GB/T 41589-2022 PDF English
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GB/T 41589-2022: In-cable control and protection device for mode 2 charging of electric road vehicles (IC-CPD)
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GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 29.120.50
CCS K 31
In-cable control and protection device for mode 2 charging
of electric road vehicles (IC-CPD)
(IEC 62752.2018, MOD)
Issued on. JULY 11, 2022
Implemented on. FEBRUARY 01, 2023
Issued by. State Administration for Market Regulation;
Standardization Administration of the PRC.
Table of Contents
Foreword... 9
Introduction... 13
1 Scope... 14
2 Normative references... 15
3 Terms and definitions... 19
3.1 Terms and definitions relating to plugs and socket-outlets... 20
3.2 Terms and definitions relating to terminals... 21
3.3 Terms and definitions relating to residual current functions... 23
3.3.1 Terms and definitions relating to currents flowing from live parts to earth... 23
3.3.2 Terms and definitions relating to the energization of the residual current function24
3.3.3 Terms and definitions relating to the operation and to the functions of the IC-CPD
... 25
3.3.4 Terms and definitions relating to values and ranges of energizing quantities... 27
3.3.5 Terms and definitions relating to values and ranges of influencing quantities... 30
3.3.6 Terms and definitions relating to conditions of operation... 30
3.3.7 Terms and definitions relating to control functions between electric vehicle and IC-
CPD... 31
3.4 Terms and definitions relating to tests... 32
3.5 Terms and definitions relating to construction... 32
4 Classification... 33
4.1 According to the supply... 33
4.2 According to the construction... 33
4.2.1 General... 33
4.2.2 IC-CPD including the function box separated from the plug and connector... 33
4.2.3 IC-CPD with the function box integrated together with the plug... 33
4.2.4 Modular IC-CPD... 33
4.3 According to the method of connecting the cable(s)... 33
4.3.1 General... 33
4.3.2 Non-rewirable IC-CPDs... 34
4.3.3 IC-CPDs wired by the manufacturer... 34
4.3.4 Pluggable IC-CPD... 34
4.4 Classification according to the protective conductor path... 34
4.4.1 General... 34
4.4.2 IC-CPDs with switched protective conductor... 34
4.4.3 IC-CPDs with non-switched protective conductor... 34
4.5 Classification according to behaviour in case of open protective conductor... 34
4.5.1 General... 34
4.5.2 IC-CPD with verification of the availability of the upstream protective conductor
... 35
4.5.3 IC-CPD without verification of the availability of the upstream protective conductor
... 35
4.6 Classification according to the usage... 35
5 Characteristics of IC-CPDs... 35
5.1 Requirements of characteristics... 35
5.2 Rated quantities and other characteristics... 36
5.2.1 Rated voltages (Un)... 36
5.2.2 Rated current (In)... 36
5.2.3 Rated residual operating current (IΔn)... 36
5.2.4 Rated residual non-operating current (IΔno)... 37
5.2.5 Rated frequency... 37
5.2.6 Rated making and breaking capacity (Im)... 37
5.2.7 Rated residual making and breaking capacity (IΔm)... 37
5.2.8 Operating characteristics in case of residual currents comprising a d.c. component
... 37
5.2.9 Insulation coordination including creepage distances and clearances... 37
5.2.10 Coordination with short-circuit protection devices (SCPDs)... 37
5.3 Standard and preferred values... 38
5.3.1 Preferred values of rated operational voltage (Ue)... 38
5.3.2 Preferred values of rated current (In)... 38
5.3.3 Standard values of rated residual operating current (IΔn)... 38
