This specification is drafted in accordance with GB/T 1.1-2009.
"Technical Specification for Cables of Electric Vehicles Conductive Charging Systems" series is proponed by China Quality Certification Center. It is one of technical specification series for voluntary certification of products. This series consists of the following 3 technical specifications:
"Technical Specification for Cables of Electric Vehicles Conductive Charging Systems - Part 1: General Requirement" (CQC 1103)
Technical Specification for Cables of Electric Vehicles Conductive Charging Systems - Part 2: Cables for AC Charging Systems (CQC 1104)
"Technical Specification for Cables of Electric Vehicles Conductive Charging Systems - Part 3: Cables for DC Charging Systems" (CQC 1105)
This specification is the converted and updated version of three standard series: CQC1103-2014, CQC1104-2014, CQC1105-2014, TICW 18-2012 and K175-2014.
Compared with CQC1103~5-2014, except editorial changes, the main technical changes of this specification are as follows:
1. Expression method of product type and specification is revised;
2. Products of halogen-free and cross linking material series are newly added;
3. EV-VV, EV-S90S90, EV-YJYJ and other series products and relevant requirements are deleted;
4. Temperature grade and the requirements of tear resistance test of TPE sheath are revised;
5. The voltage of voltage test of finished cable is changed to 3500V; specific voltage test method is specified;
6. Vehicle rolling compaction test, oil resistance test and capacitance increase rate after water penetration are deleted;
7. Extrusion test, reagent resistance test, abrasion resistance test, heat shrinkage test, insulation and long-term DC resistance test and hardness, weather resistance and saponification tests are newly added;
8. The insulation and sheath thickness of the product is revised, and the upper and lower limit requirements for outside diameter are deleted;
Chief drafting organizations of this specification:
China Quality Certification Center, National Quality Supervision and Testing Center for Cables and Wires and DEKRA Certification B. V.
Chief drafting staff of this specification:
Xie Zhiguo, Huang Xuan, Guan Lili, Li Na, Yang Juanjuan, Xiao Jidong, Zhu Yonghua, Wu Changshun, Hong Jian and Liu Weihai.
Chief participating drafting organizations and drafting staff of this specification:
Wuxi Xinhongye Wire & Cable Co., Ltd. Guan Yong
Guangdong OMG Transmitting Technology Co., Ltd. Liu Yaoxun
Zhongli Science and Technology Group Co., Ltd. Sun Jianyu
Hengyang Hengfei Cable Co., Ltd. Wang Fushan
Jiangyin Seven-star Cable Co., Ltd. Gao Wei
Zhongtian Technology Instrument Cable Co., Ltd. Chen Shuai
Wuxi Mingzhu Cable Co., Ltd. Yu Jinhua
Technical Specification for Cables of Electric Vehicles Conductive Charging Systems
Part 1: General Requirement
1 Scope
This specification specifies the designation, structure and technical requirements of the cable, the test methods, the test and inspection rules of finished cable and the marking and packaging of cable used for electric vehicle conductive charging system.
Cables specified in this specification include the charging cable (including control core) with rated voltage below AC 450/750V and DC 1.0kV.
Cables are applied to the charging systems complying with GB/T 18487.1-2001, connected with the connecting devices specified in GB/T 20234 and operated under different voltages and frequencies; they may include lower voltage grades and communication signals.
2 Normative References
The following normative documents contain provisions which, through reference in this text, constitute provisions of this standard. For dated references, only the edition cited applies. For undated references, the latest edition of the normative document (including any amendments) applies.
