IEC 62196-1 AC Charging Gun Comprehensive Test System
This test system is mainly used for functional inspection of AC plugs according to Chinese (GB), European (EU), and American (UL) standards. Each plug can be assigned a unique QR code, and the test results are automatically saved in reports. Qualified results can be printed directly. All functions are tested automatically in a single run, providing high efficiency and labor savings, making it suitable for mass production full inspection in factories.
Compliance Standards: Conforms to IEC 62196-1Ed.4CDV 2020 clause 12.2, 21.2, 21.3, IEC 62196-3-1 ed1 clause 16.102.
1.Breakage, continuity, short circuit, and wiring sequence tests for each individual wire
2.Continuity resistance test of the main conductor
3.Built-in resistance measurement (including both pressed and unpressed states of push-button switches)
4.Current carrying capacity verification and voltage drop measurement
5.Insulation test between wires
6.Dielectric withstand (high-voltage) test between wires
7.Thermocouple wire testing
| Power Supply | Single-phase AC 220V / 50Hz |
|---|---|
| Air Supply | 0.6 MPa |
| Control System | PLC + Industrial PC |
| Barcode Scanning |
The device comes with a scanner to read barcodes or QR codes on the test samples. Scan the product before testing; after the test, the scanned code is automatically associated with the test record, enabling traceability. |
| Wire Continuity Tests |
Break, continuity, short circuit, and wiring sequence tests are performed via PLC Input/Output scanning. PLC automatically determines pass/fail. |
| Built-in Resistance Range |
1 – 5000 Ω, Accuracy: 1% Upper and lower limits can be set to determine product quality. |
| CC & PE Resistance (Button Pressed / Not Pressed) |
16A AC plug: Not Pressed RC: 680Ω, Pressed RC+R4:3.38 kΩ 32A AC plug: Not Pressed RC: 220Ω, Pressed RC+R4:3.52 kΩ 63A AC plug: Not Pressed RC: 100Ω, Pressed RC+R4:3.4 kΩ The measurement accuracy of the resistance must reach 1%–2%. |
| Thermistor Testing Range |
100 – 50,000 Ω, Accuracy: 2% Upper and lower limits can be set to determine continuity quality |
| Current Carrying Capacity & Voltage Drop Test |
Measures voltage drop across connectors under rated and overload current conditions. Built-in three-phase adjustable transformer: 0-380V output, adjustable three-phase load 0-35A. Supported test ranges:
|
| Insulation Resistance Test |
Single-phase: L-N, L-E, E-N Three-phase:L1/L2/L3/E-N, L1/L2/L3/N-E, N/L2/L3/E-L1, L1/N/L3/E-L2, L1/L2/N/E-L3 Parameters: 1.Test voltage: DC 100 – 1000V (adjustable) 2.Lower limit: 1 M–1 GΩ (adjustable) 3.Accuracy: ±5% 4.Alarm when resistance < set value |
| Dielectric Withstand (Hi-Pot) Test |
Single-phase: L-N, L-E, E-N Three-phase: L1/L2/L3/E-N, L1/L2/L3/N-E, N/L2/L3/E-L1, L1/N/L3/E-L2, L1/L2/N/E-L3 Parameters: 1.Test voltage: AC 0 – 5 kV / DC 0 – 6 kV (adjustable) 2.Leakage current limit: AC 0.1 – 20 mA, DC 0.01 – 5 mA 3.Accuracy: ±1.5% + 3 digits 4.Digital display of voltage, automatic programmable adjustment 5.Alarm if leakage current exceeds set value |
| Test Station | Single station, one product per test |
| Plug Holders |
EU AC vehicle plug holder, EU AC pedestal plug holder, GB AC plug holder, US AC plug holder |
| Tail Plate |
Special pressing fixture matching the test product, with clamp and protective plate |
| Socket Height | 750 – 1000 mm, ergonomically designed |
| Computer Software |
1.Supports Win 7 and Win 10, All parameter settings can be configured through the software. 2.Each product’s test results are saved to the computer in real time for easy access, viewing, and analysis. 3.Communication interfaces are reserved for optional connection to MES systems, allowing test data to be uploaded to the MES database for management and control. 3.Test data is stored immediately after completion. 4.Stored test data can be exported in TXT or Excel format. |
| Dimensions | W 900 × D 800 × H 1800 mm |
| Weight | approx. 300 kg |
| Others |
1.Mobile casters with locking function. 2.MES Connectivity: Optional, additional cost applies. |
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