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This document is under the jurisdiction of the National Technical Committee of Auto Standardization (SAC/TC 114).
Conductive on-board charger for electric vehicles
1 Scope
This document specifies the technical requirements and test methods of conductive on-board charger for electric vehicles.
This document is applicable to conductive on-board charger for electric vehicles with nominal input voltage of 220V (AC) (single-phase) or 380V (AC) (three-phase) and output voltage not exceeding 1,500V (DC), and may also be used as reference for other types of on-board chargers.
2 Normative references
The following documents contain provisions which, through reference in this text, constitute provisions 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 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 ≤ 16A 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 ≤ 16A per phase and not subject to conditional connection
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 ≤ 75A 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 >16A and ≤ 75A 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
GB/T 18655-2018 Vehicles, boats and internal combustion engines—Radio disturbance characteristics—Limits and methods of measurement for the protection of on-board receivers
GB/T 19596 Terminology of electric vehicles
GB/T 19951 Road vehicles—Disturbances test methods for electrical/electronic component from electrostatic discharge
GB/T 28046.3-2011 Road vehicles—Environmental conditions and testing for electrical and electronic equipment—Part 3: Mechanical loads
GB/T 28046.4-2011 Road vehicles—Environmental conditions and testing for electrical and electronic equipment—Part 4: Climatic loads
GB/T 30427-2013 Technical requirements and test methods for grid-connected PV inverters
ISO 7637-2: 2011 Road vehicles—Electrical disturbances from conduction and coupling—Part 2: Electrical transient conduction along supply lines only
ISO 11452-2 Road vehicles—Component test methods for electrical disturbances from narrowband radiated electromagnetic energy—Part 2: Absorber-lined shielded enclosure
3 Terms and definitions
For the purposes of this standard, the terms and definitions given in GB/T 19596 and the following apply.
3.1
on-board charger
device which is fixedly installed on the vehicle, converts the electric energy conforming to the public power grid into the DC power required by the on-board energy storage device, and charges the on-board energy storage device
[Source: GB/T 19596-2017, 3.4.1.5.1, modified]
3.2
power factor
ratio of input active power to input apparent power of on-board charger
3.3
charging efficiency
percentage of the ratio of output power to input active power
?
3.4
output voltage tolerance
percentage of the ratio of the difference between the actual output voltage value and the output voltage set value to the set voltage value
3.5
output current tolerance
percentage of the ratio of the difference between the actual output current value and the output current set value to the set current value
3.6
voltage ripple factor
ratio of half the difference between the peak value and valley value of the output DC pulsating voltage of the on-board charger to the average value of such DC voltage
4 Technical requirements
4.1 Appearance requirements
4.1.1 The outer surface of conductive on-board charger for electric vehicles (hereinafter referred to as "on-board charger") shall be free from obvious defects such as damage and deformation.
4.1.2 The terminal or lead line of on-board charger shall be intact, and the connection of fasteners shall not be loose.
4.1.3 The accessible surface of the on-board charger shall be free from burrs, flashes and similar sharp edges.
4.2 Charging characteristic requirements
4.2.1 AC input conditions
4.2.1.1 The AC input rated voltage and frequency requirements of on-board chargers shall meet those specified in Table 1.
Table 1 Rated value of AC input
AC rated frequency Single-phase AC rated phase voltage Three-phase AC rated line voltage
50 Hz 220V 380V
4.2.1.2 The AC voltage shall be within ± 15% of the rated input voltage, and the output shall be maintained.
4.2.1.3 AC voltage frequency in the range of 50 Hz ± 1 Hz shall be able to maintain rated load output.
4.2.1.4 Three-phase AC voltage with phase deviation within ± 3° shall be able to maintain rated load output.
4.2.2 Startup input impulse current
The peak value of startup input impulse current of on-board charger shall not exceed 120% of the peak value of input current when rated load works stably.
4.2.3 DC output voltage limiting characteristics
For on-board charger with constant voltage output characteristics, when the DC output voltage reaches the set value of output voltage limit, the increase of its output voltage shall be automatically limited.
4.2.4 DC output current limiting characteristics
For the on-board charger with constant current output characteristics, when the DC output current reaches the set value of output current limit, the increase of its output current shall be automatically limited.
4.2.5 DC output power limiting characteristics
4.2.5.1 When the output power of the on-board charger reaches the rated power, the increase of its output power shall be automatically limited.
4.2.5.2 When the input AC current of the on-board charger reaches the maximum current value that the charging facilities and charging connection devices can provide, the increase of its output power shall be automatically limited.
4.2.6 DC output voltage tolerance
For on-board charger with constant voltage output characteristics, its output voltage tolerance shall not exceed 1% in the voltage limiting output state.
