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All technical contents of this standard are mandatory.
This standard is drafted in accordance with the rules given in the GB/T 1.1-2009.
This standard replaces GB/T 24155-2009 Electric Motorcycles and Electric Mopeds — Safety Specifications in whole. In addition to a number of editorial changes, the following main technical changes have been made with respect to GB/T 24155-2009 (the previous edition):
— the terms and definitions of “speed regulation unit” and “on-board charger” are added (see 3.1 and 3.2);
— the clearance and creepage distance are added (see 4.2.1.4);
— the overload protection of motor is deleted (see 4.2.6 of Edition 2009);
— the requirement that cables for voltage class B shall be classified in orange is added (see 4.2.2.7);
— the insulation resistance requirements and test methods are modified (see 4.2.2.8 and 5.2; 4.2.3.4 and 5.2 of Edition 2009);
— the specifications for barrier and degrees of protection provided by enclosure are added (see 4.2.2.11);
— the safety specifications for voltage class B electric circuits after power off are added (see 4.2.2.12);
— the safety specifications for charging interface after power off are added (see 4.2.4.2);
— the safety specifications for starting are added (see 4.3.1.2);
— the requirements for driving speed corresponding to the residual charge of power battery are added (see 4.3.2.3);
— the voltage resistance test is simplified (see 5.3; 5.3 of Edition 2009);
— the exemption of potential equalization test is added (see 5.5);
— the warning test of residual charge is added (see 5.6).
This standard was proposed by and is under the jurisdiction of the Ministry of Industry and Information Technology of the People's Republic of China.
The previous editions of this standard are as follows:
— GB 24155-2009.
Safety Specifications for Electric Motorcycles and Electric Mopeds
1 Scope
This standard specifies general safety specifications, electrical safety specifications, operational safety specifications, marking and warning specifications and test methods for battery electric motorcycles and electric mopeds.
It is applicable to battery electric motorcycles and electric mopeds (unless otherwise specified, hereinafter referred to as “electric motorcycles”).
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 4208-2017 Degrees of Protection Provided by Enclosure (IP Code)
GB/T 5359.1 Term for Motorcycles and Mopeds — Part 1: Types of Vehicles
GB 7258 Technical Specifications for Safety of Power-driven Vehicles Operating on Roads
GB 15365 Symbols for controls, indicators and tell tales for motorcycles and mopeds
GB/T 18384.1-2016 Electrically Propelled Road Vehicles — Safety Specifications — Part 1: On-board Rechargeable Energy Storage System (REESS)
GB/T 18384.3-2016 Electrically Propelled Road Vehicles — Safety Specifications — Part 3: Protection of Persons against Electric Shock
GB/T 19596 Terminology of Electric Vehicles
GB/T 24157 Test Methods of Range and Indication for the State of Charge for Electric Motorcycles and Electric Mopeds
3 Terms and Definitions
For the purposes of this document, the terms and definitions given in GB/T 5359.1, GB/T 18384.3-2015, GB/T 19596 and the following apply.
3.1
speed regulation unit
operating device that controls the speed of an electric motorcycle when it is in "driving enabled mode"
3.2
on-board charger
device fixed on electric motorcycle, conversing electric energy of public power grid to direct current and charging the on-board energy storage device
4 Specifications
4.1 General
4.1.1 Combustion or scalding caused by the heat generated by electrical components shall be avoided.
4.1.2 The design of electronic speed regulation unit shall be able to avoid fire hazard or electric shock hazard caused by abnormal operation or no operation.
4.2 Electrical safety specifications
4.2.1 Power battery
4.2.1.1 Heat dissipation and ventilation
Power battery pack shall be uniform heat dissipation and ventilation; simultaneously, structure design shall be able to ensure harmful gas produced by power battery installed in the electric motorcycle not stored in the inside corner of the electric motorcycle.
4.2.1.2 Installation
When power battery at normal installation position, its surface shall be free from any leakage or spilling of electrolyte. The installation of the power battery shall ensure that the vehicle running vibration, the battery can not be subjected to abnormal friction or stress.
4.2.1.3 Battery protection
Power battery, charging system and power circuit system shall be equipped with protective devices. In the case of over-current, undervoltage, overcharge and short circuit of connecting electric circuit of power battery, these devices shall be able to automatic break the connecting circuit of power battery. The response time of these devices shall conform to the product technical documentation.
