QC/T 1198-2023 PDF English
US$320.00 · In stock · Download in 9 secondsQC/T 1198-2023: Cable assembly with function box of conductive charging for electric vehicles Delivery: 9 seconds. True-PDF full-copy in English & invoice will be downloaded + auto-delivered via email. See step-by-step procedureStatus: Valid
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QC/T 1198-2023: Cable assembly with function box of conductive charging for electric vehicles---This is an excerpt. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.), auto-downloaded/delivered in 9 seconds, can be purchased online: https://www.ChineseStandard.net/PDF.aspx/QCT1198-2023
QC
AUTOMOTIVE INDUSTRY STANDARD
ICS 43.040
CCS T 35
Cable Assembly for Conducting Charging of Electric
Vehicles with a Function Box
Issued on. DECEMBER 20, 2023
Implemented on. JULY 1, 2024
Issued by. Ministry of Industry and Information Technology of the People’s
Republic of China
Table of Contents
Foreword... 7
1 Scope... 8
2 Normative References... 8
3 Terms and Definitions... 10
4 Technical Requirements... 10
5 Test Methods... 19
6 Inspection Rules... 30
7 Marking, Packaging, Transportation and Storage... 30
1 Scope
This Document specifies technical requirements, test methods, and requirements for marking,
packaging, transportation, and storage of cable assembly for conducting charging of electric
vehicles with a function box.
This Document applies to cable assembly for conducting charging of electric vehicles with a
function box with a rated current not exceeding 10 A (hereinafter referred to as "cable
assembly").
2 Normative References
The provisions in following documents become the essential provisions of this Document
through reference in this Document. For the dated documents, only the versions with the dates
indicated are applicable to this Document; for the undated documents, only the latest version
(including all the amendments) is applicable to this Document.
GB/T 1002 Single phase plugs and socket-outlets for household and similar purposes -
Types, basic parameters and dimensions
GB/T 2099.1 Plugs and socket-outlets for household and similar purposes - Part 1.General
requirements
GB/T 2423.5 Environmental testing - Part 2.Test methods - Test Ea and guidance. Shock
GB/T 4207-2022 Method for the determination of the proof and the comparative tracking
indices of solid insulating materials
GB/T 4208-2017 Degrees of protection provided by enclosure (IP code)
GB 4824-2019 Industrial, scientific and medical equipment - Radio-frequency disturbance
characteristics - Limits and methods of measurement
GB/T 6829-2017 General Requirements for Residual Current Operated Protective Devices
GB/T 11918.1-2014 Plugs, socket-outlet and couplers for industrial purposes - Part 1.
General requirements
GB 17625.1-2012 Electromagnetic compatibility – Limits - Limits for harmonic current
emissions (equipment input current ≤16 A per phase)
GB/T 17626.4-2018 Electromagnetic compatibility - Testing and measurement techniques
-Electrical fast transient/burst immunity test
GB/T 17626.5-2019 Electromagnetic compatibility - Testing and measurement techniques
-Surge immunity test
GB/T 17626.6-2017 Electromagnetic compatibility - Testing and measurement techniques
-Immunity to conducted disturbances, induced by radio-frequency fields
3 Terms and Definitions
For the purposes of this Document, the terms and definitions given in GB/T 18487.1 and GB/T
20234.1-2023 and the following apply.
3.1 Vehicle coupler
A component that can connect a cable to an electric vehicle, consisting of a vehicle connector
and a vehicle socket.
[SOURCE. GB/T 20234.1-2023, 3.6]
3.2 Vehicle connector
The movable part of the vehicle coupler that is connected to the charging cable.
[SOURCE. GB/T 20234.1-2023, 3.8]
3.3 Function box
A device that is contained in the Mode 2 cable assemblies, implementing control guidance
functions and safety functions.
3.4 Operating mode
It is used to describe the input and output status of the sample under test.
Operating mode 1.The sample under test is not connected to the input and output.
Operating mode 2.The input end of the sample under test is connected to the AC power supply,
but it is not in the charging output state.
Operating mode 3.The input and output of the sample under test are both in the rated state.
4 Technical Requirements
4.1 Requirements for functional status level
The functional level of the cable assembly shall meet the relevant requirements of Clause 6 of
GB/T 28046.1-2011.
Level A. All functions of the cable assembly meet the design requirements during and after the
test.
Level B. All functions of the cable assembly meet the design requirements during the test, but
one or more functions are allowed to exceed the specified tolerance. All functions shall
automatically recover to the specified limits after the test.
Level C. One or more functions of the cable assembly do not meet the design requirements
during the test, but all functions can automatically recover to normal operation after the test.
Level D. One or more functions of the cable assembly do not meet the design requirements
during the test and cannot automatically recover to normal operation after the test; and the
device or system needs to be reactivated through simple operations.
4.2 General requirements
4.2.1 The easily accessible surface of the cable assembly for conductive charging of electric
vehicles with a function box shall be free of burrs, flash and similar sharp edges.
4.2.2 The cable assembly housing shall be marked with the manufacturer's name or trademark,
product model, rated voltage and rated current, etc.; and the writing shall be clear and not easy
to erase. The function box shall have a high-voltage warning mark.
