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GB/T 40432-2021 PDF in English


GB/T 40432-2021 (GB/T40432-2021, GBT 40432-2021, GBT40432-2021)
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GB/T 40432-2021English380 Add to Cart 0-9 seconds. Auto-delivery. Conductive on-board charger for electric vehicles Valid

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GB/T 40432-2021: PDF in English (GBT 40432-2021)

GB/T 40432-2021
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.040
CCS T 35
Conductive on-board charger for electric vehicles
ISSUED ON: AUGUST 20, 2021
IMPLEMENTED ON: MARCH 01, 2022
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 Technical requirements ... 7 
4.1 Appearance requirements ... 7 
4.2 Requirements of charging characteristics ... 7 
4.3 Protection function... 9 
4.4 Electrical safety ... 10 
4.5 Electromagnetic compatibility ... 11 
4.6 Environmental adaptability ... 14 
4.7 Noise ... 16 
4.8 Durability ... 16 
4.9 Inverter output function requirements ... 16 
5 Test method ... 16 
5.1 Test conditions ... 16 
5.2 Appearance test ... 17 
5.3 Test method of charging characteristics ... 17 
5.4 Test of charge protection function ... 24 
5.5 Electrical safety test ... 27 
5.6 Electromagnetic compatibility test ... 27 
5.7 Environmental adaptability test ... 29 
5.8 Noise test ... 30 
5.9 Durability test... 30 
Appendix A (Normative) On-board charger with inverter function ... 32 
A.1 Inverter technical requirements ... 32 
A.2 Test method ... 35 
Conductive on-board charger for electric vehicles
1 Scope
This document specifies the technical requirements and test methods for
conductive on-board chargers for electric vehicles.
This document applies to conductive on-board chargers for electric vehicles,
which have a nominal input voltage of 220 V (AC) (single-phase) or 380 V (AC)
(three-phase) AND an output voltage of not more than 1500 V (DC). Other types
of on-board charger may make reference to this standard.
2 Normative references
The provisions in following documents become the provisions of this Standard
through reference in this Standard. 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 standard.
GB 4824-2019 Industrial, scientific and medical equipment - Radio-
frequency disturbance characteristics - Limits and methods of measurement
GB/T 12113 Methods of measurement of touch current and protective
conductor current
GB 17625.1 Electromagnetic compatibility - Limits - Limits for harmonic
current emissions (equipment input current ≤ 16 A per phase)
GB/T 17625.2 Electromagnetic compatibility (EMC) - Limits - Limitation of
voltage changes, voltage fluctuations and flicker in public low-voltage supply
systems, for equipment with rated current ≤ 16 A per phase and
unconditionally connected in the public low-voltage power supply system
GB/T 17625.7 Electromagnetic compatibility - Limits - Limitation of voltage
changes, voltage fluctuations and flicker in public low-voltage supply
systems for equipment with rated current ≤ 75 A and subject to conditional
connection
GB/T 17625.8 Electromagnetic compatibility - Limits - Limits for harmonic
currents produced by equipment connected to public low-voltage systems
rated output state and continue to run for 1 min. Observe the working state
of the on-board charger.
5.3.2.3 Three-phase AC voltage phase deviation test
Test method and procedure:
a) Connect the test circuit according to Figure 1. Set the electronic load to
constant voltage load mode. Set the voltage to the rated output voltage of
the on-board charger;
b) Turn on the on-board charger, under the rated input condition, to make it
work in the rated output state;
c) Adjust the phase of any one-phase AC voltage within ±3°. Keep the rated
output state and continue to run for 1 min. Observe the working state of
the on-board charger.
5.3.3 Start input impulse current test
Test method and procedure:
a) Connect the test circuit, according to Figure 1. Set the electronic load to
constant voltage load mode. Set the voltage to the rated output voltage of
the on-board charger;
b) Turn on the on-board charger, under the rated input condition. Set the
output to the rated load. Use the oscilloscope to measure the peak value
of the input current, during the turn-on process, AND the peak value of the
AC input current after stable operation;
c) Repeatedly turn on the vehicle-mounted charger under test 3 times. The
interval between two adjacent tests is not less than 2 min. Measure the
start-up input impulse current.
Note: The μs-level impulse current, which is generated by the electromagnetic
interference (EMI) circuit, is not considered.
5.3.4 Test of DC output voltage limiting characteristic
Test method and procedure:
a) Connect the test circuit according to Figure 1. Set the electronic load to
constant resistance load mode;
b) Set the output voltage to the rated voltage. Turn on the on-board charger
under the rated input condition. Adjust the load to a half-load load;
c) Change the output voltage setting value. Measure the output voltage.
5.3.5 Test of DC output current limiting characteristic
Test method and procedure:
a) Connect the test circuit according to Figure 1. Set the electronic load to
constant voltage load mode. Set the voltage to the rated output voltage of
the on-board charger;
b) Turn on the on-board charger under rated input conditions. Set the output
current to the maximum current limit value;
c) Change the output current setting value. Measure the output current.