GB/T 2900.10 Electrotechnical Vocabulary - Electric Cables
GB/T 2951.11-2008 Common Test Methods for Insulating and Sheathing Materials of Electric and Optical Cables - Part 11: Methods for General Application - Measurement of Thickness and Overall Dimensions - Tests for Determining the Mechanical Properties (IEC 60811-1-1: 2001)
GB/T 2951.12-2008 Common Test Methods for Insulating and Sheathing Materials of Electric and Optical Cables - Part 12: Methods for General Application - Thermal Ageing Methods (IEC 60811-1-2: 1985)
GB/T 2951.13-2008 Common Test Methods for Insulating and Sheathing Materials of Electric and Optical Cables - Part 13: Methods for General Application - Measurement for Determining the Density - Water Absorption Tests - Shrinkage Test (IEC 60811-1-3: 2001)
GB/T 2951.14-2008 Common Test Methods for Insulating and Sheathing Materials of Electric and Optical Cables - Part 14: Methods for General Application - Test at Low Temperature (IEC 60811-1-4: 1985)
GB/T 2951.21-2008 Common Test Methods for Insulating and Sheathing Materials of Electric and Optical Cables - Part 21: Methods Specific to Elastomeric Compounds - Ozone Resistance, Hot Set and Mineral Oil Immersion Tests (IEC 60811-2-1: 2001)
GB/T 2951.31-2008 Common Test Methods for Insulating and Sheathing Materials of Electric and Optical Cables - Part 31: Methods Specific to PVC Compounds - Pressure Test at High Temperature - Test for Resistance to Cracking (IEC 60811-3-1: 1985)
GB/T 3048.4-2007 Test Methods for Electrical Properties of Electric Cables and Wires - Part 4: Test of DC Resistance of Conductors
GB/T 3048.8-2007 Test Methods for Electrical Properties of Electric Cables and Wires - Part 8: AC Voltage Test
GB/T 3956-2008 Conductors of Insulated Cables
GB/T 5013.1-2008 Rubber Insulated Cables of Rated Voltages Up to and Including 450/750V - Part 1: General Requirements (IEC 60245-1: 2003)
GB/T 5013.2-2008 Rubber Insulated Cables of Rated Voltages Up to and Including 450/750V - Part 2: Test Methods (IEC 60245: 1998)
GB/T 5023.2-2008 Polyvinyl Chloride Insulated Cables of Rated Voltages Up to and Including 450/750V - Part 2: Test Methods (IEC 60227: 1998)
GB/T 12706.1-2008 Power Cables with Extruded Insulation and Their Accessories for Rated Voltages from 1kV (Um=1.2kV) Up to 35kV (Um=40.5kV) - Part 1: Cables for Rated Voltage of 1kV (Um=1.2kV) and 3kV (Um=3.6kV)
GB/T 17650.1-1998 Test on Gases Evolved during Combustion of Materials from Cables - Part 1: Determination of the Halogen Acid Gas Content
GB/T 17650.2-1998 Test on Gases Evolved during Combustion of Materials from Cables - Part 2: Determination of Degree of Acidity of Gases by Measuring pH and Conductivity
GB/T 17737.1-2000 Radio-frequency Cables - Part 1: Generic Specification - General, Definitions, Requirements and Test Methods
GB/T 18380.12-2008 Tests on Electric Cables under Fire Conditions - Part 12: Test for Vertical Flame Propagation for a Single Insulated Wire or Cable - Procedure for 1kW Pre-mixed Flame (IEC 60332-1-2: 2004)
GB/T 18487.1-2001 Electric Vehicle Conductive Charging System - Part 1: General Requirements
GB/T 20234.1-2011 Connection Set of Conductive Charging for Electric Vehicles - Part 1: General Requirements
GB/T 20234.2-2011 Connection Set of Conductive Charging for Electric Vehicles - Part 2: AC Charging Coupler
GB/T 20234.3-2011 Connection Set of Conductive Charging for Electric Vehicles - Part 3: DC Charging Coupler
ISO 48-2010 Rubber, Vulcanized or Thermoplastic. Determination of Hardness (Hardness between 10IRHD and 100IRHD)
IEC 60684-2-2003 Flexible Insulating Sleeving - Part 2: Methods of Test
EN 50289-4-17-2011 Communication Cables - Specifications for Test Methods - Part 4-17: Test Methods for UV Resistance Evaluation of the Sheath of Electrical and Optical Fiber Cable
EN 50289-1-5-2001 Communication Cables - Specifications for Test Methods - Part 1-5 : Electrical Test Methods - Capacitance
3 Definitions
For the purposes of this specification, the following definitions apply.
3.1 Rated Voltage
The rated voltage of cable is the reference voltage used in the design, application and electrical performance test of cable.
