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Safety requirements and test specifications of electric vehicle conductive supply equipment
1 Scope
This standard specifies the safety requirements, test guidelines and test methods for electric vehicle conductive supply equipment (hereinafter referred to as "conductive supply equipment").
This standard is applicable to all types of conductive supply equipment with a rated output voltage of 1,000V AC or 1,500V DC and below, including those with charging mode 2, charging mode 3 and charging mode 4, as well as the conductive supply equipment which are not used for public purposes and used under special conditions (such as explosion-proof and liquid-cooled ones, and those used in plateaus at altitude above 2,000m). It shall be applied in combination with the requirements of relevant standards.
The independent electrical accessories and auxiliary materials (such as connecting devices, cables and insulating materials, etc.) of conductive supply equipment shall comply with the specific product standards in conjunction with this standard.
This standard involves serious equipment damage and serious personal harm caused by electric shock hazard, energy hazard, mechanical hazard, high temperature hazard, fire spread hazard, sound pressure hazard, out-of-control hazard, etc., when the conductive supply equipment conforms to the correct use regulations but may have operational errors.
This standard does not involve the following:
——Safety requirements related to transport packaging, improper installation and application;
——Electromagnetic compatibility requirements;
——Information security requirements;
——Safety problems caused by vandalism and other purposeful behaviors;
——Other functional and performance requirements unrelated to safety.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB/T 1002 Single phase plugs and socket-outlets for household and similar purposes - Types, basic parameters and dimensions
GB/T 2099.1 Plugs and socket-outlets for household and similar purposes - Part 1: General requirements
GB/T 2423.55 Environmental testing for electric and electronic products - Part 2: Test methods - Test Eh: Hammer tests
GB/T 4776-2017 Electrical safety terminology
GB 4793.1-2007 Safety requirements for electrical equipment for measurement, control and laboratory use - Part 1: General requirements
GB 4943.1-2011 Information technology equipment - Safety - Part 1: General requirements
GB/T 5169.11 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 5169.21 Fire hazard testing for electric and electronic products - Part 21: Abnormal heat - Ball pressure test method
GB/T 12113 Methods of measurement of touch current and protective conductor current
GB/T 16842 Protection of persons and equipment by enclosures - Probe for verification
GB/T 16935.1-2008 Insulation coordination for equipment within low-voltage systems - Part 1: Principles, requirements and tests
GB/T 18487.1-2015 Electric vehicle conductive charging system - Part 1: General requirements
GB/T 20234.1-2015 Connection set for conductive charging of electric vehicles - Part 1: General requirements
GB/T 29317-2012 Terminology of electric vehicle charging/battery swap infrastructure
3 Terms and definitions
For the purposes of this document, the terms and definitions given in GB/T 4776-2017, GB 4793.1-2007, GB 4943.1-2011, GB/T 16935.1-2008, GB/T 18487.1-2015, GB/T 20234.1-2015 and GB/T 29317-2012 and the following apply. For ease of use, some terms and definitions in GB/T 4776-2017, GB 4793.1-2007, GB 4943.1-2011 and GB/T 16935.1-2008 are listed below.
3.1
enclosure
equipment component used to minimize the spread of fire or flame inside the equipment; mechanical component used to reduce the risk of injury caused by mechanical hazards and other physical hazards; equipment component used to limit contact with parts and components that may have hazardous voltage or hazardous energy level; a component of the equipment that has one or more of the above functions
Note: It is revised from GB 4943.1-2011, Definition 1.2.6.1.
3.2
tool
screwdriver, or any other appliance that can be used to install and remove screws, pins or similar fasteners
[GB 4943.1-2011, Definition 1.2.7.4]
3.3
hazard
potential source of injury
[GB 4793.1-2007, Definition 3.5.2]
3.3.1
hazardous live
when it may cause electric shock or electric burn under normal condition or single fault condition
[GB 4793.1-2007, Definition 3.5.3]
3.3.2
hazardous live part
live part that can cause harmful electric shock under certain conditions
3.4
working voltage
maximum voltage to which the insulation or the component under consideration is, or can be, subjected when the conductive supply equipment is working under normal use conditions
Note 1: Overvoltage caused by the outside of the equipment is not considered.
