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[Including 2024XG1] Safety technical requirements of charger for electric bicycles
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GB 42296-2022: PDF in English GB 42296-2022
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.140
CCS Y 14
Safety technical requirements of charger for electric bicycles
ISSUED ON: DECEMBER 29, 2022
IMPLEMENTED ON: JULY 01, 2023
Issued by: State Administration for Market Regulation;
Standardization Administration of PRC.
Table of Contents
Foreword ... 3
1 Scope ... 4
2 Normative references ... 4
3 Terms and definitions ... 5
4 Categories of electric shock protection ... 8
5 Requirements ... 8
6 Test methods ... 24
7 Signs, warnings, instructions ... 31
8 Implementation of standards ... 33
Appendix A (Informative) Emission test flow chart within frequency band of 30 MHz
~ 1000 MHz ... 34
Appendix B (Informative) Examples of clearance and creepage distance test of charger
... 35
Appendix C (Informative) Charger test circuit ... 36
Appendix D (Informative) Immunity test method ... 37
References ... 38
Safety technical requirements of charger for electric bicycles
1 Scope
This document stipulates the technical requirements for electric shock protection
categories, safety, signs, warnings, instructions for use of electric bicycle chargers;
describes the corresponding test methods.
This document applies to chargers for electric bicycles, that comply with GB 17761.
This document does not apply to charging facilities, such as on-board chargers,
charging/swapping cabinets, charging piles, fast charging stations for electric bicycles.
2 Normative references
The contents of the following documents constitute essential provisions of this
document through normative references in the text. Among them, for dated reference
documents, only the version corresponding to the date applies to this document; for
undated reference documents, the latest version (including all amendments) applies 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 2423.1 Environmental testing - Part 2: Test methods - Tests A: Cold
GB/T 2423.2 Environmental testing - Part 2: Test methods - Tests B: Dry heat
GB/T 2423.3 Environmental testing - Part 2: Testing method - Test Cab: Damp heat,
steady state
GB/T 2423.10-2019 Environmental testing - Part 2: Test methods - Test Fc:
Vibration (sinusoidal)
GB/T 4208-2017 Degrees of protection provided by enclosure (IP code)
GB 4343.1 Electromagnetic compatibility requirements for household appliances,
electric tools and similar apparatus - Part 1: Emission
GB 4706.1-2005 Household and similar electrical appliances - Safety - Part 1:
The state of the charger, where it works based on normal use, when it is connected
to the power source.
Note: Including high efficient charging, high voltage charging, trickle charging and other
states, as well as the maximum charging current and voltage states stated in the instructions.
4 Categories of electric shock protection
4.1 Category I charger
Protection against electric shock not only relies on basic insulation, but also includes a
charger with additional safety measures. The charger's protection measure is to connect
the accessible live parts to the ground protective conductor in the fixed parts of the
facility, so that the basic insulation fails, whilst the accessible live parts will not become
live. This type of charger has a protective ground.
Note: This protection measure includes protective conductors in power cords. Category I
chargers may contain category II structures.
Example: The input terminal is a single-phase two-pole charger, which has a grounded plug.
4.2 Category II charger
Electric shock protection not only relies on basic insulation, but also chargers that
provide additional safety measures, such as double insulation or reinforced insulation.
This type of charger has no protective grounding.
Example: A charger with a single-phase two-pole plug as the input terminal.
5 Requirements
5.1 Machinery safety and structure
5.1.1 Enclosure shock
After testing according to the method specified in 6.1.1, the charger shall comply with
the provisions of 21.1 in GB 4706.1-2005.
5.1.2 Drop
After testing according to the method specified in 6.1.2, the charger shall comply with
the provisions of 8.1, 15.1.1, 16.3, Chapter 29 of GB 4706.1-2005.
5.1.3 Vibration
After testing according to the method specified in 6.1.3, the charger shall meet the
following requirements:
a) All relevant parts are not deformed or fallen off;
b) Comply with the provisions of 5.2.2;
c) Can work normally.
5.1.4 Structure
5.1.4.1 The structure of the charger shall meet the following requirements:
a) Eliminate rough or sharp edges, that pose a hazard to the user during normal use
or user maintenance;
b) Power the output circuit, through an isolation device (transformer, etc.);
c) Wood, cotton, silk, plain paper and similar fibrous or hygroscopic materials shall
not be used as insulating materials, unless otherwise impregnated.
5.1.4.2 The protective impedance shall consist of at least two separate components, the
impedance of which shall not change significantly, during the lifetime of the appliance.
If any of these components is short-circuited or open-circuited, the value specified in
8.1.4 of GB 4706.1-2005 shall not be exceeded.