5.3.4 Standard value of rated residual non-operating current (IΔno)... 38
5.3.5 Standard minimum value of the non-operating overcurrent through the IC-CPD. 39
5.3.6 Preferred values of rated frequency... 39
5.3.7 Minimum value of the rated making and breaking capacity (Im)... 39
5.3.8 Minimum value of the rated residual making and breaking capacity (IΔm)... 39
5.3.9 Standard value of the rated conditional short-circuit current (Inc)... 39
5.3.10 Standard value of the rated conditional residual short-circuit current (IΔc)... 39
5.3.11 Limit values of break time... 39
6 Marking and other product information... 40
6.1 Data to be marked on the IC-CPD... 40
6.2 Information to be provided to the end-user... 42
7 Standard conditions for operation in service and for installation... 43
7.1 Standard conditions... 43
7.2 Conditions for installations... 44
8 Requirements for construction and operation... 44
8.1 Mechanical design... 44
8.2 Pluggable electrical connections of pluggable IC-CPDs according to 4.3.4... 45
8.2.1 General... 45
8.2.2 Degree of protection of pluggable electrical connection against solid foreign objects
and water for pluggable IC-CPD... 46
8.2.3 Breaking capacity of pluggable electrical connection for pluggable IC-CPD... 46
8.2.4 Additional requirements... 47
8.3 Construction... 48
8.3.1 General... 48
8.3.2 Terminations of IC-CPDs... 48
8.3.3 Enclosure of IC-CPDs according to 4.3.3... 49
8.3.4 Terminal screws or nuts of IC-CPDs according to 4.3.3... 49
8.3.5 Strain on the conductors of IC-CPDs according to 4.3.3... 49
8.3.6 Additional requirements for IC-CPDs according to 4.3.3... 49
8.3.7 Insulating parts which keep the live parts in position... 50
8.3.8 Screws for IC-CPD according to 4.3.3... 50
8.3.9 Means for suspension from a wall or other mounting surfaces... 50
8.3.10 Plug as an integral part of plug-in equipment... 50
8.3.11 Flexible cables and cords and their connection... 51
8.4 Electrical performance... 52
8.4.1 Protective conductor path... 52
8.4.2 Contact mechanism... 52
8.4.3 Clearances and creepage distances (see Annex C)... 53
8.5 Protection against electric shock... 55
8.5.1 General... 55
8.5.2 Requirements relating to plugs, whether incorporated or not in integral items... 56
8.5.3 Degree of protection of the function box... 56
8.5.4 Requirements relating to vehicle connectors... 56
8.6 Dielectric properties... 56
8.7 Temperature rise... 57
8.8 Operating characteristics... 57
8.8.1 General... 57
8.8.2 Safe connection operating characteristic... 57
8.8.3 Operating characteristics with a.c. residual currents and residual currents having a
d.c. component... 58
8.8.4 Operating characteristics with smooth d.c. residual current... 58
8.8.5 Behaviour of the IC-CPD after a residual current operation... 58
8.9 Mechanical and electrical endurance... 58
8.10 Performance at short-circuit currents... 58
8.11 Resistance to mechanical shock and impact... 59
8.12 Resistance to heat... 59
8.13 Resistance to abnormal heat and to fire... 59
8.14 Performance of the test function... 59
8.15 Behaviour in case of loss of the supply voltage... 60
8.16 Resistance of IC-CPDs against unwanted tripping due to surge currents to earth
resulting from impulse voltages... 60
8.17 Control pilot function controller... 60
8.18 Reliability... 60
8.19 Resistance to tracking... 61
8.20 Electromagnetic compatibility (EMC)... 61
8.21 Behaviour of the IC-CPD at low ambient air temperature... 61
8.22 Operation with supply failure and hazardous live protective conductor conditions 61
