QC/T 1175-2022 PDF in English
QC/T 1175-2022 (QC/T1175-2022, QCT 1175-2022, QCT1175-2022)
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High voltage contactor for electric vehicles
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QC/T 1175-2022: PDF in English (QCT 1175-2022) QC/T 1175-2022
QC
AUTOMOBILE INDUSTRY STANDARD
OF THE PEOPLE’S REPUBLIC OF CHINA
ICS 43.020
CCS T 09
High voltage contactor for electric vehicles
ISSUED ON: APRIL 08, 2022
IMPLEMENTED ON: OCTOBER 01, 2022
Issued by: Ministry of Industry and Information Technology of PRC
Table of Contents
Foreword ... 6
1 Scope ... 7
2 Normative references ... 7
3 Terms and definitions ... 8
4 Symbols and abbreviations ... 10
5 Requirements ... 10
6 Test method ... 16
7 Inspection rules ... 35
Appendix A (Informative) Contactor classification ... 38
Appendix B (Informative) Guidelines for the use of contactors ... 39
References ... 41
High voltage contactor for electric vehicles
1 Scope
This document specifies the technical requirements, test methods, inspection rules for
high-voltage contactors for electric vehicles.
This document applies to high-voltage contactors for electric vehicles (hereinafter
referred to as contactors), which has a rated DC operating voltage of the main contacts
in the range of 60 V ~ 1500 V.
This document does not apply to AC contactors for electric vehicles.
2 Normative references
The contents of the following documents constitute the essential provisions of this
document through normative references in the text. Among them, for dated references,
only the version corresponding to the date is applicable to this document; for undated
references, the latest version (including all amendments) is applicable to this document.
GB/T 2423.56-2018 Environmental testing - Part 2: Test methods - Test Fh:
Vibration, broadband random and guidance
GB/T 2423.18-2012 Environmental testing - Part 2: Test methods - Test Kb: Salt
mist, cyclic (sodium chloride solution)
GB/T 2423.34-2012 Environmental testing - Part 2: Test methods - Test Z/AD:
Composite temperature/humidity cyclic test
GB/T 2900.18-2008 Electrotechnical terminology - Low voltage apparatus
GB/T 5169.11-2017 Fire hazard testing for electric and electronic products - Part 11:
Glowing/hot-wire based test methods - Glow-wire flammability test method for end-
products (GWEPT)
GB/T 14048.1-2012 Low-voltage switchgear and controlgear - Part 1: General
principles
GB/T 17626.4-2018 Electromagnetic compatibility - Testing and measurement
techniques - Electrical fast transient/burst immunity test
GB/T 18655-2018 Vehicles, boats and internal combustion engines - Radio
disturbance characteristics - Limits and methods of measurement for the protection
of on-board receivers
GB/T 19951 Road vehicles - Disturbances test methods for electrical/electronic
component from electrostatic discharge
GB/T 21437.2-2008 Road vehicles - Electrical disturbances from conduction and
coupling - Part 2: Electrical transient conduction along supply lines only
GB/T 28046.3-2011 Road vehicles - Environmental conditions and testing for
electrical and electronic equipment - Part 3: Mechanical loads
GB/T 33014.2-2016 Road vehicles - Component test methods for
electrical/electronic disturbances from narrowband radiated electromagnetic energy
- Part 2: Absorb-lined shielded enclosure
GB/T 33014.4-2016 Road vehicles - Component test methods for
electrical/electronic disturbances from narrowband radiated electromagnetic energy
- Part 4: Bulk current injection (BCI)
ISO 11452-8:2015 Road vehicles - Component test methods for electrical
disturbances from narrowband radiated electromagnetic energy - Part 8: Immunity
to magnetic field
3 Terms and definitions
The terms and definitions as defined in GB/T 2900.18-2008 and GB/T 14048.1-2012,
as well as the following terms and definitions, apply to this document.
3.1
Contactor
A non-manually operated mechanical switching device, that has only one rest
position and can make, carry and break current, under normal circuit conditions
(including overload operating conditions).
3.2
Contact resistance
The resistance value between the closed contacts, which are measured from the two
terminals of the contact assembly.
3.3
Contact rated voltage
a) Operation mode 1: The contactor coil's end connector is normally connected, BUT
no power is supplied;
b) Operation mode 2: The coil end of the contactor supplies power, BUT the contact
does not supply power;
c) Operation mode 3: The coil end of the contactor supplies power, AND the contacts
supply power.
