QC/T 895-2011 PDF English
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On-board conductive charger for electric vehicles
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QC/T 895-2011: On-board conductive charger 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/QCT895-2011
ICS 43.040
T 35
QC
INDUSTRY STANDARD
On-board conductive charger for
electric vehicles
Issued on. DECEMBER 20, 2011
Implemented on. JULY 01, 2012
Issued by. The 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... 9
4 Basic components... 10
5 Parameters... 11
6 Requirements... 12
7 Test method... 17
8 Inspection rules... 26
9 Marking, packaging, transportation and storage... 29
Annex A (Normative) Control guide circuit... 31
1 Scope
This standard specifies the basic structure, parameters, requirements, test methods,
inspection rules and markings, packaging, transport and storage of on-board conductive
charger for electric vehicles (hereinafter referred to as on-board charger).
This standard applies to the on-board charger used for the pure electric vehicles and the
hybrid electric vehicles which are external rechargeable.
2 Normative References
The following standards contain provisions which, through reference in this standard,
constitute provisions of this standard. For the dated references, all the subsequent
amendment lists (excluding the content of corrigendum) or revisions do not apply to this
standard; however, the involved parties who enter into agreements based on this standard
are encouraged to investigate the possibility of applying the latest editions of the
standards indicated below. For the undated references, the latest edition applies to this
standard.
GB 191 Packaging - Pictorial markings for handling of goods (eqv ISO 780)
GB/T 2423.17 Basic environmental testing procedures for electric and electronic
products - Test Ka. Salt mist
GB 4208-2008 Degrees of protection provided by enclosure(IP code)
GB/T 15139-1994 General technical standard for electrical equipment structure
GB 17625.1-2003 Electromagnetic compatibility-Limits - Limits for harmonic current
emissions (equipment input current��16A per phase)
GB/Z 17625.6-2003 Electromagnetic compatibility--Limits--Limitation of emission of
harmonic currents in low-voltage power supply systems for equipment with
rated current greater than 16A
GB/T 18384.3-2001 Electric vehicles-Safety specification-Part 3.Protection of
persons against electric hazards
GB/T 18487.1 Electric vehicle conductive charging system--Part 1.General
requirements
GB/T 18487.3 Electric vehicle conductive charging system A.C./D.C. Electric vehicle
charging station
GB/T 18488.1-2006 The electrical machines and controllers for electric vehicles -
Part 1.General specification
3 Terms and definitions
Terms defined in GB/T 19596 and GB/T 18487.1 as well as following definitions and terms
apply to this standard.
3.1 On-board charger
Refers to a device that installed on the electric automobile, and can converted the power
of the public grid into direct current required by the on-board energy storage device and
can charge the on-board energy storage device.
3.2 Charging efficiency
The percentage of the ratio of the on-board charger DC output power and the AC input
active power.
3.3 Total harmonic distortion (THD)
The square-root of sum of squares of the ratio of the 2-th �C 40-th harmonic current
component AND the fundamental current.
3.4 Output voltage tolerance
The percentage of the RATIO of the DEVIATION between the on-board charger��s actual
output voltage value and output voltage pre-set value AND output voltage pre-set value.
3.5 Output current tolerance
The percentage of the RATIO of the DEVIATION between the on-board charger��s actual
output current value and output current pre-set value AND output current pre-set value.
3.6 Charging coupler
Other components except for the cable and the cable control box (if any) in the charging
connecting apparatus, including the power supply interface and vehicle interface.
4 Basic components
On-board charger consists of AC input interface, power unit, control unit, DC output
interface and other components.
5 Parameters
5.1 Rated input voltage, rated input current
The on-board charger input voltage and current levels are shown in Table 1.
5.2 Recommended values of output voltage
It is recommended to divide the on-board charger output voltage levels into 6 in
accordance with Table 2.
6 Requirements
6.1 General provisions
6.1.1 The outer surface of on-board charger shall be smooth, without obvious
scratches, deformation and other defects. The surface coating shall be uniform.
6.1.2 Nameplate and markings installation shall be upright and fixed, with clear
handwriting.
6.1.3 Parts shall be securely tightened. There shall be no rust, burrs, cracks and other
defects and damages.