8.23 Verification of a standing current in the protective conductor in normal service... 61
8.24 Behaviour at specific environmental conditions... 61
8.25 Resistance to vibration and shock... 62
9 Tests... 62
9.1 General... 62
9.1.1 Opening and closing of contacts... 62
9.1.2 Type tests... 62
9.1.3 Test sequences... 63
9.1.4 Routine tests... 64
9.2 Test conditions... 64
9.3 Test of indelibility of marking... 64
9.4 Protection against electric shock... 65
9.5 Test of dielectric properties... 66
9.5.1 Resistance to humidity... 66
9.5.2 Insulation resistance of the main circuit... 66
9.5.3 Dielectric strength of the main circuit... 67
9.5.4 Secondary circuit of detection transformers... 68
9.5.5 Verification of impulse withstand voltages (across clearances and across solid
insulation) and of leakage current across open contacts... 68
9.6 Temperature-rise test... 72
9.6.1 Test conditions... 72
9.6.2 Test procedure... 72
9.6.3 Measurement of the temperature rise of different parts... 72
9.6.4 Temperature rise of a part... 72
9.7 Verification of the operating characteristic... 73
9.7.1 General... 73
9.7.2 Test circuit... 73
9.7.3 Residual sinusoidal alternating currents tests... 73
9.7.4 Verification of the correct operation with residual currents having a d.c. component
... 76
9.7.5 Verification of behaviour in case of composite residual current... 77
9.7.6 Verification of the correct operation in case of smooth d.c. residual current... 79
9.7.7 Miswiring and supply failure tests... 79
9.7.8 Verification of protective conductor contact behaviour... 82
9.7.9 Verification that the protective conductor is connected to the electric vehicle... 82
9.7.10 Verification of standing current in the protective conductor in normal service... 83
9.8 Verification of mechanical and electrical endurance... 83
9.8.1 Endurance of plug and vehicle connector part... 83
9.8.2 Endurance test of the residual current function of the IC-CPD... 83
9.9 Verification of the behaviour of the IC-CPD under overcurrent conditions... 86
9.9.1 List of the overcurrent tests... 86
9.9.2 Short-circuit tests... 86
9.9.3 Verification of the making and breaking capacity of the plug of the IC-CPD... 94
9.10 Verification of resistance to mechanical shock and impact... 95
9.10.1 General... 95
9.10.2 Drop test... 95
9.10.3 Test for screwed glands of IC-CPDs... 96
9.10.4 Mechanical strength test on IC-CPDs provided with cords... 96
9.11 Test of resistance to heat... 97
9.11.1 General... 97
9.11.2 Temperature test in heating cabinet... 97
9.11.3 Ball pressure test for insulating material necessary to retain in position current-
carrying parts... 97
9.11.4 Ball pressure test for insulating material not necessary to retain in position current-
carrying parts... 98
9.12 Resistance of insulating material to abnormal heat and to fire... 98
9.13 Verification of the self test... 99
9.14 Verification of the behaviour of IC-CPDs in case of loss of the supply voltage... 100
9.14.1 Verification of correct operation at the minimum operating voltage (UX)... 100
9.14.2 Verification of the automatic opening in case of loss of the supply voltage... 100
9.14.3 Verification of the reclosing function of IC-CPD... 101
9.15 Verification of the limiting values of the non-operating current under overcurrent
conditions... 101
9.16 Verification of resistance of IC-CPD against unwanted tripping due to surge currents
to earth resulting from impulse voltages... 101
9.17 Verification of reliability... 102
9.17.1 Climatic test... 102
9.17.2 Test at a temperature of 50 °C... 104