Note: Contact power supply generally means that the contactor's contacts pass a constant
rated current, without requirements for the voltage. If there are special circumstances, the
contact power supply situation can be determined, through negotiation, between the supplier
and the buyer. The coil power supply refers to the supply of test voltage to the contactor
coil's control circuit.
4 Symbols and abbreviations
The following symbols and abbreviations apply to this document.
RT - Room temperature;
Tmax - Maximum operating temperature;
Tmin - Minimum operating temperature;
UN - Rated voltage;
Usmin - Minimum operating voltage;
tA - Glow wire application time;
tE - Duration from application of the tip of the glow-wire to the start of the test until
all flames are extinguished;
ΔT - Temperature difference.
5 Requirements
5.1 Working environment
Unless otherwise specified, the contactor shall work normally under the following
environmental conditions:
a) Working environment temperature: -40 °C ~ 85 °C;
b) Relative humidity: 5% ~ 95%;
5.4.3 Requirements for make time and release time
Carry out the test according to 6.4.3. The make time of the contactor shall be less than
50 ms; the release time shall be less than 30 ms.
5.4.4 Coil short-term overvoltage requirements
Carry out the test according to 6.4.4. During the test, the contactor shall work normally.
After the test, the contactor shall meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9,
5.4.10.
5.4.5 Coil long-term overvoltage requirements
Carry out the test according to 6.4.5. During the test, the contactor shall work normally.
After the test, the contactor shall meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9,
5.4.10.
5.4.6 Voltage drop requirements
Carry out the test according to 6.4.6. Within the operating voltage range of the coil, the
contactor shall work normally. Outside the operating voltage range of the coil, the
contactor can be disconnected. After the test, the contactor shall meet the requirements
of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10.
5.4.7 Coil reverse voltage requirements
Carry out the test according to 6.4.7. The contactor shall meet the following
requirements:
a) Contactor with circuit board: When a reverse voltage is applied to the coil end,
the circuit board of the contactor shall not be damaged. When the forward test
voltage is applied after the test, the contactor shall comply with the requirements
of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10;
b) Contactor without circuit board: The contactor shall work normally during the test.
The contactor shall comply with the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9,
5.4.10.
5.4.8 Requirements for contact voltage drop/contact resistance
Carry out the test in accordance with 6.4.8. The contact voltage drop/contact resistance
of the contactor, before and after the test, shall meet the values, which are negotiated
and determined between the supplier and the purchaser.
5.4.9 Requirements for insulation resistance
Carry out the test according to 6.4.9. Before the test, the insulation resistance of the
contactor shall be greater than 1000 MΩ. After the test, the insulation resistance of the
contactor shall be greater than 50 MΩ.
5.4.10 Requirements for power frequency withstand voltage
Carry out the test according to 6.4.10. During the test, the contactor shall have no
defects, such as flashover, arcing, or insulation breakdown. The leakage current of the
contactor shall not exceed 0.5 mA.
5.4.11 Requirements for anti-short-circuit current capability
Carry out the test according to 6.4.11. During the test, the contactor shall be free from
smoke, explosion, fire, appearance damage.
5.4.12 Requirements for ultimate breaking capacity
Carry out the test according to 6.4.12. The contactor shall be able to break safely at least
once, that is, the contactor has no adhesion, smoke, fire, explosion, appearance damage.
5.4.13 Electrical life requirements
Carry out the test according to 6.4.13. During the test, the contactor shall work normally.
After the test, the contactor shall meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9,
5.4.10, 5.4.14.
5.4.14 Temperature rise requirements
Carry out the test in accordance with 6.4.14. If there is no special requirement, the
temperature rise of the contactor contact and the shell shall not exceed 60 K. After the
life test, the temperature rise test shall be carried out, under high temperature conditions.
It is required that the maximum temperature of the contactor's contact and the shell shall
not exceed 150 °C. After the test, the contactor shall meet the requirements of 5.4.2,
5.4.3, 5.4.8, 5.4.9, 5.4.10.
5.5 Environmental adaptability
5.5.1 Low temperature requirements
Carry out the test according to 6.5.1. During the test, the contactor shall work normally.