Note 2: It is revised from GB 4943.1-2011, Definition 1.2.9.6.
3.5
decisive voltage
maximum voltage continuously occurring between two arbitrary live components when used for the intended purpose under the worst rated working conditions
3.5.1
decisive voltage classification A; DVCA
voltage of voltage classification A for protection measures against electric shock
3.5.2
decisive voltage classification B; DVCB
voltage of voltage classification B for protection measures against electric shock
3.5.3
decisive voltage classification C; DVCC
voltage of voltage classification C for protection measures against electric shock
3.6
safety extra-low voltage circuit
secondary circuit which is properly designed and protected
Note 1: Its voltage value will not exceed the safe value under normal working conditions and single fault conditions.
Note 2: It is revised from GB 4943.1-2011, Definition 1.2.8.8.
3.7
hazardous voltage
voltage whose AC peak value exceeds 42.4V or DC value exceeds 60V in a circuit that does not meet the requirements of a current-limiting circuit or a TNV circuit
[GB 4943.1-2011, Definition 1.2.8.6]
3.8
normal use
operations performed according to the instructions for use or instructions for obvious intended use
Note 1: It includes standby.
Note 2: It is revised from GB 4793.1-2007, Definition 3.5.9.
3.9
normal condition
condition under which all protective measures against hazards are intact
[GB 4793.1-2007, Definition 3.5.10]
3.10
single fault condition
condition under which a protective measure against hazard fails or certain hazard may occur and result in a fault
Note: If a single fault condition will inevitably cause another one, then such two faults are considered as a single fault condition.
[GB 4793.1-2007, Definition 3.5.11]
3.11
protective earthing conductor
conductor in building wiring or conductor in power line used to connect the power supply protective earthing terminal in equipment with the earth point of building facilities
Note: It is revised from GB 4943.1-2011, Definition 1.2.13.10.
3.12
touch current
electric current that flows through the human body or animal body when touching one or more accessible parts and components of a device or equipment
Note: It is revised from GB 4943.1-2011, Definition 1.2.13.12.
3.13
clearance
shortest spatial distance measured between two conductive parts/components or between a conductive part/component and the equipment protection interface
[GB 4943.1-2011, Definition 1.2.10.1]
3.14
creepage distance
shortest path between two conductive parts/components or between a conductive part/component and the equipment protection interface measured along an insulating surface
[GB 4943.1-2011, Definition 1.2.10.2]
3.15 Insulation
3.15.1
functional insulation
insulation only required for the equipment to complete its normal function
Note: The functional insulation defined here does not play a role in protecting against electric shock. However, it may be used to reduce the possibility of ignition and fire hazard.
[GB 4943.1-2011, Definition 1.2.9.1]
3.15.2
basic insulation
insulation providing basic protection against electric shock
[GB 4943.1-2011, Definition 1.2.9.2]
3.15.3
supplementary insulation
independent insulation applied in addition to basic insulation to reduce the risk of electric shock in case of failure of basic insulation
[GB 4943.1-2011, Definition 1.2.9.3]
3.15.4
double insulation
insulation consisting of basic insulation and supplementary insulation
[GB 4943.1-2011, Definition 1.2.9.4]
3.15.5
reinforced insulation
a single insulation structure, which provides a level of protection against electric shock equivalent to double insulation under the conditions specified herein
Note: The term "insulation structure" does not mean that the insulation is a homogeneous whole. This kind of insulation may be composed of several separate insulation layers such as supplementary insulation or basic insulation.
[GB 4943.1-2011, Definition 1.2.9.5]
3.16
overvoltage category
numerical expression of transient overvoltage conditions
Note 1: Overvoltage categories are indicated by I, II, III and IV.
Note 2: It is revised from GB/T 16935.1-2008, Definition 3.10.