4.2.3 The vehicle connector of the cable assembly shall comply with the provisions of GB/T
20234.1-2023 and GB/T 20234.2-2015.
4.2.4 The three-core plug of the cable assembly shall comply with the provisions of GB/T
2099.1 and GB/T 1002.
4.2.5 The shell protection level of the vehicle connector and the three-core plug of the cable
assembly and the corresponding socket after being plugged in shall at least meet the
requirements of IPXXD in GB/T 4208-2017.
4.3 Control and guidance function
The control and guidance function of the cable assembly shall comply with the relevant
provisions of GB/T 18487.1.
4.4 Safety protection function
4.4.5 Residual current protection
The cable assembly shall at least be able to meet the operating characteristic requirements for
type A residual current protection devices in GB/T 6829-2017.The rated residual operating
current values of different products should refer to the provisions of Table 1.
4.4.6 Overtemperature protection
The function box of the cable assembly shall have an overtemperature protection function.
When the temperature exceeds its set value, the function box shall enter the overtemperature
protection state, and the functional state level shall be no lower than Level D. When the
temperature returns to normal, it shall be able to charge normally. The specific temperature
value and response time shall be subject to the manufacturer's agreed requirements.
4.4.7 Grounding warning function
When the cable assembly cuts off the electrical connection of the protective grounding
conductor before charging, the charging shall not be started. When the electrical connection of
the protective grounding conductor is cut off during charging, the output shall be cut off within
100 ms, and an alarm shall be given through an indicator light or other means.
4.5 Electrical insulation performance
4.5.1 Insulation resistance
The insulation resistance of the cable assembly shall meet the following requirements.
a) The insulation resistance between each independent live port loop and the ground
(housing) shall be no less than 100 MΩ;
b) The insulation resistance between each live port loop that is not electrically connected to
each other shall be no less than 100 MΩ.
4.5.2 Withstand voltage
The withstand voltage performance between each independent live port circuit of the cable
assembly and the ground (housing), and between each live port circuit that is not electrically
connected to each other shall meet the requirements that under 2,000 V AC, test duration of 1
min, there is no breakdown and arc phenomenon, and leakage current shall be no greater than
10 mA.
4.5.3 Impulse withstand voltage
Apply 3 short-term impulse voltages of positive polarity and 3 short-term impulse voltages of
negative polarity lightning waves between each independent live port circuit of the cable
assembly and the ground (housing), and between each live port circuit that is not electrically
connected to each other, with each interval no less than 5 s, impulse voltage 2.5 kV, impulse
waveform 1.2/50 μs, power supply impedance 500 Ω, other circuits and exposed conductive
parts are grounded during the test, and no breakdown discharge shall occur at the test position.
4.6 Environmental adaptability
4.6.1 Environmental conditions
4.6.1.1 Ambient temperature
Unless otherwise specified, the cable assembly shall meet the ambient temperature limits
specified in Table 2.
4.6.1.3 Altitude
Altitude is no higher than 4,000 m.
4.6.2 Storage at low temperature
The storage performance at low temperature of cable assemblies shall meet the requirements of
5.1.1.1 in GB/T 28046.4-2011.
4.6.3 Operating at low temperature
The operating performance at low temperature of cable assemblies shall meet the requirements
of 5.1.1.2 in GB/T 28046.4-2011.
4.6.4 Storage at high temperature
The storage performance at high temperature of cable assemblies shall meet the requirements
of 5.1.2.1 in GB/T 28046.4-2011.
4.6.5 Operating at high temperature
The operating performance at high temperature of cable assemblies shall meet the requirements
of 5.1.2.2 in GB/T 28046.4-2011.
4.6.6 Temperature cycle
The temperature cycle performance of the cable assembly shall meet the requirements of 5.3.1
of GB/T 28046.4-2011.
5 Test Methods
5.1 Appearance structure
5.1.1 Check the appearance and structure of the product by observation and manual test.
5.1.2 Use a cotton cloth soaked in water to wipe the mark for 5 s; and then use a cotton cloth
soaked in gasoline to wipe for 5 s; the mark after wiping is still clearly visible.
NOTE. It is recommended to use gasoline composed of hexane solvent, the volume content of the
aromatic agent of the hexane solvent is up to 0.1%; the kauri-butanol value is about 29; the initial boiling
point is about 65 ℃; the dry point is about 69 ℃; and the concentration is about 0.68 g/cm3.
5.2 Control and guidance function test
The test is carried out in accordance with the requirements of 6.4 in GB/T 34657.1-2017.
5.3 Safety protection function test
5.3.1 Input overvoltage protection
Connect the cable assembly to the load and the control guide simulation device; start the cable
assembly under the rated input conditions; make it operate under the rated power state;
gradually adjust the AC input voltage to the overvoltage protection value; and observe the
output state of the cable assembly.
5.3.2 Input undervoltage protection
Connect the cable assembly to the load and the control guide simulation device; start the cable
assembly under the rated input conditions; make it operate under the rated power state;
gradually adjust the AC input voltage to the undervoltage protection value; and observe the
output state of the cable assembly.