5.3.6 Test of DC output limit power characteristic
Test method and procedure:
a) Connect the test circuit according to Figure 1. Set the electronic load to
constant voltage mode. Set the voltage to the rated output voltage of the
on-board charger;
b) Turn on the on-board charger under rated input conditions. Set the output
voltage to the maximum voltage value. Set the output current to the
maximum current limit value;
c) Adjust the voltage of the electronic load. Measure the output power;
d) Set the input current limit. Measure the output power.
Note: The input current limit is determined by the charging facility and charging cable.
The input current limit can also be set.
5.3.7 Test of DC output voltage tolerance
Test method and procedure:
a) Connect the test circuit according to Figure 1. Set the electronic load to
constant resistance load mode;
b) Turn on the on-board charger under the condition of rated input. Make it
work in a constant voltage output state. Set the output voltage to a certain
voltage value Uzo, within the output range of the on-board charger;
c) When the regulated output load is 10%, 50%, 100% of the rated load,
respectively, measure the actual output voltage Uz of the on-board charger;
calculate the output voltage tolerance, according to formula (1).
5.3.11 Test of output dump load
Test method and procedure:
a) Connect the test circuit according to Figure 1. Set the electronic load to
constant voltage load mode. Set the voltage to the rated output voltage of
the on-board charger;
b) Turn on the on-board charger under the rated input condition. Make it work
in the rated power output state;
c) Suddenly disconnect the output load. Use an oscilloscope to measure the
overshoot value of the output voltage.
5.3.12 Power factor test
Test method and procedure:
a) Connect the test circuit according to Figure 1. Set the electronic load to
constant voltage load mode. Set the voltage to the rated output voltage of
the on-board charger;
b) Turn on the on-board charger under the rated input condition, to make it
work in the rated output state;
c) Measure the power factor under rated load AND 50% rated load,
respectively.
5.3.13 Test of charging efficiency
Test method and procedure:
a) Connect the test circuit according to Figure 1. Set the electronic load to
constant voltage load mode;
b) Turn on the on-board charger under the condition of rated input. Start
measuring the efficiency, after working for 30 minutes in the rated state;
c) Within the output voltage range, which is specified in the product technical
documents, equally divide 10 output voltage values;
d) Adjust the output voltage, to make it work at 10 output voltage values,
respectively. Use a power meter to measure the efficiency under each
output voltage;
e) Calculate the average of each efficiency.
5.4 Test of charge protection function
5.4.1 Test of AC input over-voltage and under-voltage protection
Test method and procedure:
a) Connect the test circuit according to Figure 1. Set the electronic load to
constant voltage load mode. Set the voltage to the rated output voltage of
the on-board charger;
b) Turn on the on-board charger under rated input conditions, to make it work
at rated power;
c) Gradually adjust the AC input voltage to the overvoltage protection value
or the undervoltage protection value. Observe the output state of the on-
board charger;
d) Gradually adjust the AC input voltage, FROM the overvoltage protection
value or the undervoltage protection value TO within ±15% of the rated
input voltage. Observe the working state of the on-board charger.
5.4.2 Test of phase failure protection
Test method and procedure:
a) Connect the test circuit according to Figure 1. The input is a three-phase
AC adjustable power supply. The electronic load is set to the constant
voltage load mode. The voltage is set to the rated output voltage of the
on-board charger;
b) Turn on the on-board charger under the rated three-phase input condition,
to make it work at the rated output power;
c) Artificially create a phase voltage missing state of a certain phase.
Observe the output state of the on-board charger;
d) Restore the phase missing state to normal. Observe the working state of
the on-board charger.
5.4.3 Test of DC output over-voltage and under-voltage protection
5.4.3.1 Test of DC output overvoltage protection
Test method and procedure:
a) Connect the test circuit according to Figure 1. Connect the output terminal
to a DC voltage source;
Test method and procedure:
a) Connect the test circuit according to Figure 1;
b) Under the rated input condition, turn on the on-board charger, to make it
in the rated working state;
c) Short-circuit the output DC positive and negative poles. Observe the state
of the on-board charger;
d) After the output short circuit is eliminated, observe its output state. OR
restart the on-board charger under rated conditions, to observe its output
state.
5.4.5 Test of over-temperature protection
The over-temperature protection test of the on-board charger is carried out as
follows.
a) For air-cooled on-board chargers, after high temperature work test:
1) Gradually increase the temperature of the thermostat, to reach the over-
temperature protection. Observe the output state of the on-board
charger;
2) Restore the thermostat to the working temperature range. The on-board
charger can automatically restore output OR restore output after
necessary human intervention.
b) For liquid-cooled on-board chargers, after high-temperature work test:
1) Gradually increase the temperature of the coolant, to achieve over-
temperature protection. Observe the output state of the on-board
charger;
2) Restore the coolant temperature to the working temperature range.
Observe the working state of the on-board charger.
