GB/T 20234.1-2023Connection set for conductive charging of electric vehicles - Part 1: General requirements (English PDF)

Foreword

This document was issued on 7 September 2023 by the State Administration for Market Regulation; Standardization Administration of the PRC and takes effect on 7 September 2023.

It is a GB/T standard: recommended rather than compulsory, but it is the text a Chinese reviewer applies when assessing a submission.

1 Scope

GB/T 20234.1-2023 is the general part of the standard behind the Chinese EV charging connector — the plug and socket that every electric vehicle sold in China must accept. It is the piece of the charging system that is physically handled by an untrained person, in the rain, several times a week, for the life of the vehicle, while carrying enough current to be lethal. That combination is what makes the requirements unusually broad: the connector has to survive thousands of mating cycles without contact degradation, remain safe when dropped or driven over, prevent any possibility of touching a live contact, and interlock so that current only flows once the connection is confirmed. This part specifies the technical requirements for connection sets for conductive charging of electric vehicles, covering voltage and current ratings, appearance, structure, environmental adaptability, electrical performance and mechanical performance. It is the foundation the other parts of GB/T 20234 build on. Under ICS 43.040.99 and CCS T35, it is written for connector and charging equipment manufacturers, for vehicle makers, for charging network operators, and for the certification bodies that approve equipment for the Chinese market.

This document specifies the technical requirements for voltage and current ratings,

appearance, structure, environmental adaptability, electrical performance, and

mechanical performance of connection set for conductive charging of electric vehicles.

It describes the test conditions, test methods, inspection items and other inspection

requirements for connection set for conductive charging of electric vehicles.

The document is applicable to AC charging connection set with a frequency of 50 Hz,

a rated voltage not exceeding AC 690 V, and a rated current not exceeding 250 A for

conductive charging of electric vehicles, as well as DC charging connection set with

rated voltage not exceeding DC 1500 V and rated current (duration maximum current)

not exceeding 1000 A.

This document does not apply to the charging connection set that uses standard plugs

and sockets that comply with GB/T 1002 and GB/T 2099.1 for the plug and socket-

outlet.

When the charging connection set specified in this document is used for electric

vehicles in special places such as water conservancy, mining, construction sites,

agricultural operations, or other fields other than road vehicles, additional requirements

may be required in terms of the installation location, operating conditions, usage

methods, environmental adaptability, etc. of the charging connection set.

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 261, Determination of flash point -- Pensky-Martens closed cup method

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

erection of electrical equipment -- Earthing arrangements and protective conductors

GB/T 16935.1, Insulation coordination for equipment within low-voltage systems --

Part 1.Principles, requirements and tests

GB/T 18487.1, Electric vehicle conductive charging system -- Part 1.General

requirements

GB/T 19596, Terminology of electric vehicles

GB/T 20234.2, Connection set for conductive charging of electric vehicles -- Part 2.

AC charging coupler

GB/T 20234.3, Connection set for conductive charging of electric vehicles - Part 3.

DC charging coupler

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 28957.1, Road vehicles -- Test dust for filter evaluation -- Part 1.Silicon

dioxide test dust

GB/T 29317, Terminology of electric vehicle charging/battery swap infrastructure

GB/T 33594, Charging cables for electric vehicles

3 Terms and definitions

For the purposes of this document, the terms and definitions defined in GB/T 11918.1-

2014, GB/T 18487.1, GB/T 19596 and GB/T 29317 as well as the followings apply.

3.1 charging connection set

Components or devices that conductively connect electric vehicles to electric vehicle

charging equipment (or external power sources).

NOTE 1.It has the function of connecting and disconnecting circuits, as well as realizing the

transmission of electric energy, low-voltage auxiliary power supply, control signals or

communication data.

NOTE 2.Charging connection sets include charging couplers, charging cables, in-cable devices

and protective cap accessories. The schematic diagram of the charging connection set is shown in

Figure 1.

3.2 charging coupler

Components used to connect and disconnect the circuit connection between electric

vehicles and electric vehicle charging equipment (or external power sources).

NOTE. A part of the charging connection set, including the plug and socket-outlet and the vehicle

coupler.

3.3 plug and socket-outlet

It consists of a plug and a socket-outlet, and is a component that can connect cables to

electric vehicle charging equipment or external power sources.

NOTE. It corresponds to the plugs and socket-outlets in GB/T 11918.1-2014.

4 Symbols and abbreviations

The following symbols and abbreviations apply to this document.

A. ampere

V. volt

Hz. hertz

~ or AC. alternating current

or DC. direct current

L1, L2, L3.AC power phase wires

N. neutral line

. protective earth (PE)

DC+. DC power supply positive or battery positive pole

DC-. DC power supply negative or battery negative pole

CP. control guidance

CC. charging connection confirmation

S+. charging communication CAN_H

S-. charging communication CAN_L

A+. low voltage auxiliary power supply (e.g.. 12V+)

A-. low voltage auxiliary power supply negative (e.g.. 12V-)

IPXX (relevant numbers). IP code (protection level specified in GB/T 4208)

5 Rated values

5.1 Rated voltage (preferred value)

5.1.1 AC. 250 V, 440 V, 690 V.

5.1.2 DC. 400 V, 750 V, 1000 V, 1500 V.

5.1.3 Signal, control or low-voltage auxiliary power supply. DC 0 V ~ 30 V.

5.2 Rated current or duration maximum current (preferred value)

5.2.1 AC. 10 A, 16 A, 32 A, 63 A, 125 A, 250 A.

5.2.2 DC. 10 A, 16 A, 25 A, 32 A, 50 A, 80 A, 125 A, 200 A, 250 A, 300 A, 400 A, 500

A, 600 A, 800 A, 1000 A.