9.18 Verification of resistance to ageing... 105
9.19 Resistance to tracking... 106
9.20 Test on pins provided with insulating sleeves... 106
9.21 Test of mechanical strength of non-solid pins of plugs... 107
9.22 Verification of the effects of strain on the conductors... 107
9.23 Checking of the torque exerted by IC-CPDs on fixed socket-outlets... 107
9.24 Tests of the cord anchorage... 107
9.25 Flexing test of non-rewirable IC-CPDs... 108
9.26 Verification of the electromagnetic compatibility (EMC)... 109
9.27 Tests replacing verifications of creepage distances and clearances... 110
9.27.1 General... 110
9.27.2 Abnormal conditions... 110
9.27.3 Temperature rise resulting from fault conditions... 110
9.28 Verifications for single electronic components used in IC-CPDs... 112
9.28.1 General... 112
9.28.2 Capacitors... 112
9.28.3 Resistors and inductors... 112
9.29 Chemical loads... 115
9.30 Heat test under solar radiation... 115
9.31 Resistance to ultra-violet (UV) radiation... 115
9.32 Damp and salt mist test for marine and coastal environments... 116
9.32.1 Test for internal metallic parts... 116
9.32.2 Test for external metallic parts only... 116
9.32.3 Test criteria... 116
9.33 Hot damp test for tropical environments... 117
9.34 Vehicle drive-over... 117
9.34.1 General... 117
9.34.2 Test at crushing force 5000 N... 117
9.34.3 Test at crushing force 11000 N... 117
9.34.4 Performance after the tests... 117
9.35 Low storage temperature test... 118
9.36 Vibration and shock test... 118
Annex A (Normative) Test sequences and number of samples to be submitted for
verification of conformity to this document... 144
A.1 Verification of conformity... 144
A.2 Test sequences... 144
A.3 Number of samples to be submitted for full test procedure... 146
A.4 Number of samples to be submitted for simplified test procedures in case of submitting
simultaneously a range of IC-CPDs of the same fundamental design... 148
Annex B (Normative) Routine tests... 151
Annex C (Normative) Determination of clearances and creepage distances... 152
C.1 Overview... 152
C.2 Orientation and location of a creepage distance... 152
C.3 Creepage distances where more than one material is used... 152
C.4 Creepage distances split by a floating conductive part... 152
C.5 Measurement of creepage distances and clearances... 152
Annex D (Informative) Switched-protective conductor (SPE) application... 158
D.1 Explanation of switched-protective conductor (SPE) function and application... 158
D.2 Examples of incorrect supply wiring... 159
Annex E (Informative) Example of IC-CPD for mode 2 charging... 161
Annex F (Informative) Types of IC-CPD according to construction and assembly.. 162
Annex G (Informative) Methods for determination of short-circuit power factor... 163
G.1 Overview... 163
G.2 Method I - Determination from d.c. components... 163
G.3 Method II - Determination with pilot generator... 164
Bibliography... 165
Foreword
This document is drafted in accordance with GB/T 1.1-2020 "Directives for
standardization - Part 1.Rules for the structure and drafting of standardizing
documents".
This document modifies and adopts IEC 62752.2018 "In-cable control and protection
device for mode 2 charging of electric road vehicles (IC-CPD)".
Compared with IEC 62752.2018, this document has made the following structural
adjustments.
- 4.1 corresponds to 4.1.2 in IEC 62752.2018.Delete 4.1.1, 4.1.3, and 4.1.4;
- 4.6 corresponds to 4.6.1 in IEC 62752.2018.Delete 4.6.2 and 4.6.3.
The technical differences between this document and IEC 62752.2018 and their reasons
are as follows.
