GB 42295-2022Safety requirements for electric bicycles electrical (English PDF)

4.1 General

4.1.1 The vehicle shall meet the relevant electrical safety requirements of GB 17761.

4.1.2 Lead-acid batteries for vehicles shall meet the requirements of 4.3, 4.4, 4.6, 4.7,

4.12 in GB/T 32504-2016 and

4.15 in GB/T 22199.1-2017.Lithium-ion batteries shall meet the requirements of

5.3 in GB/T 36972-2018.

4.2 Signs and warnings

4.2.1 For the main circuit and battery system whose vehicle voltage is higher than the extra-low voltage

16.0 V (AC), the protective cover of its easy-to- contact live parts shall be clearly and firmly marked with the sign shown in Figure 1 at an easily visible position.

4.2.2 The outer surface of the battery system shall have a striking warning statement "Non-professionals are forbidden to open it".

4.2.3 The outer surface of the battery system shall clearly and visibly indicate its operating temperature range for charging and discharging, the maximum charging and discharging current, the minimum discharge termination voltage, the maximum charge termination voltage and other parameters for identification.

4.3 Wiring, wires and connections

4.3.1 Wiring Vehicle wiring shall meet the following requirements.

4.3.2 Wires Wires with a maximum operating current greater than 200 mA in the vehicle circuit shall be copper conductor wires. The technical requirements shall meet the requirements of the fifth conductor in Chapter 6 of GB/T 3956-2008.

4.3.3 Connection The vehicle wire connection shall meet the following requirements.

4.3.4 Contact resistance If the current limiting protection value of the vehicle is greater than

10.0 A, all connections of the main circuit cables shall be permanent connections or terminal loose connections. The contact resistance value shall not be greater than the wire resistance of the same contact length.

4.4 Voltage Vehicle voltage shall meet the following requirements.

4.5 Insulation resistance When the electrical components and circuits of the vehicle are at room temperature, after undergoing heating, high temperature, low temperature storage and constant damp heat tests respectively, the insulation resistance values shall not be less than the values shown in Table 2.

4.6 Electric strength After the vehicle is subjected to the constant heat and humidity test, carry out the electric strength test on the electrical components according to the method described in 5.6.There shall be no breakdown or flashover between the battery system, control system, etc. and exposed conductive parts.

5.1 Test conditions

5.1.1 Test environment Unless otherwise specified, the test environment meets the following conditions.

5.1.2 Measurement accuracy error During the measurement process, the accuracy error of all control values (actual values) relative to the specified value shall be.

5.2 Labels and warnings Check by visual inspection.

5.3 Wiring, wires and connections

5.3.1 Wiring Check by visual inspection and touch method.

5.3.3 Connection test The vehicle wire connection test method is as follows:

5.3.4 Contact resistance measurement Use a low resistance tester with an accuracy of ±0.2% to test vehicle contact resistance. Measure as follows:

5.4 Voltage measurement The vehicle voltage is measured with a voltage measuring instrument according to the following method.

5.5 Insulation resistance measurement Use an insulation resistance meter with a DC voltage of 500 V to measure the insulation resistance value of the electrical components of the vehicle. Measure the insulation resistance value of each electrical component as follows:

5.6 Electric strength test After each electrical component of the vehicle has passed the constant heat and humidity test, conduct the electric strength test at the following test points (non-metallic components covered with metal foil) according to the values shown in Table 3.

5.9 Temperature and humidity resistance test

5.9.1 Constant heat and humidity test Before the test, according to the manufacturer's indicated requirements, the specimen battery system shall be fully charged and then put aside for 1h before carrying out the test of this item.

5.9.2 High temperature resistance test The electrical components on the vehicle shall be subjected to the high temperature resistance test according to the method described in "Test Bd" in GB/T 2423.2.

5.9.3 Low temperature resistance storage test The electrical components on the vehicle shall be subjected to the low temperature resistance storage test according to the method described in "Test Ab" in GB/T 2423.1. Put the electrical components into the test box with an ambient temperature of - 25°C±1°C for 2 h. Take out the specimen after the test. Measure its insulation resistance value by the method described in 5.5.

5.10 Vibration and shock test

5.10.1 Vibration test Before the test, according to the manufacturer's indicated requirements, the specimen battery system shall be fully charged and then put aside for 1 h before carrying out the test of this item.