are performed.
(c) All the single test are listed in column 15

Rev A 21 of 22
 108-94323

LTR REVISION RECORD DWN APP DATE

A Creation of the Design Objective T.Meissner F.Wittrock 18.04.16

Rev A 22 of 22