GB/T 40432-2021 PDF English
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GB/T 40432-2021: Conductive on-board 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/GBT40432-2021
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
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
with input current > 16 A and ≤ 75 A per phase
GB/T 17626.4-2018 Electromagnetic compatibility - Testing and
measurement techniques - Electrical fast transient/burst immunity test
GB/T 17626.5 Electromagnetic compatibility - Testing and measurement
techniques - Surge immunity test
GB/T 17626.11 Electromagnetic compatibility - Testing and measurement
techniques - Voltage dips, short interruptions and voltage variations
immunity tests
3 Terms and definitions
The terms and definitions as defined in GB/T 19596, as well as the following
terms and definitions, apply to this document.
3.1
On-board charger
It is a device, which is fixedly installed on a vehicle; converts the electric
energy, which conforms to the public power grid into the direct current, which
is required by the on-board energy storage device; charges the on-board
energy storage device.
[Source. GB/T 19596-2017, 3.4.1.5.1, with modification]
3.2
Power factor
The ratio of the input active power of the vehicle charger TO the input
apparent power.
3.3
Charging efficiency
The percentage of the ratio of output power TO the input active power.
3.4
Output voltage tolerance
The percentage of the ratio, of the difference between the actual output
voltage value and the output voltage setting value, TO the setting voltage
value.
3.5
Output current tolerance
The percentage of the ratio, of the difference between the actual output
current value and the output current setting value, TO the setting current
value.
3.6
Voltage ripple factor
The ratio, of half of the difference between the peak value and the valley
value of the DC pulsating voltage, which is output by the on-board charger,
TO the average value of the DC voltage.
4 Technical requirements
4.1 Appearance requirements
4.1.1 Conductive on-board chargers for electric vehicles (hereinafter referred to
as "on-board chargers"), shall have no defects, such as obvious damage or
deformation, on the outer surface.
4.1.2 The terminal or lead wire of the on-board charger shall be intact and
undamaged; the fastener connection shall not be loose.
4.1.3 The accessible surface of the on-board charger shall be free of burrs,
flashes, or similar sharp edges.
4.2 Requirements of charging characteristics
4.2.1 AC input conditions
4.2.2 Start input impulse current
The peak value of the start input impulse current, of on-board charger, shall not
exceed 120% of the input current peak value, when the rated load is in stable
operation.
4.2.3 DC output voltage limiting characteristics
For vehicle chargers, which have constant voltage output characteristics, when
the DC output voltage reaches the set value of output voltage limit, they shall
automatically limit the increase in output voltage.
4.2.4 DC output current limiting characteristics
For vehicle chargers, which have constant current output characteristics, when
the DC output current reaches the set value of output current limit, they shall
automatically limit the increase in output current.
4.2.5 DC output power limiting characteristics
4.2.6 DC output voltage tolerance
For on-board chargers, which have constant voltage output characteristics, the
output voltage tolerance shall not exceed ±1%, in the voltage-limiting output state.
4.2.7 DC output current tolerance
For the on-board charger in the current-limiting output state, when the output
current is greater than 10 A, the output current tolerance shall not exceed ±5%;
when the output current is not greater than 10 A, the output current deviation
shall not exceed ±0.5 A.
4.2.8 Output voltage ripple factor
For on-board chargers, which have constant voltage output characteristics, the
output voltage ripple factor shall not be greater than 5%, in the voltage-limiting
output state.
4.2.9 Start output overshoot
4.2.10 Output dump requirements
When the on-board charger is subject to output load dump, its output voltage
overshoot value shall not be greater than the voltage value, which is specified
in the product technical file.
4.2.11 Power factor
The power factor of the on-board charger shall meet the requirements of Table 2.
4.2.12 Charging efficiency
When the on-board charger is in the output voltage range AND is working at the
rated power output or the maximum output current, the test shall be carried out
in accordance with 5.3.13.
According to different energy efficiency grades, the average efficiency shall
meet the requirements of Table 3.
4.3 Protection function
4.4 Electrical safety
4.4.1 Insulation resistance
The insulation resistance of the on-board charger shall meet the following
requirements.