Note: Resistors complying with 5.5.6 in GB 4943.1-2022 and Y-class capacitors complying
with GB/T 6346.14-2015 are considered to be sufficiently stable impedance components.
5.1.4.3 Appliances connected to the power supply through a plug shall be constructed,
so that when the pins of the plug are touched during normal use, there will be no risk
of electric shock due to overcharged capacitors.
Note: Capacitors with a rated capacitance of no greater than 0.1 μF are not considered to cause
an electric shock hazard.
5.1.5 Internal wiring
The internal wiring of the charger shall meet the following requirements.
a) When bushings are used as additional insulation for internal wiring, hold it in
place by a reliable means.
b) The wiring path is smooth and has no sharp edges.
c) The wiring is protected, so that it does not come into contact with burrs, cooling
fins or similar objects, that may cause damage to the insulation. There is a metal
hole through which insulated wires pass; it has a flat, smooth surface or an
insulating sleeve.
Test according to the method specified in 6.2.4. The structure and casing of the charger
shall provide adequate protection against accidental contact with live parts.
5.2.5 Abnormal operation
5.2.5.1 Wrong connection
Carry out the test according to the method specified in 6.2.5.1. The charger shall have
no current output; there is no electric shock, fire or mechanical hazard. The charger
shall work properly, when connected correctly.
5.2.5.2 Short circuit
Carry out the test according to the method specified in 6.2.5.2. The charger shall be free
of any faults, electric shock, fire, mechanical hazards.
5.2.5.3 Fan stalling
The charger, which is equipped with a fan, is tested according to the method specified
in 6.2.5.3; meanwhile it shall comply with the requirements of 5.2.2.
5.2.5.4 Component failure
Conduct the test according to the method specified in 6.2.5.4. Any component in the
charger circuit, that is short-circuited or open-circuited (except components that meet
the requirements of basic insulation, supplementary insulation, reinforced insulation),
shall not have the following phenomena:
a) Electric shock, fire, mechanical hazards;
b) Lithium-ion battery chargers produce an output voltage, that is 15% higher than
the rated maximum output voltage; lead-acid battery chargers produce an output
voltage, that is 20% higher than the rated maximum output voltage;
c) A current is generated that lasts longer than 1.0 s and the effective value of the
output current is higher than 200% of the rated current.
After the above test, the charger is cooled to room temperature and shall comply with
the requirements of 5.2.2.
5.2.6 Fuse
5.2.6.1 The input terminal of the charger shall be equipped with an independent fuse;
its output terminal is on the circuit board AND an independent fuse shall be installed
between it and the output wire.
5.2.6.2 The nominal current specification of the charger’s output fuse shall not be
greater than three times the nominal rated output current.
5.3.1 Low temperature
After testing according to the method specified in 6.3.1, the charger shall work normally.
5.3.2 High temperature
After testing according to the method specified in 6.3.2, the charger shall work normally.
5.3.3 Constant damp heat
After testing according to the method specified in 6.3.3, the electrical strength shall
comply with the requirements of 5.2.2.
5.3.4 Prevention of foreign matter intrusion
Carry out the test according to the method specified in 6.3.4. The test probe shall not
touch live parts.
5.3.5 Waterproof
After testing according to the method specified in 6.3.5, the charger shall work normally
AND the electrical strength shall meet the requirements of 5.2.2.
5.4 Heating and thermal runaway
5.4.1 Temperature rise
Carry out the test according to the method specified in 6.4.1. The temperature rise of
the charger surface, power cord, output cord shall meet the following requirements:
a) For metallic material, it is ≤ 30 K;
b) For non-metallic material, it is ≤ 50 K.
5.4.2 Over-temperature protection
Carry out the test according to the method specified in 6.4.2. The charger shall cut off
the output current within 15 minutes.
5.4.3 Overcharge cut-off
Carry out the test according to the method specified in 6.4.3. When the charger charges
the battery in the high efficient charging range, when the battery charge does not exceed
1.20 C (rated capacity), the charger shall automatically transfer to the next charging
stage (state), OR cut off the output current.
5.4.4 Delayed cut-off
Carry out the test according to the method specified in 6.4.4. When the charger charges
the battery in the high voltage charging range, the duration shall not exceed 180 minutes.
The charger shall automatically transfer to the next charging stage (state), OR cut off
the output current.
When the charger enters the trickle charging stage and the duration does not exceed 180
minutes, it shall automatically cut off the output current.
Note: Lithium-ion battery chargers and other chargers designed without trickle charging stage
are not evaluated for the cut-off function in trickle charging stage.
