IEC 62196 EV Connector Temperature Rise and Short-Time Current Test System 6500A
Designed for IEC 62196 compliance testing, this EV Connector Temperature Rise and Short-Time Current Test System provides programmable current output up to 6500A and 16-channel temperature measurement for CCS1, CCS2, Type 1, Type 2, EV plugs, EV sockets, vehicle inlets and charging cable assemblies.
Compliance Standards
In compliance with IEC 62196-1 clause 12.3, clause 24, table 10, clause 34.2, 34.4, and 35.4, IEC 62196-2, IEC 62196-3, and other relevant standards.
The EV Connector Testing Equipment is specially designed for IEC 62196 compliance testing of EV charging connectors, plugs, sockets, vehicle inlets and cable assemblies.
The system integrates high-current output up to 6500A and 16-channel temperature measurement, enabling accurate temperature rise testing, current carrying capability testing and short-time withstand current testing for AC and DC charging interfaces.
Suitable for:
- CCS1 Connectors
- CCS2 Connectors
- Type 1 Connectors
- Type 2 Connectors
- NACS@TPC Connectors
- CHAdeMO Connectors
- GB/T AC Connectors
- GB/T DC Connectors
- Chaoji-1 Connectors
- Chaoji-2 Connectors
- EV Plugs
- EV Sockets
- Vehicle Inlets
- Charging Cable Assemblies
System Overview
This comprehensive test system evaluates temperature rise in electric vehicle plugs and sockets at rated current, while also assessing surface heating of electrical accessories during load connection. The system supports short-duration, high-current withstand testing of ground contacts, ensuring reliable performance and safety verification.
Equipped with proprietary software and computer control, the system enables fully automated test execution and data analysis. Its intuitive operation and precise performance provide an efficient solution for temperature rise assessment and compliance verification of electric vehicle charging interfaces and related components.
Key Features
- Maximum Test Current up to 6500A
- 16-Channel Temperature Measurement
- PLC Automatic Control
- Real-Time Temperature Monitoring
- Current Stability Control
- Automatic Data Recording
- Trend Curve Display
- Report Generation
- Emergency Stop Protection
- Over-Current Protection
Technical Specifications
| Parameter |
Specification |
| Output Workstation |
1 DC output station |
| Maximum Output Voltage |
DC less than 15V |
| Constant Adjustable Test Current Output |
DC 200-6500A |
| Current Display Accuracy |
±(0.25% of reading + 0.25% of range), resolution 1A |
| Voltage Display Accuracy |
±(0.25% of reading + 0.25% of range), resolution 0.01V |
| Test Current Stability |
±(1% of set value + 0.5A), response time approximately 1s |
| Control Contact Power Supply |
Current range AC (0-2) A |
| Operating Modes |
Continuous mode, On/Off mode, Automatic temperature control mode |
| Temperature Measurement Range |
0-260°C, Accuracy: ±0.3% of reading + 1°C; Resolution: 0.1°C |
| Temperature Measurement Points |
16 channels (including 1 point for measuring ambient temperature) |
| Thermocouple Types Supported |
J, K, T, E, S, N, B, R types |
| Thermocouple Used for Measurement |
USA Ω Company K-type 30AWG fine wire thermocouples, length 2 meters, 20 pieces total |
Operating Mode Details
- Continuous Mode: Test Time: 0.01-99.99 hours
- On/Off Mode: Power On/Off Time: 0.01-99.99 hours, Count: 1-9999 times with automatic stop
- Programmable Control: Configurable settings according to IEC62196 with time and current combinations
- Automatic Temperature Control Mode: Set stable temperature rise value (0-100°C) with ±0.5°C stability accuracy; automatically calculates required current for desired temperature rise
IEC 62196 Temperature Rise Test Setup
- Plug
- Socket
- Thermocouples
- Current Source
- Temperature Acquisition
System Images
This testing system is widely used by:
- EV Connector Manufacturers
- EVSE Manufacturers
- Automotive OEM Laboratories
- Certification Laboratories
- Third-Party Testing Organizations
- Government Testing Institutes
Applicable standards include:
- IEC 62196-1
- IEC 62196-2
- IEC 62196-3
- IEC 62752
- SAE J1772
- IEC 61851
Typical Test Functions
Temperature Rise Test
Used to verify connector thermal performance under rated current conditions.
Short-Time Current Test
Used to evaluate connector capability under high short-time current loading.
Current Carrying Capability Test
Used to assess long-term electrical performance and contact reliability.
Protective Earth Circuit Test
Used to verify grounding circuit performance.
Why Temperature Rise Testing Matters?
Temperature rise is one of the most critical indicators of EV charging connector safety and reliability.
Poor contact design, insufficient contact pressure, oxidation, plating degradation, or conductor defects can cause excessive heat generation during charging.
IEC 62196 requires charging connectors to maintain acceptable temperature rise levels under rated current conditions.
Accurate temperature rise testing helps manufacturers:
• Identify contact resistance issues
• Optimize terminal structures
• Improve charging reliability
• Reduce failure risk
• Accelerate certification approval
• Ensure long-term field performance
What standards does this system comply with?
IEC 62196-1, IEC 62196-3, SAE J1772 and related EV charging connector standards.
What is the maximum test current?
The system can provide test current up to 6500A.
Can the system test CCS2 connectors?
Yes. The system is suitable for CCS1, CCS2, Type 1 and Type 2 and others EV charging connectors.
How many temperature channels are available?
The standard configuration includes 16 temperature measurement channels. The temperature measuring channels can be customized.
Can the system generate test reports automatically?
Yes. Test data can be recorded, exported and converted into test reports automatically.
Looking for IEC 62196 EV Connector Testing Equipment?
Sinuo provides complete testing solutions for:
- Temperature Rise Test
- Short-Time Current Test
- Insertion and Withdrawal Force Test
- Cable Anchorage Test
- Mechanical Operation Test
- Breaking Capacity Test
- Drive Over Test
- Short-Circuit Withstand Current Test
Contact our engineering team today to receive a customized testing solution for your EV connector products.