4.4.2 Withstanding voltage
The withstanding voltage performance, between the independent live port
circuits of the on-board charger and the ground (shell), AND between the live
port circuits that are not electrically connected to each other, shall meet the
requirements of Table 4.The withstanding voltage test lasts for 1 min, without
break down and arc. The leakage current limit shall be in accordance with the
product technical documents.
4.4.3 Contact current
The contact current, BETWEEN any phase line or neutral line of the AC port of
the on-board charger AND the accessible metal shell, shall not be greater than 3.5 mA.
4.5 Electromagnetic compatibility
4.5.1 Function characteristic state
The functional characteristic state defines the expected target of the functional
characteristics of the device under test (DUT), in the test environment. It is
suitable for each independent function of the DUT. It describes the working state
of the expected function, during and after the test. The four characteristic states
are given below.
4.5.2 Electromagnetic immunity requirements
4.5.3 Requirements for electromagnetic emission disturbance
4.6 Environmental adaptability
4.6.1 Environmental conditions
4.6.2 High and low temperature resistance
The high and low temperature performance shall be able to meet the
requirements of 5.1 in GB/T 28046.4-2011.
4.6.3 Damp heat resistance
4.6.4 Salt spray resistance
The salt spray resistance of the on-board charger shall be able to meet the
requirements of 5.5 in GB/T 28046.4-2011.
4.6.5 Vibration resistance
The vibration resistance of the on-board charger shall be able to meet the
requirements of 4.1 in GB/T 28046.3-2011.
4.6.6 Mechanical shock resistance
The mechanical shock resistance of the on-board charger shall be able to meet
the requirements of 4.2 in GB/T 28046.3-2011.After the test, the on-board
charger shall not cause the live part to contact the shell, due to permanent or
temporary deformation.
4.7 Noise
For forced-air-cooled vehicle-mounted chargers, the maximum measured noise
of the sound power level, when working at rated power, shall not be greater
than 65 dB(A).
4.8 Durability
For liquid-cooled on-board chargers, under the conditions of an ambient
temperature of 65 °C and a coolant of 40 °C, the coolant flow rate shall be in
accordance with the product technical documents; it shall run continuously at
full power, for not less than 1000 h. For air-cooled on-board chargers, at the
maximum allowable operating temperature, it shall run continuously at full
power, for not less than 1000 h, OR meet the requirements of the product
technical documents.
4.9 Inverter output function requirements
For on-board chargers, which have inverter output function, the technical
requirements and test methods for inverter output shall comply with the
requirements of Appendix A.
5 Test method
5.1 Test conditions
5.1.1 Environmental conditions
When there are no special environmental requirements, the test shall be carried
out, according to the following environmental conditions.
5.1.2 Equipment requirements
The test equipment shall be at least one level higher than the technical
indicators of the equipment under test. Meanwhile it shall have sufficient
resolution, accuracy, stability. Unless otherwise specified, the following
requirements shall be met.
5.2 Appearance test
Visual inspection and surface touch inspection.
5.3 Test method of charging characteristics
5.3.1 Basic principle diagram of charging test
The basic principle diagram of the charging test is as shown in Figure 1.
Figure 1 -- Basic schematic diagram of charging test
5.3.2 AC input condition test
5.3.3 Start input impulse current test
Test method and procedure.
5.3.4 Test of DC output voltage limiting characteristic
Test method and procedure.
5.3.10 Test of start output overshoot
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.
5.4 Test of charge protection function
5.4.1 Test of AC input over-voltage and under-voltage protection
Test method and procedure.
5.4.2 Test of phase failure protection
Test method and procedure.
5.4.3 Test of DC output over-voltage and under-voltage protection
5.4.4 Test of output short circuit protection
5.4.4.1 Test of short-circuit protection before starting
Test method and procedure.
a) Connect the test circuit according to Figure 1.Short-circuit the DC positive
and negative poles of the on-board charger;
b) Under rated input conditions, turn on the on-board charger. Observe the
state of the on-board charger;
c) After the output short circuit is removed, observe its output state, OR
restart the on-board charger under rated conditions, to observe its output
state.
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
room temperature. Connect all electrical wiring harnesses in good condition.
After adjusting the temperature of the thermostat to reach the temperature
specified in 4.8 AND keep it for 2 hours, start the on-board charger, to make it
work at the rated load, for not less than 1000 h.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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