IEC/TS 62196-4: Plugs and Socket-Outlets for Light Electric Vehicles (LEV)

What is IEC/TS 62196-4?

IEC/TS 62196-4 is a Technical Specification titled “Plugs, socket-outlets, vehicle connectors and vehicle inlets – Conductive charging of electric vehicles – Part 4: Dimensional compatibility and interchangeability requirements for DC pin and bush-tube accessories for Class II or Class III applications.”

While the better-known parts of the IEC 62196 series (such as Type 2 or CCS) focus on full-sized passenger cars, Part 4 is dedicated to Light Electric Vehicles (LEV). This includes e-bikes, mopeds, electric motorcycles, and small industrial robots. Its goal is to provide a standardized DC Charging interface that ensures Interoperability between different LEV manufacturers and charging station providers.

Technical Scope and Configurations

The specification categorizes the Charging Interface based on power levels and the presence of communication pins. It specifically addresses:

• Class II and Class III Applications: Focuses on systems with low to medium voltage ranges (typically up to 120V DC) where safety is managed through double insulation or extra-low voltage.
• Pin and Bush-Tube Design: Establishes the precise Dimensional Compatibility for the contact pins to ensure that a connector from one brand physically fits and electrically connects with an inlet from another.
• System Configurations: Standardizes several “Interface Sheets” (e.g., Configuration S, Configuration T) that define the arrangement of power pins and signal pins.

Safety and Communication

For LEVs, Operational Safety is critical because batteries are often handled in domestic or high-traffic urban environments. IEC/TS 62196-4 mandates:

• Signal Contacts: In addition to power, the interface includes pins for CAN-bus or other Connectivity protocols. This allows the charger to verify the battery’s temperature, state of charge (SoC), and chemistry before initiating current.
• Arcing Protection: Requirements for “first-mate, last-break” sequences to ensure that the power is only applied after the signal pins have confirmed a secure mechanical connection.
• Ingress Protection (IP Rating): Standards for resistance against dust and water, essential for Plugs and Sockets used outdoors in varying weather conditions.

Impact on the LEV Market

The absence of a standard like IEC/TS 62196-4 previously led to a fragmented market where every e-bike brand required a proprietary charger. This specification enables:

• Public Charging Infrastructure: The development of universal charging docks for e-scooter sharing programs.
• Battery Swapping Stations: Providing a standardized interface for automated battery exchange kiosks.
• Reduced E-Waste: Allowing consumers to use the same charger for multiple light vehicles, reducing the need for brand-specific hardware.

Comparison: EV Charging (Part 2/3) vs. LEV Charging (Part 4)