- Use normatively-referenced GB/T 2099.1-2021 to replace IEC 60884-1.2013.The
degree of consistency between the two documents is MOD, to adapt to the technical
conditions of China and increase operability (see Clause 1, Table 4, 8.1, 8.3.1, 8.4.3,
8.5.2, 9.2, 9.9.3, 9.20, 9.21, 9.23, 9.34.1, A.1);
- Use normatively-referenced GB/T 1043.1 to replace ISO 179-1, to adapt to the
technical conditions of China and increase operability (see 9.31);
- Use normatively-referenced GB/T 2423.1 to replace IEC 60068-2-1, to adapt to the
technical conditions of China and increase operability (see 9.35);
- Use normatively-referenced GB/T 2423.4 to replace IEC 60068-2-30, to adapt to
the technical conditions of China and increase operability (see 9.17.1.1, 9.17.1.4,
9.32.1, 9.32.2);
- Use normatively-referenced GB/T 2423.5 to replace IEC 60068-2-27, to adapt to
the technical conditions of China and increase operability (see 9.36);
- Use normatively-referenced GB/T 2423.7 to replace IEC 60068-2-31, to adapt to
the technical conditions of China and increase operability (see 9.10.2);
- Use normatively-referenced GB/T 2423.17 to replace IEC 60068-2-11, to adapt to
the technical conditions of China and increase operability (see 9.32.1 and 9.32.2);
- Use normatively-referenced GB/T 2423.24 to replace IEC 60068-2-5, to adapt to
the technical conditions of China and increase operability (see 9.30);
- Use normatively-referenced GB/T 2423.56 to replace IEC 60068-2-64, to adapt to
the technical conditions of China and increase operability (see 9.36);
- Use normatively-referenced GB/T 2424.2 to replace IEC 60068-3-4, to adapt to the
technical conditions of China and increase operability (see 9.17.1.1, 9.17.1.2,
9.17.1.4);
- Use normatively-referenced GB/T 4207 to replace IEC 60112, to adapt to the
technical conditions of China and increase operability (see Table 6 and 9.19);
- Use normatively-referenced GB/T 4208-2017 to replace IEC 60529.1989, to adapt
to the technical conditions of China and increase operability (see 8.1 and 8.5.3);
- Use normatively-referenced GB 4343.1 to replace CISPR 14-1, to adapt to the
technical conditions of China and increase operability (see 9.26 and Table A.1);
- Use normatively-referenced GB/T 5013 (all parts) to replace IEC 60245 (all parts),
to adapt to the technical conditions of China and increase operability (see 8.3.11.2);
- Use normatively-referenced GB/T 5023 (all parts) to replace IEC 60227 (all parts),
to adapt to the technical conditions of China and increase operability (see 8.3.11.2);
- Use normatively-referenced GB/T 5169.10 to replace IEC 60695-2-10, to adapt to
the technical conditions of China and increase operability (see 9.12);
- Use normatively-referenced GB/T 5169.11 to replace IEC 60695-2-11, to adapt to
the technical conditions of China and increase operability (see 9.12);
- Use normatively-referenced GB/T 6346.14 to replace IEC 60384-14, to adapt to
the technical conditions of China and increase operability (see 9.28.2);
- Use normatively-referenced GB 8898 to replace IEC 60065, to adapt to the
technical conditions of China and increase operability (see 9.28.3);
- Use normatively-referenced GB/T 9286 to replace ISO 2409, to adapt to the
technical conditions of China and increase operability (see 9.31);
- Use normatively-referenced GB/T 9341 to replace ISO 178, to adapt to the
technical conditions of China and increase operability (see 9.31);
- Use normatively-referenced GB/T 11918 (all parts) to replace IEC 60309 (all parts),
to adapt to the technical conditions of China and increase operability (see 8.2.1);
- Use normatively-referenced GB/T 11918.1-2014 to replace IEC 60309-1.2012.
The degree of consistency between the two documents is MOD, to adapt to the
technical conditions of China and increase operability (see 8.2.1 and 8.2.3);
- Use normatively-referenced GB/T 16935.3 to replace IEC 60664-3, to adapt to the
technical conditions of China and increase operability (see 9.27.3);
- Use normatively-referenced GB/T 28046.5-2013 to replace ISO 16750-5.2010.