3.17
equipment safety classification
classification according to the protection measures against electric shock provided by the conductive supply equipment
3.17.1
class I equipment
equipment which not only relies on basic insulation for protection against electric shock, but also includes an additional safety measure, that is, connecting the conductive part prone to electric shock to the protective (earthing) conductor in the fixed wiring of the equipment, so that the easily accessible conductive part will become a live part when the basic insulation fails
[GB/T 4776-2017, Definition 2.3.3.2]
3.17.2
class II equipment
equipment which not only relies on basic insulation for protection against electric shock, but also includes additional safety measures (such as double insulation or reinforced insulation), without requirements for protective earthing or dependent equipment conditions
[GB/T 4776-2017, Definition 2.3.3.3]
3.18
pollution
adherence of external substances such as solids, liquids or gases (ionized gases), which may reduce the dielectric strength and surface resistivity
Note: It is revised from GB/T 16935.1-2008, Definition 3.11.
3.19
pollution degree
numerical representation of the expected degree of pollution of the micro-environment
Note: It is revised from GB/T 16935.1-2008, Definition 3.13.
3.19.1
pollution degree 2; PD2
pollution degree where only non-conductive pollution appears usually but short-time conduction due to agglomeration appears occasionally
3.19.2
pollution degree 3; PD3
pollution degree where conductive pollution or dry non-conductive pollution becomes conductive due to agglomeration
Note: Under such condition, the equipment shall usually be protected from direct sunlight, rainfall and strong wind pressure, but not be subjected to temperature or humidity control.
3.20
bushing
ring sleeve that acts as a cushion
Note: It is used outside mechanical components for the purposes of sealing and wear protection.
4 Safety requirements
4.1 Use environment
4.1.1 Environmental classification
The classification of the use environment of conductive supply equipment is shown in Table 1.
Table 1 Environmental classification
Type a Outdoor Indoor
Pollution degree Min. PD3 Min. PD2
Degree of protection Min. IP54 Min. IP32
Range of ambient temperature -20℃~+50℃ -5℃~+50℃
Range of relative humidity 5%~95% (without condensation) 5%~95% (without condensation)
Ultraviolet exposure Required Not required
Altitude b 2,000m or below 2,000m or below
a The minimum environmental conditions specified by the manufacturer shall meet the minimum requirements.
b For conductive supply equipment used at an altitude above 2,000m, the clearance and creepage distance shall be corrected according to the correction factors specified in GB/T 16935.1-2008.
4.1.2 Pollution degree
The pollution degree of conductive supply equipment is the pollution degree of external environment, which shall meet the requirements in Table 1. In the indoor industrial environment exposed to pollution, the pollution degree shall be PD3.
4.1.3 Degree of protection
The degree of protection provided by the enclosure of conductive supply equipment shall meet the requirements in Table 1. The degree of protection of the power supply interface shall meet the requirements specified in GB/T 20234.1-2015.
4.1.4 Ultraviolet exposure
For conductive supply equipment used outdoors, the polymer material of the enclosure and the exposed sealing material shall be sufficiently tolerant to material degradation caused by ultraviolet radiation, and shall not have obvious deformation, crack or rupture, and shall not affect normal use.
4.2 Structure
4.2.1 General requirements
The structure of the conductive supply equipment includes enclosure, partitions, door locking devices and hinges. The connection and splicing parts shall have sufficient mechanical strength to bear the stress encountered under normal use and fault conditions. The edges, bulges, corners, holes, shields, handles and other accessible parts of the conductive supply equipment structure shall be smooth and shall not cause any injury during normal use.
4.2.2 Enclosure material
The enclosure material of conductive supply equipment shall be able to withstand the mechanical stress, electrical stress, thermal stress and environmental pressure generated under the specified use conditions.
4.2.3 Handle and manual control device
The handles, knobs, clamps, joysticks and similar parts and components shall be firmly installed and shall not be loose under normal use.
Foreword II
1 Scope
2 Normative references
3 Terms and definitions
4 Safety requirements
5 Guidance on tests
6 Test methods
Annex A (Informative) Identification symbols used on electric vehicle conductive supply equipment
Annex B (Normative) Safety test items of electric vehicle conductive supply equipment
Bibliography