4.2.1.4 Clearance and creepage distance
The creepage distance of power batteries shall meet the following requirements:
a) Creepage distance, d1, in millimetres (mm), between power battery connection terminals can be calculated by using Formula (1):
d1 ≥ 0.25U + 5 (1)
Where:
U — The maximum working voltage between the two output terminals of the power battery, in volts (V).
b) The creepage distance, d2, in millimetres (mm), between the live part and the level station can be calculated by using Formula (2):
d2 ≥ 0.125U + 5 (2)
Where:
U — The maximum working voltage between the two output terminals of the power battery, in volts (V).
The clearance between conductive parts shall be no less than 2.5 mm.
The measurement of clearances and creepage distances is shown in Figure 1.
Key:
1 — Conductive surface;
2 — Connect terminals (battery module, battery pack or power battery);
3 — Creepage distance;
4 — Clearance.
Figure 1 Clearance and creepage distance
4.2.2 Electric shock protection for live parts
4.2.2.1 Live parts with nominal voltage not higher than 36 V (d.c.) and 12 V (a.c.) do not specified in this standard.
Note: When impulse voltage is used, take the peak voltage above 10 ms as operating voltage; if duration time of peak value all less than 10 ms, take their root mean square value.
4.2.2.2 Live parts with nominal voltage higher than 36 V (d.c.) and 12 V (a.c.) (rms).
4.2.2.3 Insulation materials of live parts shall be able to meet the requirements of nominal voltage and temperature. Insulated coating of live parts shall only be dismantled by destroy. Insulating paint, coatings, glues, enamels and similar materials shall not used as insulation cladding (basic insulation).
4.2.2.4 Isolated sealing of live parts shall be equipped with guard boards, protective covers or fender brackets with suitable strength to prevent direct contact. In which, isolated and protective devices at the space of personal ridden on and goods placement shall not be unclosed, dismantled without tools or in the case of have no intention. Other parts that can be opened without tools shall be marked warning symbols; warning symbols as shown in Figure 2.
4.2.2.5 Exposed conductors, terminals and connection units are not permissible. Electric wiring on the electric motorcycle shall be protected, which shall not contact with burrs, cooling fin and other parts, in order to avoid damage of electric wiring insulation; the surface of insulated wire pass through the metal holes shall be smooth, round and equipped with sleeves.
4.2.2.6 Connecting wires between each each electrical component shall not be subjected to excessive tensile force; connection between handlebars and frame shall not result in conductor insulation damage caused by proper rotation and shall effectively prevent the wire from contacting the moving parts.
4.2.2.7 The cables in voltage class B electric circuits and the sheath (which may be a cable sheath) in the circuit shall be distinguished in orange, except those inside the enclosure or behind the barrier.
4.2.2.8 The insulation resistance of voltage class B electric circuits shall be greater than 1 000 Ω/V, and the insulation resistance measurements shall be carried out in accordance with 5.2.
4.2.2.9 For electric motorcycles installed with on-board charger, voltage resistance test shall be carried out between the input end of the on-board charger and the level station. After the test, the insulation resistance between the input end of the on-board charger and the level station shall meet the requirements of 4.2.2.8.
4.2.2.10 After waterproof test carried out in accordance with 5.4, insulation resistance of the circuit shall be measured immediately (the electric motorcycle still wet) in accordance with 5.2. The insulation resistance value shall be greater than 500 Ω/V; after standing for 24h, a second measured value shall be greater than 1 000 Ω/V.
4.2.2.11 The degree of protection provided by barrier/enclosure shall at least meet the requirements of IPXXB specified in GB/T 4208-2017:
a) the degree of protection provided by barrier/enclosure in the cabin and baggage compartment shall at least meet the requirements of IPXXD specified in GB/T 4208-2017;
b) for connectors with voltage class B electric circuits that can be disconnected without tools and are not engaged, they shall meet at least the requirements of IPXXB specified in GB/T 4208-2017 in the disconnected state.
4.2.2.12 Voltage class B electric circuits with fault can be protected by power off. The disconnecting circuits shall meet one of the following requirements within the time specified by the vehicle manufacturer:
— AC circuits shall drop below 30 V (a.c.)(RMS) and DC circuits below 60 V (d.c.);
— the total stored energy of the circuits is less than 0.2J.
Foreword II
1 Scope
2 Normative References
3 Terms and Definitions
4 Specifications
5 Test Methods
6 Instructions