After the test, the contactor shall meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9,
5.4.10, 5.4.14.
5.5.2 High temperature requirements
Carry out the test according to 6.5.2. During the test, the contactor shall work normally.
After the test, the contactor shall meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9,
5.4.10, 5.4.14.
5.5.3 Requirements for constant damp heat
5.4.10, 5.4.14.
5.6.2 Mechanical vibration requirements
Carry out the test according to 6.6.2. The contactor in the test shall meet the following
requirements:
a) In the operation mode 1 when the contact is opened, the contactor shall not be
closed instantaneously (the single closing time of the open contact shall not
exceed 10 μs);
b) In the operation mode 2 when the contact is closed, the contactor shall not be
disconnected instantaneously (the single disconnection time of the closed contact
shall not exceed 10 μs).
After the test, the contactor shall have no mechanical damage and meet the requirements
of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10, 5.4.14.
5.6.3 Mechanical shock requirements
Carry out the test according to 6.6.3. The contactor in the test shall meet the following
requirements:
a) In the operation mode 1 when the contact is opened, the contactor shall not be
closed instantaneously (the single closing time of the open contact shall not
exceed 10 μs);
b) In the operation mode 2 when the contact is closed, the contactor shall not be
disconnected instantaneously (the single disconnection time of the closed contact
shall not exceed 10 μs).
After the test, the contactor shall have no mechanical damage and meet the requirements
of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10, 5.4.14.
5.6.4 Sound level requirements
The test shall be carried out according to 6.6.4. The limit value of the contactor's sound
level test shall be determined, through negotiation between the supplier and the
purchaser.
5.7 Electromagnetic compatibility
5.7.1 General requirements
Contactors with electronic circuits shall meet the technical requirements, which are
specified in 5.7.2 ~ 5.7.8.
5.7.2 Conducted disturbance requirements
Conduct the test according to 6.7.1. If there is no special requirement, the conduction
disturbance of the contactor shall comply with the limit values of level 3, which are
specified in Table 5 and Table 6 in GB/T 18655-2018.
5.7.3 Radiation disturbance requirements
Conduct the test in accordance with 6.7.2. If there is no special requirement, the
radiation disturbance of the contactor shall comply with the limit values of level 3,
which is specified in Table 7 in GB/T 18655-2018.
5.7.4 Transient conducted disturbance requirements
Conduct the test according to 6.7.3. If there is no special requirement, the transient
conduction disturbance of the contactor shall comply with the limit value requirements
of level 3, in C.2 and C.3 of GB/T 21437.2-2008
5.7.5 Transient conduction immunity requirements for power lines
Carry out the test according to 6.7.4. If there is no special requirement, the contactor
shall work normally, during and after the test.
5.7.6 Electrical fast transient burst immunity requirements
Carry out the test according to 6.7.5. If there is no special requirement, the contactor
shall work normally, during and after the test.
5.7.7 Radiated immunity requirements
Carry out the test according to 6.7.6. If there is no special requirement, the contactor
shall work normally, during and after the test.
5.7.8 Electrostatic discharge requirements
Carry out the test according to 6.7.7. If there is no special requirement, the contactor
shall work normally, during and after the test.
6 Test method
6.1 General test conditions
6.1.1 Standard atmospheric conditions of test
Unless otherwise specified, all tests shall be carried out, under the following
environmental conditions:
a) Room temperature: 23 °C ± 5 °C;
temperature (ΔT ≤ ±2 °C);
b) Apply a voltage value, within the voltage range in Table 1, to the coil end of the
contactor;
c) Monitor contactor's contact state.
6.4.2 Pick-up and release voltage test
6.4.2.1 The contactor is tested under the conditions of operation mode 2.
6.4.2.2 Type tests are carried out at 85 °C, 23 °C, -40 °C, respectively. The exit-factory
inspections are carried out at 23 °C.
6.4.2.3 The pick-up voltage test process is as follows:
a) Place the contactor in the temperature box before the test. The test can be carried
out, after the temperature of the contactor is consistent with the test environment
temperature (ΔT ≤ ±2 °C);
b) Adopt the method of increasing voltage: Start the low-voltage power supply and
adjust the voltage, starting from 0 V and increasing at 0.1 V stepwise voltage,
until it is detected that the moving and static contacts are connected;
c) Increase voltage by step-up method: First adjust the voltage of the low-voltage
power supply to the voltage, which is shown in Table 2; then start the low-voltage
power supply after connecting the contactor coil.