In AC system, the rated voltage is expressed with U0/U. U0 means the voltage effective value between any main insulated conductor and "ground" (metallic shield, metallic sheath or surrounding medium); U means the voltage effective value between two-phase conductors in multi-core cable or single-core cable system. The rated voltage of cable shall be at least equal to the systematic nominal voltage of the applied cable, and this condition goes for both U0 and U.
In DC system, the rated voltage is expressed with U0, which means the voltage effective value between conductor and shield.
The working voltage of system shall not be greater than 1.1 times of its nominal voltage.
3.2 Routine Test (R)
The test carried out, by the manufacturer, on all manufacture lengths of the finished cables in order to inspect whether all the said cables meet the specified requirements.
3.3 Sampling Test (S)
The test carried out, by the manufacturer, on the specimens of finished cables or on some components taken from finished cables in order to inspect whether the cables meet the relevant requirements.
3.4 Type Test (T)
The test carried out on a type of cable covered by this specification before supply according to general commercial principle, in order to verify that the cable performance meets the intended service conditions.
Note: as for the type test, it is unnecessary to be repeated unless the cable characteristic is potentially changed due to the change in material, design or manufacturing process of cable.
3.5 Electric Vehicles
Vehicles driven by motor traction current which are produced for operation on public streets, highways or expressways; the traction current of motor is derived from chargeable battery or other portable energy storage devices (may be charged by the energy sources separated from the vehicle, such as residences or public electrical equipment maintenance).
3.6 Charging
The standard voltage and current providing certain voltage/current for the energy storage device of electric vehicle, in order to ensure that the on-board electrical equipment is equipped with proper energy transmission and may be operated under control.
3.7 Energy Storage Device
The device installed on electric vehicle and capable of storing electricity.
3.8 Electric Vehicle Charging Station
All equipment installed in an enclosure other than the vehicle body, used for transmitting AC/DC current to electric vehicles and provided with specific control and communication functions.
4 Service Characteristics
4.1 Rated Voltage of Cable
AC: 450/750 V
DC: 1.0kV
4.2 Temperature Range
Recommended ambient temperature range: -40(or -25)~+50℃; suitable cable shall be selected according to environmental requirements during application.
See Table 2 for the maximum temperature of conductor during normal operation and at short circuit (with maximum duration of 5s).
5 Cable Type and Expression Method
5.1 Composition of Type
Composition and arrangement sequence of product type are as shown in Figure 1.
Note:
a: As for situation where shielding structure is available for signal and control core, it shall be discriminated by adding a character "P" following the nominal sectional area.
Figure 1 Composition and Arrangement Sequence of Product Type
5.2 Codes
Product codes
EV Electric vehicles
AC (omitted) For AC charging
DC For DC charging
The cable type is composed as follows:
Conductor structure code + insulating material code + inner sheath (if any) material code + shielding structure code + sheath material code
Conductor structure code
R Class 6 flexible conductor
Omitted Class 5 flexible conductor
Insulating (inner sheath) material code
E Ethylene propylene rubber or similar synthetic elastomer continuously operating at 90℃
E1(EVI-2) Halogen-free high-elasticity modulus ethylene propylene rubber or similar synthetic elastomer continuously operating at 90℃
S Thermoplastic elastomer continuously operating at 70℃
S90 Thermoplastic elastomer continuously operating at 90℃
S1(EVI-1) Halogen-free thermoplastic elastomer (only applicable to the insulation of signal and control core) continuously operating at 90℃
Sheath (inner sheath) material code
S Thermoplastic elastomer continuously operating at 70℃
U Polyurethane
U1(EVM-1) Halogen-free polyurethane
YJ XLPO or similar synthetic elastomer
YJ1(EVM-2) Halogen-free XLPO or similar synthetic elastomer
Shielding structure code
Omitted Unshielded structure
P Overall copper wire braid shield
Spring cable structure code
Omitted Linear cable, non-spring cable
T Spring cable structure
5.3 Designation of Common Cable Types
See Table 1 for the designation of common cable types.