The degree of consistency between the two documents is MOD, to adapt to the
technical conditions of China and increase operability (see 9.29);
- Use normatively-referenced GB/T 30789.3 to replace ISO 4628-3, to adapt to the
technical conditions of China and increase operability (see 9.32.3);
- Types, basic parameters and dimensions of plugs and socket-outlets are in
accordance with the requirements of GB/T 1002 (see Clause 1). Types and
dimensions of vehicle connector are in accordance with the requirements of GB/T
20234.1-2015 and GB/T 20234.2-2015 (see 8.1, 8.4.3, 8.5.4, 9.2, A.1);
- Delete the requirements for plugs for industrial purposes (see Clause 1, 7.1, 8.1,
8.4.3, 8.5.2, 9.2, 9.34.1 of IEC 62752.2018);
- Delete the types and requirements of two-phase and three-phase products (see
Clause 1, 3.3.3.12, 3.3.3.13, 3.3.3.15, 3.3.3.16, 4.1, 5.3.2, 9.2, 9.6.2, 9.7.7.1, 9.7.7.2,
9.7.7.3, 9.7.11, 9.7.12, and Annex D of IEC 62752.2018);
- Delete the types and requirements of products with rated current above 16A (see
Clause 1, 5.3.2, 8.3.11.2, 9.9.2.1, and 9.24 of IEC 62752.2018);
- Delete the classification and relevant requirements of wall mounted IC-CPD (see
4.6.2, 4.6.3, 8.5.3, 9.10.1, 9.10.5, and 9.34.1 of IEC 62752.2018);
- Consistent with GB/T 18487.1, change the upper limit of ambient temperature in
this document from "45 ℃" to "50 ℃" (see 7.1, 9.7.3.7, 9.17.2);
- Delete the performance of IC-CPD when plugged into incompatible power system
(see 9.7.7.4 of IEC 62752.2018).
Attention is drawn to the possibility that some of the elements of this document may be
the subject of patent rights. The issuing authority of this document shall not be held
responsible for identifying any or all such patent rights.
This document was proposed by China Electrical Equipment Industry Association.
This document shall be under the jurisdiction of National Technical Committee 189 on
Low-voltage Apparatus of Standardization Administration of China (SAC/TC 189).
Drafting organizations of this document. Shanghai Electrical Apparatus Research
Institute, Shanghai CHINT Intelligent Technology Co., Ltd., Shanghai Liangxin
Electrical Co., Ltd., Zhejiang Tengen Electric Co., Ltd., Zhongshan Kaper Electrical
Co., Ltd., Panasonic Information Instruments (Shanghai) Co., Ltd., Suzhou ELE
Electric Appliance Manufacturing Co., Ltd., Xiamen ZTC Technology Co., Ltd., Yuyao
Jiarong Electron & Electrical Co., Ltd., Shanghai Baolong Automotive Corporation,
Shanghai Electrical Apparatus Research Institute (Group) Co., Ltd.
Main drafters of this document. Wang Yuxuan, Zhou Changqing, Wu Peifeng, Yu
Cuntai, Zou Jianhua, Chen Yijie, Li Chengli, Cai Chongsheng, Qian Jiacan, Li Wei, Li
Hui, Hu Hongyu.
1 Scope
This document applies to in-cable control and protection devices for mode 2 charging
of electric road vehicles, hereafter referred to as IC-CPD including control and safety
functions.
2 Normative references
The contents of the following documents, through normative references in this text,
constitute indispensable provisions of this document. Among them, for dated references,
only the edition corresponding to that date applies to this document. For undated
references, the latest edition (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
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
4 Classification
Cables in-between different components of the IC-CPD can be connected to these
components by different methods.
An IC-CPD can be classified to have a switched or a non-switched protective conductor.
An IC-CPD can be classified according to the behaviour related to the availability of
the upstream protective conductor.
5 Characteristics of IC-CPDs
The value of current, assigned to the IC-CPD by the manufacturer, which the IC-CPD
can carry under permanent load conditions.
The power frequency for which the IC-CPD is designed and to which the values of the
other characteristics correspond.
6 Marking and other product information
In addition, screwless terminals of IC-CPD according to 4.3.3 shall be marked with an
appropriate marking indicating the length of insulation to be removed before the
insertion of the conductor into the screwless terminal.
7 Standard conditions for operation in service and for installation
IC-CPDs shall be used in accordance with their instructions.
8 Requirements for construction and operation
The manufacturer shall specify the minimum level of engagement of each contact of
the electrical connection from which it can be used at nominal current.
It shall not be possible to disassemble an IC-CPD classified according to 4.3.2.
9 Tests
For the purpose of verification of conformity with this document, type tests are carried
out in test sequences.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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