Note: Choose one of the two test methods to test; the double-coil contactor with energy-saving
board and with driver board shall be tested, in step-up voltage increasing mode.
6.4.2.4 The release voltage test process is to slowly reduce the power supply voltage
from the rated voltage of the coil, until the movable and static contacts are completely
disconnected.
6.4.3 Make time and release time test
The make time and release time tests shall be carried out, according to the following
requirements:
a) Apply the rated voltage to the coil end of the contactor; the load connected to the
contact end does not exceed 12 V/l A;
b) Use an oscilloscope to collect the voltage waveform, at both ends of the coil, as
well as the voltage waveform, at both ends of the load;
c) The time difference -- between the voltage at both ends of the coil and the voltage
at both ends of the load changing from low level to high level -- is the make time;
d) When the coil end of the contactor is powered off, the time difference -- between
the voltage at both ends of the coil and the voltage at both ends of the load
changing from high level to low level -- is the release time.
6.4.4 Coil short-term overvoltage test
6.4.4.1 The test object is a contactor, which has a coil rated voltage of 12 V.
6.4.4.2 The contactor is tested under the conditions of operation mode 2.
6.4.4.3 The coil short-term overvoltage test process is to place the contactor in a room
temperature environment. Apply 2 times the rated voltage to the coil end, which lasts
for 60s.
6.4.5 Coil long-term overvoltage test
6.4.5.1 The contactor is tested under the conditions of operation mode 2.
6.4.5.2 The test is carried out at 85 °C.
6.4.5.3 The coil long-term overvoltage test process is to place the contactor in the
temperature box. Apply 1.5 times the rated voltage, to the coil end, after the temperature
of the contactor remains consistent with the test environment temperature (ΔT ≤ ±2 °C)
for 60 minutes.
6.4.6 Voltage drop-jumpback test
6.4.6.1 The contactor is tested under the conditions of operation mode 2.
6.4.6.2 The voltage drop-jumpback test process is as follows:
a) According to Figure 1, apply a test pulse to the coil end of the contactor, in which
the supply voltage drops from Usmin to 0.95Usmin, at a 5% amplitude, maintaining
for 5 s; then jump back to Usmin from 0.95Usmin, maintaining for at least 10 s.
Repeat the above operations in sequence, until the power supply voltage drops
from Usmin to 0 V, at a 5% amplitude; then jump the voltage back to Usmin;
b) Check the reset performance of the contactor.
level, when the contactor is pick-up and released;
c) Repeat the test for more than 30 times on each side of the specimen; take the
average value as the test result.
6.7 Electromagnetic compatibility
6.7.1 Conducted disturbance test
The conducted disturbance test shall be carried out, according to the test method in 6.3
of GB/T 18655-2018.
6.7.2 Radiation disturbance test
The radiation disturbance test shall be carried out, according to the test method in 6.5
of GB/T 18655-2018.
6.7.3 Transient conducted disturbance test
The transient conduction disturbance test shall be carried out, in accordance with the
test method in Chapter 4 of GB/T 21437.2-2008.
6.7.4 Power line transient conduction immunity test
The power line transient conduction immunity test shall be carried out, according to the
test method 5.6 in GB/T 2143 7.2-2008; the test severity level shall be level III.
6.7.5 Electrical fast transient burst immunity test
The electrical fast transient burst immunity test shall be carried out, according to the
test method in GB/T1 7626.4-2018; the test level is level 3; the pulse repetition
frequency is 5 kHz.
6.7.6 Radiated immunity test
The radiation immunity test shall be carried out, in accordance with the following
requirements:
a) Carry out the radiation immunity test, according to the test method of GB/T
33014.2-2016; the test frequency range is 400 MHz ~ 2 GHz; the intensity level
of test field is 30 V/m;
b) According to the test method of GB/T 33014.4 -2016, conduct a large current
injection test, on the power line and the signal line connected to the outside. The
test frequency range is 1 MHz ~ 400 MHz; the injection current level is 60 mA;
c) Carry out the magnetic field immunity test, according to the test method of ISO
11452-8:2015; the test frequency range is 15 Hz ~ 150 kHz; the test level is level
......
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.
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