NOTE 1.The charging connection set achieves the duration maximum current when equipped with

a thermal management system that provides positive cooling.

NOTE 2.The duration maximum current of the charging connection set is affected by the cooling

conditions. When the cooling capacity is sufficient, the duration maximum current of the charging

connection set is greater than the optimal value.

NOTE 3.Rated current or duration maximum current is used for product shaping, performance

calibration, selection and matching of charging connection sets, and does not represent the actual

charging current.

NOTE 4.The short time (non-duration) maximum current allowed by the charging connection set

is usually greater than the rated current or the duration maximum current. When charging, the

charging current is adjusted in real time based on the thermal management system of the charging

connection set, contact temperature, surface temperature and other conditions.

5.2.3 Signal or control. DC 2 A.

5.2.4 Low-voltage auxiliary power supply. DC 10 A.

6 Requirements

6.1 General

6.1.1 Appropriate measures shall be taken for the charging connection set in material

selection, design, production, packaging, storage, transportation, installation, etc., so

that the product has normal functions and meets the expected use needs.

6.1.2 Charging connection sets shall have appropriate product performance. When used

in normal operation, the product shall work normally during its normal life span. When

misused, the product shall not cause leakage, short circuit, fire or other safety accidents.

It shall not cause harm or adverse effects to surrounding people, vehicles, equipment

and the environment. When charging equipment or electric vehicles experience

overload, short circuit or other faults in the charging circuit, it shall not cause serious

accidents such as melting or burning of the charging connection set.

6.1.3 The charging connection set shall comply with the climatic and environmental

conditions of the charging site. Product durability shall meet the application

requirements of electric vehicles and charging equipment.

6.1.4 The charging connection set shall be easy for personnel to operate and use,

facilitate regular maintenance and maintenance, and meet the needs of product use

management such as recycling and storage of electric vehicles and charging equipment.

6.1.5 The charging connection set shall adopt appropriate structure and measures. Avoid

dismantling or modifying it by non-professionals unless it is seriously damaged.

7 Test methods

7.1 General provisions

7.1.1 Test conditions

Unless otherwise required, all tests shall be conducted under the following

environmental conditions.

a) Ambient temperature. 20 degrees C+/-5 degrees C;

b) Relative humidity. 15%~90%;

c) Atmospheric pressure. 86 kPa ~ 106 kPa.

7.1.2 Test equipment

All test instruments and equipment shall have sufficient accuracy. Its accuracy shall be

at least one order of magnitude higher than the accuracy of the measured indicator or

the error shall be less than one-third of the allowable error of the measured parameter.

7.1.3 Test subjects

7.1.3.1 Charging connection sets or related components (such as vehicle inlets, cable

assemblies, electronic locking devices, in-cable device or contacts, etc.) can be used as

test objects. The product specimen status provided by the manufacturer will be used as

the test object by default. Relevant tests will be carried out, unless otherwise specified.

7.1.3.2 In the tests related to the charging coupler, the reference test tool of the plug,

socket-outlet, vehicle connector or vehicle inlet shall be used. The test shall be carried

out after being plugged into the test object, respectively. The reference test tool shall

not affect the test results of the specimen. The contact surface of the reference test tool

shall have a silver or silver alloy coating containing at least 95% silver as required by

ISO 4521.2008, with a coating thickness of at least 5 um. Among them, the hardness of

the surface coating of the plug shall be at least 70 HV. The coating thickness shall be at

least 8 um. The surface roughness Ra shall not be greater than 1.0 um.

NOTE. If the test object is only a vehicle inlet, the specimen cannot be independently tested related

to the charging coupler. According to the nominal parameters of the specimen, select a matching

cable assembly with a vehicle connector as a reference test tool for testing.

7.1.3.3 For charging coupler-related tests that require the participation of charging

cables, the charging coupler test shall be performed after connecting the charging cable.

If the specimen provided by the manufacturer includes a charging cable, the charging

cable and charging coupler will be jointly used as the test object by default. If the cross-

sectional area and other wiring requirements of the charging cable meet the

requirements of the test project, the charging cable may not be used as a test object. If

the specimen provided by the manufacturer does not include the charging cable, the

manufacturer shall provide the test cable and complete the wiring.

7.2 Appearance and structure

Inspect the appearance and structure of the charging connection set through visual

observation or manual testing.

7.3 Temperature cycling

7.3.1 Temperature shock

The charging connection set shall undergo a temperature shock test in accordance with

the requirements of 5.3.2 in GB/T 28046.4-2011.The test set the high temperature to

85°C and the low temperature to -30°C. The exposure duration is 20 min. The number

of cycles is 100.

7.3.2 High and low temperature tolerance

High and low temperature endurance test using 3 charging connection sets.

a) Carry out the initial temperature rise test according to the requirements of 7.24.

Record the temperature rise value;

b) Conduct temperature cycle test according to method Na of GB/T 2423.22.Some

test parameters are as follows.

1) High temperature. 125 degrees C;

2) Low temperature. -40 degrees C;

3) Temperature exposure duration. 30 min;

4) Conversion time. no more than 3 min;

5) Number of cycles. 10 times.

c) After the charging connection set returns to ambient temperature, conduct a final

temperature rise test according to the requirements of 7.24.Record the

temperature rise value.

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