Foreword I
1 Scope
2 Normative References
3 Definitions
3.1 Rated Voltage
3.2 Routine Test (R)
3.3 Sampling Test (S)
3.4 Type Test (T)
3.5 Electric Vehicles
3.6 Charging
3.7 Energy Storage Device
3.8 Electric Vehicle Charging Station
4 Service Characteristics
4.1 Rated Voltage of Cable
4.2 Temperature Range
5 Cable Type and Expression Method
5.1 Composition of Type
5.2 Codes
5.3 Designation of Common Cable Types
6 Technical Requirements
6.1 Conductor
6.2 Isolation Layer
6.3 Insulation
6.4 Twisted Insulated Core and Padding (if Any)
6.5 Inner Sheath
6.6 Overall Shield (if Any)
6.7 Sheath or Outer Sheath
6.8 Signal and Control Cores
6.9 Outside Diameter of Cable
7 Cable Marks
7.1 Mark of Origin and Cable Identification
7.1.1 General Requirements
7.1.2 Continuity of Marks
7.1.3 Legibility and Scuff Resistance
7.2 Color Identification for Insulated Core
7.2.1 General Requirements
7.2.2 Color Spectrum
7.2.3 Yellow-green Composition
8 Routine Tests
8.1 DC Resistance of Conductor
8.2 Voltage Test
9 Sampling Tests
9.1 General
9.2 Frequency of Sampling Tests
9.2.1 Conductor Inspection and Dimension Inspection
9.2.2 Sampling Frequency
9.3 Re-testing
9.4 Conductor Inspection and Dimension Inspection
9.5 Hot Elongation Test for Materials of Insulation and Sheath
9.6 Flame Retardancy Test of Single Cable
10 Type Test
10.1 Dimension of Cable Construction
10.2 Electrical Type Test
10.2.1 Withstand Voltage Test of Finished Cable
10.2.2 Withstand Voltage Test of Insulated Core
10.2.3 Insulation Resistance Test
10.2.4 Resistance of Sheath Surface
10.2.5 Impedance Transfer between Signal and Shielding Layer Surface of Control Core
10.2.6 Long-term DC Resistance Test of Insulation
10.2.7 Capacitance between Control/Data Core Wire and Power Core Wire
10.3 Mechanical and Physical Performance of Insulation (Inner Sheath)
10.4 Mechanical and Physical Performance of Sheath (Inner Sheath)
10.5 Special Test of Finished Cable
10.5.1 Compatibility Test
10.5.2 Test of Resistance to Chemical Reagent
10.5.3 Mechanical Strength Test of Finished Cable
10.5.4 Test of Resistance to Scrapping and Rubbing
10.5.5 Spring Cable Test
10.5.6 Weather Resistance Test
10.5.7 Low-temperature Impact Test of Finished Cable
10.5.8 Extrusion Test of Finished Cable
10.5.9 Damp Heat Test
10.5.10 Halogen evaluation test
10.5.11 Flame Retardancy Test of Single Cable
Appendix A (Normative) Tear Resistance Test of Sheath
A1. Application Scope
A2. Specimen Preparation
A3. Test Treatment
A4. Test Procedure
A5. Test Result
Appendix B (Normative) Saponification Test
B1. Reagents and Instruments
B2. Determination Procedure
B3. Result Calculation
Table 1 Type Designation
Table 2 Insulating and Sheathing Materials
Table 3 Nominal Diameter of Round Copper Wire (Tinned Round Copper Wire) for Braiding
Table 4 Quantity of Samples for Sampling Test
Table 5 Requirements for Electrical Performance Test
Table 6 Requirements for Test of Mechanical and Physical Performance of Insulation (Inner Sheath)
Table 7 Requirements for Test of Mechanical and Physical Performance of Sheath (Inner Sheath)
Table 8 Test Liquid
Table 9 Vertical Force for Test of Resistance to Scrapping and Rubbing
Table 10 Parameters of Low-temperature Impact Test
Table 11 Requirements for Halogen Evaluation Test
Figure 1 Composition and Arrangement Sequence of Product Type
Figure 2 Torsion Pendulum Test Device
Figure 3 Device for Test of Resistance to Scrapping and Rubbing
Figure A1 Tear Resistance Test Specimen
Figure A2 Specimen before being Clamped by Tensile Test Equipment