5.4.6 Test of output reverse connection protection
Connect the output positive pole of the on-board charger to the negative pole
of the battery (or battery simulation device); connect the output negative pole
to the positive pole of the battery (or battery simulation device). Under the rated
input conditions, turn on the on-board charger, to check the working state of the
on-board charger.
5.5 Electrical safety test
5.5.1 Insulation resistance test
When the on-board charger is not working, use an insulation resistance tester
to measure the insulation resistance. Apply a test DC voltage of 500 V AND
maintain a steady-state value for 60 s, to determine the insulation resistance.
5.5.2 Voltage withstand test
Before the test, it may disconnect the surge protection equipment and insulation
monitoring equipment, which may affect the test results.
When the on-board charger is not working, the withstand voltage tester applies
the test voltage, as shown in Table 4, for 1 min, between the various port circuits
required by 4.4.2. Record the magnitude of the leakage current during the test.
5.5.3 Contact current test
The on-board charger measures the contact current, in accordance with the test
method of GB/T 12113, under the condition of 115% of the rated input voltage
AND the rated power output.
5.6 Electromagnetic compatibility test
5.6.1 Working state
When the on-board charger is, in the charging state, subject to the
electromagnetic compatibility test, if there is no special requirement, the DC
output terminal is connected to the battery simulator; the output voltage is set
to the rated voltage; the output load is the rated load state.
5.6.2 Electromagnetic immunity test
5.6.2.1 Test of electrostatic discharge immunity
The test arrangement and test method are carried out, in accordance with GB/T
19951.
5.6.2.2 Test of immunity of anechoic chamber method
The test arrangement and test method are carried out, in accordance with ISO
11452-2.
5.6.2.3 Immunity test of electrical fast transient pulse group
17625.2.
5.6.3.6.2 When the rated input current of the on-board charger is > 16 A, the
test arrangement and test method shall be carried out, in accordance with GB/T
17625.7.
5.7 Environmental adaptability test
5.7.1 High temperature and low temperature test
5.7.1.1 Low temperature storage test
Put the on-board charger into a thermostat, which has an initial temperature of
room temperature. Connect all electrical wiring harnesses in good condition.
Adjust the temperature of the thermostat to -40 °C ± 2 °C. During low-
temperature storage, the on-board charger is in a non-energized state. For the
liquid-cooling on-board charger, do not lead in the coolant. Store it at low
temperature for 24 h.
5.7.1.2 Low temperature working test
After the low-temperature storage test, adjust the temperature of the thermostat,
to reach the low-temperature working temperature value. Keep it for 2 h. Then
turn on the power to start the on-board charger. Make it work in the rated load
state AND continue to work for 12 h. For liquid-cooled on-board chargers, the
temperature and flow of the coolant, during the test, are in accordance with the
product technical documents.
5.7.1.3 High temperature storage test
Put the on-board charger in a thermostat, which has an initial temperature of
room temperature. Connect all electrical wiring harnesses in good condition.
Adjust the temperature of the thermostat to 85°C ± 2 °C. During high-
temperature storage, the on-board charger is in a non-energized state. For
liquid-cooled on-board charger, do not lead in the coolant. Store it at high
temperature for 24 h.
5.7.1.4 High temperature working test
After the high-temperature storage test, adjust the temperature of the
thermostat, to reach the high-temperature working temperature value. Keep it
for 2 h. Then power on to start the on-board charger, to make it work at the
rated load AND continue working for 12 h. For liquid-cooled on-board chargers,
the temperature and flow of the coolant, during the test, are in accordance with
the product technical documents.
5.7.2 Damp heat resistance test
5.7.2.1 Cyclic damp heat test
Carry out the cyclic damp heat test, according to the requirements of 5.6 in
GB/T 28046.4-2011.
5.7.2.2 Steady-state damp heat test
Carry out the steady-state damp heat test, according to the requirements of 5.7
in GB/T 28046.4-2011.
5.7.3 Salt spray resistance test
Carry out the salt spray resistance test, according to the requirements of 5.5 in
GB/T 28046.4-2011.
Note: According to Table 4 and Appendix A in GB/T 28046.4-2011, some installation
positions do not require salt spray test.
5.7.4 Vibration resistance test
The vibration test of the on-board charger is based on its installation position in
the vehicle. The vibration test is carried out, in accordance with the
requirements of 4.1.2 in GB/T 28046.3-2011.
The on-board charger is subjected to the test in a non-powered state. The
detection point of the vibration test is at the junction of the test fixture and the
test bench.
5.7.5 Test of mechanical shock resistance
Carry out the mechanical impact test, according to the requirements of 4.2 in
GB/T 28046.3-2011.
5.8 Noise test
When the air-cooled on-board charger is in the rated working state, in a semi-
anechoic chamber test environment, under the condition that the background
noise ratio 10 dB(A) less than the measured noise, measure the working noise
of the on-board charger, at a horizontal position 1 m from the sound source
AND 1 m ~ 1.5 m above the ground.
5.9 Durability test
Put the on-board charger into a thermostat, which has an initial temperature of
......
 
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.