5.5 Output interface safety
5.5.1 The output interface of the charger (nominal voltage 48 V and below) shall not be
plugged into the input interface, that complies with the provisions of GB/T 2099.1 and
GB/T 1002.
5.5.2 The plug and socket systems of chargers of different battery types cannot be
plugged into each other. When the charger charges an unsuitable battery pack system,
there shall be no output.
Example: The output interfaces of two types of chargers, lead-acid battery charger and lithium-
ion battery charger.
5.5.3 The two metal conductive parts of the positive and negative poles of the DC output
terminal of the charger cannot be touched at the same time.
5.5.4 The effective value of the no-load output voltage of the charger shall not be higher
than 42.4 V.
5.5.5 The charger and the battery pack (system) being charged shall have a mutual
recognition and collaboration agreement. Lithium-ion battery pack chargers or other
battery pack chargers shall first recognize and cooperate with the battery pack (system)
being charged, to confirm the technical parameters of the battery pack, before starting
charging.
Example 1: The technical parameters of lithium-ion battery pack include battery type, voltage,
number of strings, battery capacity, etc.
Example 2: The technical parameters of sodium-ion battery pack include battery type, voltage,
number of strings, battery capacity, etc.
5.5.6 The positive and negative pole settings of the power terminal of the lead-acid
battery charger's output interface shall comply with the requirements of Figure 1 and
Figure 2. The positive and negative pole settings of the power supply terminal of the
output interface of a lithium-ion battery charger or other battery charger shall comply
with the requirements of Figure 3 and Figure 4.
5.6.2 Glow wire
5.6.2.1 For the insulating material parts inside the charger, that support the connections
carrying current exceeding 0.2 A during normal operation, as well as the insulating
materials within 3 mm of these connections, they are tested according to the method
specified in 6.6.2.1 and shall pass the glow wire flammability test at 850 °C (GWEPT).
5.6.2.2 For the insulating material parts inside the charger, that support the current-
carrying connections, as well as the insulating material parts within 3 mm from these
connections, they are tested according to the method specified in 6.6.2.2. It shall pass
the glow wire flammability test at 750 °C (GWEPT). However, if the above glow wire
test is passed, BUT the flame generated during the test lasts for more than 2 s, THEN,
the components within a cylindrical range, which has a 20 mm diameter and 50 mm
height, above the connector shall be subjected to an additional needle flame test, in
accordance with 6.6.4.1. However, components shielded by isolation baffles, that
comply with the needle flame test, do not need to be tested. If meeting the following
conditions, it can be considered to be resistant to the needle flame test:
a) There is no flame or burning in the specimen; the specified bottom layer or
packaging tissue paper does not ignite;
b) After removing the needle flame, the flame or burning of the test sample is
extinguished within 30 s, meanwhile the specified bottom layer or packaging
tissue paper does not ignite.
5.6.3 Vertical combustion
5.6.3.1 The non-metallic materials in the charger shall be tested according to the method
specified in 6.6.3. The specimen may be prepared from the finished product. If it is
impossible to prepare a specimen from the finished product, it can be prepared
separately. The thickness of the specimen shall not be larger than those of the relevant
parts.
5.6.3.2 The charger enclosure material shall comply with the V-0 level requirements in
GB/T 5169.16-2017.
5.6.3.3 The materials of components, which are installed in the opening of the charger
enclosure, shall comply with the level V-0 requirements in GB/T 5169.16-2017. These
components shall be limited to switches, indicator lights (except indicator light leads),
connectors, appliance sockets.
5.6.3.4 The charger's fan material shall comply with level V-1 in GB/T 5169.16-2017.
5.6.3.5 Unless any one of the following items a), b), c) is met, the materials of other
internal components of the charger shall comply with level V-2 in GB/T 5169.16-2017:
a) The charger enclosure only has openings filled with connecting wires and
openings for ventilation, which has a width not exceeding 1 mm and an unlimited
length;
b) For small electrical components, if these components are installed on materials
that comply with the vertical combustion level V-1 or better in GB/T 5169.16-
2017, such as integrated circuits, optocouplers, capacitor which has a volume not
exceeding 1750 mm3;
c) Except for metals, glass, ceramics, the small mechanical parts whose non-metallic
material mass does not exceed 4 g per part.
5.6.3.6 If the charger adopts glue filling process, the glue used shall comply with the V-
0 level in GB/T 5169.16-2017.
5.6.4 Needle flame
5.6.4.1 The base material of the printed circuit board, which is used in the charger, shall
be tested according to the method specified in 6.6.4.1. Test is not performed on
materials of category V-0 according to GB/T 5169.16-2017, when the base material
specimen is not thicker than the printed circuit board.