5.3.3 Output overload protection
Connect the cable assembly to the load and the control guide simulation device; under the rated
input conditions, make the cable assembly under the rated power state; adjust the load to
simulate the output overload; and observe the output state of the cable assembly.
5.3.4 Output short-circuit protection
Connect the cable assembly to the load and the control guide simulation device; under the rated
input conditions, make the cable assembly under the rated power state; adjust the load to
simulate the short-circuit fault; and observe the output state of the cable assembly.
5.3.5 Residual current protection
Test in accordance with the provisions of GB/T 6829.
5.3.6 Overtemperature protection
Put the cable assembly in a temperature chamber; connect the load and control guide simulation
device; set the output voltage to the rated voltage; under the rated input conditions, put the cable
assembly under the rated power state; and observe the output state of the cable assembly when
the temperature of the temperature chamber exceeds its set value.
5.3.7 Grounding warning
Connect the cable assembly to the load and control guide simulation device; cut off the
grounding wire connection before and during operation; and observe the output status of the
cable assembly.
5.4 Electrical insulation test
5.4.1 Insulation resistance
5.4.2 Dielectric strength
5.4.3 Impulse withstand voltage
Apply short-term impulse voltages of 3 positive and 3 negative lightning waves, each with a
interval of no less than 5 s; impulse voltage 2.5 kV, pulse waveform 1.2/50μs, power supply
impedance 500 Ω; and other circuits and exposed conductive parts are grounded during the test.
Test location. between non-electrically connected live circuits, and between each independent
live circuit and the ground (metal casing).
5.5 Environmental adaptability test
5.5.1 Storage at low-temperature
Put the cable assembly in a temperature chamber with an initial temperature of room
temperature and connect all electrical harnesses intact; adjust the temperature of the
temperature chamber to -40 ℃ ± 2 ℃; and the cable assembly is in a non-powered state during
storage at low-temperature for 24 h.
5.5.4 Operating at high temperature
After the test of storage at high temperature, adjust the temperature of the temperature chamber
to the temperature value of operating at high temperature and keep it for 2 h; then power on the
cable assembly to make it operate at rated power and continue to operate for 48 h.
5.5.5 Temperature cycle test
According to the requirements of 5.3.1 in GB/T 28046.4-2011, the cable assembly is placed in
a temperature chamber and subjected to the following temperature change environment. The
cable assembly is required to operate normally when the temperature reaches -40°C; and during
the period of 210 min to 410 min, it takes operating mode 3; and the test cycle is 30 times. The
test time and corresponding temperature requirements are shown in Table 4.
5.5.6 Temperature shock test
Time/min Temperature/°C
According to the requirements of 5.3.2 of GB/T 28046.4-2011, set the high temperature to 85 ℃,
20 min; low temperature to -40 ℃, 20 min; conversion time is less than 30 s; the number of
cycles is 100 times (1 time for hot and cold alternation), and take operation mode 1.
5.5.7 Damp heat cycle test
According to the requirements of 5.6.2.2 of GB/T 28046.4-2011, set the upper limit temperature
to 55 ℃; the number of cycles. 6; each cycle is 24 h. Perform insulation resistance and dielectric
strength retests 2 h before the end of the damp heat test.
5.5.8 Salt spray test
According to the requirements of 5.5.1 of GB/T 28046.4-2011, during the test, the cable
assembly takes operating mode 1.Test chamber temperature. 35°C ± 1°C; brine concentration.
5%; brine pH value 6.5~7.2; start the test machine for testing, time. 48 h.
5.5.9 High-altitude test
Place the cable assembly in a high-altitude environment chamber; simulate the altitude of 4,000
m atmospheric pressure (62 kPa); connect the rated load and control guide simulation device;
the cable assembly takes operation mode 3, test time. 24 h.
5.5.10 Protection level
Perform the protection level test in accordance with the provisions of GB/T 4208.
5.5.11 Corrosive environment test
Perform the test in accordance with the "luggage compartment" and "external installation"
required by Table 1 in GB/T 28046.5-2013; select at least 3 solvents; and the cable assembly
takes operation mode 1.
5.6 Mechanical properties test
6 Inspection Rules
If all specimens pass all tests, the specimens are deemed to meet the requirements of this Part.
If a specimen fails a test, then this test and the previous test or tests that may have affected the
test results shall be repeated on another group of 3 specimens. When retesting, all 3 specimens
shall pass the test.
7 Marking, Packaging, Transportation and Storage
7.1 Marking
The following contents shall be clearly marked.
7.2 Packaging
7.2.1 The documents and attachments accompanying the product shall include. packing list,
exit-factory inspection report, certificate of conformity, wiring diagram and installation and
operation instructions.
7.2.2 There shall be protective measures in the product packaging box to prevent the product
from being bumped. The outer surface of the box shall be marked with rainproof, moisture-
proof, and allowed stacking layers, etc.
7.3 Transportation
7.3.1 Rainproof, snow-proof, and waterproof measures shall be taken during transportatio.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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