6.1.4 The strength and stiffness of the on-board charger structure shall conform to the
requirements of 6.5 in GB/T 15139-1994.
6.2 Environmental Requirements
6.2.1 Humidity.
Relative Humidity is 5% - 95%, non-condensing, non-frosting.
6.2.2 Temperature.
The on-board charger operating temperature and storage temperature range shall comply
with the requirements of Table 3
6.3 Input voltage and frequency
6.3.1 Input voltage range.
Within the range of �� 15% of the rated input voltage, the on-board charger shall be able to
work normally.
6.4 Functional requirements
6.4.1 Charging Function.
6.4.2 Voltage-limiting and current-limiting characteristics.
6.4.3 Protection functions.
6.4.4 Low voltage power supply function.
For the on-board charger with a low-voltage auxiliary power, the low voltage auxiliary
power supply shall provide a DC voltage with a nominal value of 12V or 24V, and the DC
voltage ripple factor shall be less than 1%.
6.5 High voltage electrical performance requirements
6.5.1 Starting surge starting current.
The starting surge current of the on-board charger (on-board charger input current) shall
not exceed 150% of the maximum value of the working input current.
6.5.2 Output voltage tolerance.
When the on-board charger is running in a state of constant voltage output, the deviation
between its output voltage and the set voltage shall be �� 1%.
6.5.3 Output current error.
When the on-board charger is running in a state of constant current output, the deviation
between its output current value and the set current value shall be �� 5%.
6.5.4 Ripple coefficient of voltage.
The on-board charger voltage ripple factor shall be �� 5%.
6.5.5 Power factor and charging efficiency.
6.6 Electrical safety requirements
6.6.1 Insulating property.
On-board charger insulation performance shall meet the following provisions.
6.7 Electromagnetic compatibility
6.7.1 Electromagnetic immunity.
Electromagnetic immunity of on-board charger during operation shall meet requirements
in 11.3.1 of GB/T 18487.3-2001.
6.7.2 Electromagnetic disturbance.
Electromagnetic immunity generated during the operation of on-board charger shall meet
requirements in 11.3.1 of GB/T 18487.3-2001.
6.7.3 Harmonic current.
6.8 Environmental performance requirements
6.8.1 Vibration resistance performance.
Sweep vibration test shall be conducted on on-board charger according to 7.8.1.After the
test, parts shall be free of damage, fasteners shall be free of loosening, and normal
operation shall be assured.
6.8.4 IP Protection class.
On-board charger IP protection class shall comply with the provisions of 3.6 in
QC/T413-2002.The specific protection class shall be set in accordance with the
requirements of the body layout, and the minimum shall not be less than IP20B.
6.8.5 Salt mist resistance.
On-board charger shall be able to withstand salt mist test prescribed in 7.9.5, and to
operate normally after test and standing.
6.9 Noise
Maximum operating noise of on-board charger and its cooling system measured in
accordance with 7.9 shall not exceed 65dB (level A).
6.10 Durability.
Conduct the test according to requirements of 7.10, normal operation of the product shall
be assured during the test.
7 Test method
7.1 Test conditions
7.1.1 Environmental conditions.
Without special provisions, the test shall be carried out under the following environmental
conditions.
7.1.2 Measuring instruments and meters.
Measuring instruments and meters specified in Table 4 are recommended, accuracy of
measuring instruments and meters shall be more than 3 times higher than the accuracy of
the test sample parameters.
7.1.3 On-board charger basic states.
7.2 Environmental test
7.2.1 Humidity test.
The test shall be carried out according to provisions of 3.11 in QC/T413-2002 for two
cycles, during test process; on-board charger shall be in operating state under
temperature of 0-45oC.
7.2.2 Temperature test.
7.3 Input voltage and frequency test
7.3.1 Voltage fluctuation range test.
Start up the on-board charger to make it run at rated load condition; respectively, adjust
on-board charger input voltage to 85%, 100% and 115% of the rated value, and
continuously run at each input voltage for 1min.
7.3.2 Frequency fluctuation test.
Adjust the on-board charger input voltage to the rated voltage, start up on-board charger
to make it run at rated load; respectively adjust on-board charger to make it at input
frequency of 49Hz and 51 Hz, and continuously run at each frequency for 1 min.