4.2.7 DC output current tolerance
In case the on-board charger is in current limiting output state, when the output current is greater than 10A, the output current tolerance shall not exceed ± 5%; when the output current is not greater than 10A, the tolerance of the output current shall not exceed ± 0.5A.
4.2.8 Output voltage ripple factor
For on-board charger with constant voltage output characteristics, the output voltage ripple factor shall not be greater than 5% in the voltage limiting output state.
4.2.9 Startup output overshoot
4.2.9.1 For the on-board charger with constant voltage output characteristics, the output voltage overshoot shall not be greater than 10% of the set value of voltage limit during the startup of voltage limit operation.
4.2.9.2 In case the on-board charger is in the startup process of current limiting operation, when the output current limit value is greater than 10A, the output current overshoot shall not be greater than 5% of the set value of current limiting; when the output current limit value is not greater than 10A, the output current overshoot value shall not exceed the set value of current limit by 0.5A.
4.2.10 Output dump load requirements
When the on-board charger outputs the dump load, its output voltage overshoot value shall not be greater than the voltage value specified in the product technical documents.
4.2.11 Power factor
The power factor of on-board charger shall meet those specified in Table 2.
Table 2 Power factor requirements
Power factor at rated power output Power factor at 50% rated power output
≥ 0.98 ≥ 0.95
4.2.12 Charging efficiency
The on-board charger shall be tested in accordance with 5.3.13 when operating at rated power output or maximum output current within the output voltage range.
According to different energy efficiency grades, the average efficiency shall meet those specified in Table 3.
Table 3 Requirements for energy efficiency grades
E3 E2 E1
90%–< 92% 92%–< 94% ≥ 94%
The output voltage range is specified in the product technical documents.
4.3 Protection function
4.3.1 AC input overvoltage and undervoltage protection
When the AC input voltage of the on-board charger is not less than the overvoltage protection value or not greater than the undervoltage protection value, the power output shall be stopped. After troubleshooting, the output can be restored automatically or through necessary human intervention.
AC input overvoltage protection value and undervoltage protection value shall meet the requirements of product technical documents.
4.3.2 Phase-loss protection
The three-phase on-board charger can derate or stop the power output in case of AC input and phase-loss of any phase voltage. After troubleshooting, the output can be restored automatically or through necessary human intervention.
4.3.3 DC output overvoltage and undervoltage protection
When the DC output voltage of the on-board charger is not less than the overvoltage protection value or not greater than the undervoltage protection value, the power output shall be stopped. After troubleshooting, the output can be restored automatically or through necessary human intervention.
DC output overvoltage protection value and undervoltage protection value shall meet the requirements of product technical documents.
4.3.4 Output short-circuit protection
The output end of the on-board charger shall be provided with short-circuit protection. In case of short circuit at the DC output end, the power output shall be stopped. After troubleshooting, the output can be restored automatically or through necessary human intervention.
4.3.5 Over-temperature protection
The on-board charger shall be provided with over-temperature protection. When the ambient temperature or coolant temperature reaches the temperature protection value, the power output shall be reduced or stopped. After troubleshooting, the output can be restored automatically or through necessary human intervention.
The temperature protection value shall meet the requirements of product technical documents.
4.3.6 Output reverse polarity protection
For the on-board charger without any structural anti-reverse polarity treatment in the output port circuit, when the positive and negative poles of the DC output terminal are connected with the positive and negative poles of the on-board energy storage device in reverse, there shall be no output power after being electrified. After troubleshooting, the on-board charger shall be able to operate at rated power.
4.4 Electrical safety
4.4.1 Insulation resistance
The insulation resistance of on-board charger shall meet the following requirements:
a) The insulation resistance between independent live port circuit and the ground (enclosure) shall not be less than 10 MΩ;
b) The insulation resistance between each live port circuit without electrical connection shall not be less than 10 MΩ.
4.4.2 Voltage withstand
The voltage withstand between independent live port circuit and the ground (enclosure) and between each live port circuit without electrical connection shall meet those specified in Table 4. The duration of voltage withstand test shall be 1 min, without breakdown and arc phenomenon, and the leakage current limit shall meet the requirements of product technical documents.
Foreword i
1 Scope
2 Normative references
3 Terms and definitions
4 Technical requirements
4.1 Appearance requirements
4.2 Charging characteristic requirements
4.3 Protection function
4.4 Electrical safety
4.5 Electromagnetic compatibility
4.6 Environmental adaptability
4.7 Noise
4.8 Durability
4.9 Inverter output functional requirements
5 Test methods
5.1 Test conditions
5.2 Appearance test
5.3 Test method for charging characteristics
5.4 Charging protection function test
5.5 Electrical safety test
5.6 Electromagnetic compatibility tests
5.7 Environmental adaptability test
5.8 Noise test
5.9 Durability test
Annex A (Normative) On-board charger with inverter function
A.1 Technical requirements for inverter
A.2 Test methods
