EV-PLUG-16/63A - FCI Electronics Interconnection Solutions

FCI MVL Division

OWERS3P .Power Supply Safe Solutions

EV-PLUG-16/63A

Charge plug 16A – 63A 2010

FCI COPYRIGHT

2FCI – MVL 2010 FCI COPYRIGHT

Introduction

FCI has been launching several innovative high power connectors, named:

These are developed to meet the booming demand for high performance but cost effective high power interconnections from virtually all automotive OEM worldwide starting with Electric Vehicle (EV) programs scheduled for launch in 2010/11

Building on FCI Motorized Vehicles in-depth experience and expertise in the automotive sector, the new High power Interconnect and charge plugs incorporate a serie of ground- breaking features that reflect the unique challenges presented by EV and HEV applications, along with the requirement to keep size, weight and cost to a minimum.

OWER S3P .OWER S3P .Power Supply Safe Solutions


Charge plug applications

EVSE = Electric Vehicle Supply Equipment

Since May 2010, standardization committees have agreed on these product designations.They will be used from now on by all parties involved in charge plug business

OUT LETEVSE TERMINOLOGY

SAE J1772 – 16/32A

IEC 62196-2-2–16/32/63A

Ren

ault

©

IEC 62196-2-1–16/32ASLOW CHARGE

AC current

SLOW & FAST CHARGE AC current

Example only AC/DC ‘Combo’

VERY FAST CHARGEWhich standard in future?

Example – CHAdeMO


International standard IEC-62196 for connection devices 3 main interface definitions

SpecificationIEC-62196-1 General specificationsIEC-62196-2 xEV charge plug interfaces

Type-1introduced by YAZAKIdescribed also in SAE-J1772 standard1-phase AC 250V - 32A (up to 80A in USA)

Type-2introduced by MENNEKES, modified by FCI-REMA3-phase AC up to 500V – 63A and 1-phase up to 70A‘Vehicle’

Connector

female terminalsInlet

male terminals‘Wall’:

Plug

male terminalsOutlet

female terminals

Type-3introduced by SCAME, with Schneider and Legrand3 versions AC current

3-phase 500V - 32A (2 pilot contacts)1-phase 250V – 32A (2 pilot contacts)1-phase 250V-16A (1 pilot contact)

Type-1

Type-3

Type- 2 Connector

Type- 2 Plug


Interface choices and their combinations will vary across regions

Charge plugs product descriptions 3 interfaces – 4 product types


Line protection modes 1-2-3Domestic charging

Mode 1 (16A)No line protection

Mode 2 (16A)Portable line protection

CCID or BCB * * (Battery Connection Box)

Mode 3 (16A/32A)Connector to Plug jumper

Example here below Type 2 + Type-3

wall Electric Management Box


General view EV-PLUG-16/63A Vehicle side

InletMale terminals

ConnectorFemale terminals

Fully compatible with IEC62196-2-2


1st serial application on Renault ZOE (2012)


From IEC norm

Electrical circuit

No switch in plug

Differences versus SAE J1772 norm

No resistor in inlet

Usage of way according single or three phase


Inlet interface (male terminals) Connector interface (female terminals)

Interface definition vehicle side


Electrical 16, 32 or 63 A400 V - High voltage insulation protection1-phase, 2-phase, 3-phase possibilities (1-L3, N, PE)additional 2x 30V/2A signal terminals (control pilot)

Mechanical10 000 mating cycles Can handle 5 hot disconnects

EnvironmentalAmbient temperature – 40°c + 50°cIP67 (mated)IP67 (unmated inlet)

IEC 16/63A charge connector Specifications according to IEC 62196-2-2


Male terminal with front plastic protection on power

Terminal sizes: 6 mm for power and ground, 3 mm for signalsPlating : nickelCable crimping : hexagonal

Terminal systemFemale terminals with calibrated spring device to precisely control mating/un-mating forces

Spring

Contact beams


Flap with seal

Area and fixation for locking finger mechanism (not

supplied by FCI)

Interfacial seal protected

Inlet main technical features

Drain for water egress

IP2XB protection

Possible integrated thermal protection against abnormal temperature increase


Inlet general views

Cover (possible different 90°cable exit)

Rear viewFront view

Hole for locking finger

Flap closed (right or left side)


Inlet main dimensions


Interfacial sealing internal area protected

Hole for locking finger

Plug general view


THANK YOU !

EV-PLUG-16/63A - FCI Electronics Interconnection Solutions

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