7.4 Function requirements test
7.4.1 Charging function test.
Under the voltage and frequency range condition specified in 6.3, start on-board charger,
the on-board charger output rated power.
7.4.2 Voltage-limiting and current-limiting characteristics test.
7.4.3 Protection function test.
7.4.3.1 Overvoltage protection test.
7.4.3.2 Under-voltage protection test.
7.4.3.3 Short circuit protection test.
7.4.3.5 Reverse-connection protection test.
Connect the output positive pole of the on-board charger to the negative pole of the
capacitive load, and connect the output negative pole of the on-board charger to the
positive pole of the capacitive load, and under the voltage and frequency conditions
specified in the 6.3, start up on-board charger.
7.4.4 Low voltage power supply function test.
At the low-voltage auxiliary power output terminal, connect adjustable resistive load circuit
(adjustable resistive load must meet adjustment requirement of the low-voltage auxiliary
power from no load to full load), and connect the oscilloscope at the output; start on-board
charger, read and record the maximum peak �C peak shown on the oscilloscope and the
DC output average voltage, and obtain the ripple coefficient values through calculation.
7.5 High voltage electrical performance requirements test
7.5.1 Starting surge current test.
At nominal input voltage and rated input frequency, start up the on-board charger to make
it work at rated load, and use the oscilloscope to measure input current peaks during such
start-up process.
7.5.5 Power factor and charging efficiency test.
At nominal input voltage and rated frequency, start up on-board charger to make it work in
the full load condition; use power meter to measure the power factor of the on-board
charger, record input active power and DC output power of the on-board charger, and
obtain the charging efficiency of the on-board charger through calculation.
7.5.6 Output response time test.
At rated input voltage and rated frequency, start up on-board charger to make it operate in
constant voltage output mode; after using the oscilloscope to measure and confirm that
the on-board charger has fully started up, the rise time of the output voltage, output
voltage rise peak and stable value, output voltage rise time and the calculated overshoot
shall meet the requirements of 6.5.6; after the on-board charger receives the shutdown
command, fall time of the output current shall meet the requirements of 6.5.6.
7.6 Electrical safety test
7.8 Environmental performance test
7.8.1 Vibration test
When the on-board charger is at non-working state, make it withstand scanning frequency
vibration test from the following three directions - up and down, left and right, front and
rear; 8h test time for each direction, and scanning frequency vibration test conditions shall
comply with the requirements of Table 6.
8 Inspection rules
8.1 General provisions
On-board charger shall be checked and qualified before delivery, and attached with
documents or labels to prove the product quality.
8.2 Inspection type
The inspection of on-board charger is classified into ex-factory inspection and type
inspection.
8.2.1 Ex-factory inspection
Visual inspection shall comply with the provisions as specified in 6.1 and performance test
shall comply with the provisions as specified in Table 8 when make delivery inspection.
8.2.2 Type inspection
8.2.2.1 Type inspection shall be conducted under one of the following conditions.
8.2.2.2 The products conducted with type inspection shall be randomly selected from
products that are qualified in the factory inspection and shall be able to cover the whole
production process, totally 12 samples, all of which shall accomplish the performance test;
after qualified they will be divided into 6 groups, 2 samples for each group. Test items and
test sequence of each group of samples shall comply with provisions as specified in Table
9.
9 Marking, packaging, transportation and storage
9.1 Marking
9.1.1 Product marking
9.2 Packaging
9.2.1 Product package shall consider the following items.
9.2.2 Packing carton shall be firm, products shall be motionless in the carton, free of
mechanical damage in transportation, handling and stacking process and packaging
carton can be moisture proof, corrosion prevention, shake proof and dust prevention.
Technical documents accompanied with packaging carton shall include the packing list,
product factory quality certification, product operation instruction and prepared
attachments list. Outside the packaging carton shall be marked.
9.3 Storage and custody
Product storage and custody shall be maintained under clean, dry and well-ventilated
environment of 5 oC to 40 oC. It shall avoid sun, fire-roasted, water immersion, and putting
together with corrosive substances.
9.4 Handling and transportation
Shock and vibration of products suffered during in carrying shall be limited to a minimum.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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