The following conditions can be considered to be resistant to the needle flame test:
a) There is no flame or burning in the specimen, meanwhile the specified bottom
layer or packaging tissue paper does not ignite;
b) After removing the needle flame, the flame or burning of the test sample is
extinguished within 15 seconds, meanwhile the specified bottom layer or
packaging tissue paper does not ignite.
Note: If the charger uses glue filling technology and the glue filling covers the entire printed
board, the base material of the printed board is not subject to undergo this test.
5.6.4.2 If the material of the charger enclosure and the components, which are installed
in the opening of the charger enclosure, do not meet the specimen preparation
conditions for the test of 5.6.3, THEN, the above materials shall be tested according to
6.6.4.2. The evaluation requirements are that after the first test flame is applied, the test
sample shall not be completely burned out. After any test flame is applied, the burning
duration of any sample shall not exceed 15 s, meanwhile the average burning time shall
not exceed 10 s. Tissue paper shall not ignite; white pine boards are not carbonized
either.
5.7 Emission
5.7.1 Terminal disturbance voltage
Carry out the test according to the method specified in 6.7.2. The charger power
current tester, to connect to any pole of the charger's input power supply; connect the
other test rod to connect the accessible parts of the charger's metal foil, to measure the
charger's leakage current.
6.2.2 Electrical strength
Use a withstanding voltage tester, to perform an electrical strength test, between the
charger's live parts and accessible parts (non-metallic parts covered with metal foil).
The test voltage values are as follows:
a) Basic insulation: 1250 V;
b) Additional insulation: 1750 V;
c) Reinforced insulation: 3000 V.
The voltage frequency of the test is 50 Hz; the time is 1 min; the trip current is set to 10
mA.
6.2.3 Clearances, creepage distances, solid insulation
6.2.3.1 Electrical clearance
Carry out the test, according to the method specified in 29.1 of GB 4706.1-2005.
Note: See Appendix B, for examples of charger's electrical clearance test.
6.2.3.2 Creepage distance
Carry out the test, according to the method specified in 29.2 of GB 4706.1-2005.
Note: See Appendix B, for an example of the charger’s creepage distance test.
6.2.3.3 Solid insulation
Carry out the test, according to the method specified in 29.3 of GB 4706.1-2005.
6.2.4 Protection against electric shock
Carry out the test, according to the method specified in Chapter 8 of GB 4706.1-2005.
6.2.5 Abnormal operation
6.2.5.1 Wrong connection
Connect the input end of the charger to the power supply, to make it work normally.
Connect an ammeter in series to the output end of the charger; then wrongly connect it
to the positive and negative poles of the input end of a fully charged battery pack (the
capacity of the battery pack is the maximum capacity, which is stated in the instruction
manual). Hold for 10 minutes. Then disconnect it. Observe whether the ammeter
reading is always less than 5 mA. After reconnecting correctly, check whether the
charger work normally.
6.2.5.2 Short circuit
Connect the input end of the charger to the power supply. Connect the output end to the
electronic load, to make it work at full load. Take a plug, that matches the output end
of the charger. Use a wire, which has a cross-sectional area greater than 1 mm2 (short-
circuit resistance less than 50 mΩ), to short circuit the output ends of the charger,
between the positive and negative poles of the plug; OR use an electronic load for short
circuiting. Remove it after connecting for 15 s.
6.2.5.3 Fan stalling
In the test, mechanical methods are used to artificially stall the fan for 30 minutes.
6.2.5.4 Component failure
Connect the charger to the electronic load. Connect a voltmeter, which has data
recording function (recording interval ≤ 10 ms), in parallel to the output end. Connect
an ammeter, which has data recording function (recording interval ≤ 10 ms), in series
to the output end.
First, adjust the load. After the charger is powered on, it works in the highest voltage
state. Choose to short-circuit the two pins of the feedback optocoupler at the secondary
end of the power supply, the voltage sampling resistor, and other components that can
replace the voltage feedback loop (only perform a single fault, short circuit or open
circuit of a component). Hold for 60 seconds. Take the voltmeter reading.
Adjust the load, to make the charger work at the maximum current state, whilst ensuring
that the output voltage is the rated output voltage. Select a short-circuit current sampling
resistor or other components that can replace the current feedback loop (only single
fault, short circuit or open circuit a component). Hold for 60 s. Take the ammeter
reading.
During the test, visual inspection is performed, to ensure there are no fire hazards,
mechanical hazards, etc. The framework diagram of the measurement principle of
charger component failure is as shown in Figure 5.
......
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.
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