NB/T 10641-2021Testing equipment on-site for off-board charger of electric vehicle (English PDF)

3.1 Testing equipment on-site for off-board charger of electric vehicle

Device for on-site testing of off-board charger performance.

5.2 Mechanical requirements

5.2.2 Heat resistance and flame retardancy

The testing equipment shall be able to withstand the glow-wire test, and shall not catch fire after being subjected to the test method in GB/T 5169.11.

Test severity: The test temperature is 650 °C ± 10 °C, and the action time is 30 s ± 1 s.

5.2.3 Enclosure protection grade

The enclosure protection grade of the testing equipment shall not be lower than the requirements of IP30 in GB/T 4208-2017.

5.2.4 Earthing terminal

The testing equipment shall have a protective earthing terminal with an obvious earthing mark, and shall have a reliable electrical connection with an accessible metal enclosure. The electric conductor of the terminal shall be made of copper; the surface shall be anti-corrosion treated; the diameter of the thread shall not be less than 5 mm.

5.3 Electrical requirements

5.3.1 Power supply

The AC power supply is required as follows:

a) rated voltage: single-phase 220 V, allowable deviation -15% ~ +10%;

b) frequency: 50 Hz, allowable deviation ±0.5 Hz;

c) waveform: sine, waveform distortion factor not greater than 5%.

5.3.2 Insulation resistance

The insulation resistance between non-electrically connected live circuits and between each independent live circuit and the ground (metal enclosure) shall not be less than 10 Mohm.

5.3.3 Dielectric strength

The testing equipment shall be able to withstand the test of 6.3.3 without breakdown, flashover and component damage.

5.4 Electromagnetic compatibility requirements

5.4.1 Electrostatic discharge immunity

The testing equipment shall be able to withstand the electrostatic discharge immunity test of severity grade 3 specified in Table 1 of GB/T 17626.2-2018. After the test, the […]

5.6 Interface requirements

5.6.2 Power pulse input interface

The testing equipment shall have an electric energy pulse input interface for electric energy measurement calibration. The low level of the pulse signal is 0 V ~ 0.7 V, and the high level is 3.5 V ~ 24 V. The input impedance shall be greater than 10 kohm, and the interface should be compatible with passive pulse signals.

5.6.3 Power pulse output interface

The testing equipment shall have an electric energy pulse output interface for electric energy measurement calibration. The lower level of the output pulse signal is 0 V ~ 0.4 V, and the high level is 4.75 V ~ 24 V.

5.6.4 Auxiliary interface

It can be equipped with charging communication (S+, S-) interface, low-voltage auxiliary power supply (A+, A-) interface, charging connection confirmation (CC1, CC2) signal lead-out interface, grounding (PE) signal lead-out interface, DC power supply (DC+, DC-) lead-out interface. If there is a DC power lead-out interface, the interface shall be protected against accidental collision.

5.7 Functional requirements

5.7.1 Control guide circuit simulation

The testing equipment shall have the vehicle control guide circuit simulation function.

The electrical components include resistors R4, R5 and pull-up voltage U2. The resistance of resistor R4 is adjustable. The circuit shall comply with the requirements of Appendix B.1 of GB/T 18487.1-2015.

5.7.2 Connection loop on-off state simulation

The testing equipment shall have the simulation function of the on-off state of the connection loop, with loop on-off switches PE, S+, S-, CC1, CC2, A+, A-, and vehicle contactors K5, K6, which can simulate the abnormal conditions of vehicle charging control sequence and switch disconnection. The testing equipment shall meet the test requirements such as connection confirmation, charging connection control timing, and vehicle interface disconnection specified by GB/T 34657.1.

5.7.3 Signal acquisition

The testing equipment shall have the acquisition function of signals from various channels. The charging pile side of the DC+, DC-, PE, S+, S-, CC1, CC2, A+, A- loop on-off switches and the vehicle side of the DC+, DC- on-off switches shall be provided with voltage signal acquisition interfaces. The DC+, DC- major loop and the A+, A- auxiliary power supply loop shall be equipped with current acquisition interfaces (voltage type), which shall meet the acquisition requirements of GB/T 34657.1 on the DC output voltage, DC output current, CAN signal voltage, auxiliary power supply voltage, auxiliary power supply current, detection point 1 voltage, detection point 2 voltage, vehicle battery voltage and other signals of the charging pile.

5.7.4 Insulation state simulation

The testing equipment shall have an insulation state simulation function and a charging major loop insulation state simulation function, which can at least simulate asymmetric insulation faults between DC+ and PE or between DC- and PE in the charging DC loop, and symmetrical insulation faults between DC+ and PE and between DC- and PE. The testing equipment shall meet the insulation fault test requirements specified in GB/T 34657.1.

5.7.5 Battery voltage simulation

The testing equipment shall have a battery voltage simulation function and meet the requirements of self-inspection stage test, charging readiness test, and output voltage exceeding the vehicle's allowable value test specified in GB/T 34657.1.

5.7.6 Vehicle BMS simulation

The testing equipment shall have the vehicle BMS simulation function. The communication protocol of the vehicle BMS simulation software shall comply with the regulations for BMS in GB/T 27930. The interoperability test cases shall meet the standard test requirements in GB/T 34657.1. The protocol consistency test cases shall meet the standard test requirements in GB/T 34658.

6.1 Environmental test

6.1.1 High-temperature test

Put the testing equipment into the environmental test chamber, according to the requirements of GB/T 2423.2, Test Bd, at the test temperature of 50 °C± 2 °C. After the temperature of the test sample reaches a stable state, the device shall work normally, and the measurement accuracy shall comply with the requirements of Table 3.

6.1.2 Low temperature test

Put the testing equipment into the environmental test chamber, according to the requirements of GB/T 2423.1, Test Ad, at the test temperature of -20 °C ± 3 °C. After the temperature of the test sample reaches a stable state, the device shall work normally, and the measurement accuracy shall comply with the requirements of Table 3.

6.1.3 Damp heat resistance performance test

Put the testing equipment into the environmental test chamber, according to the requirements of GB/T 2423.4, test Db, at the test temperature of 40 °C, for 2 cycles.

Conduct a retest of insulation resistance and dielectric strength 2 hours before the end of the damp heat test. The insulation resistance shall not be less than 1 Mohm, and the dielectric strength shall apply a measurement voltage of 75% of the required value.

After the test, return to normal environmental conditions, and check that the equipment shall work normally after power-on.

6.2 Mechanical performance test

6.2.1 Enclosure test

6.2.1.1 Static thrust

The equipment shall be firmly fixed on a rigid support surface and withstand a thrust of 30 N. The thrust shall be applied through the hemispherical end of a rigid rod of 12 mm in diameter, and shall be applied to every part of the enclosure which is accessible when the equipment is ready for use and whose deformation may cause a hazard.

6.2.1.2 Dynamic impact

The equipment shall be firmly fixed on the rigid support surface, and a steel ball with a diameter of 50 mm and a mass of 500 g ± 25 g shall be freely dropped from a height of 1 m. A maximum of 3 points shall be applied to any location on the surface that may be touched during normal use and that may cause a hazard if damaged.

6.2.1.3 Vibration test

The equipment shall be subjected to the vibration test of the following severities in non-working and unpackaged conditions. After the test, the equipment shall be able to operate normally without damage or information changes.

-- frequency range: 10 Hz ~ 150 Hz;

-- crossover frequency: 60 Hz;

-- When the frequency is less than 60 Hz, the constant displacement amplitude is 0.075 mm;

-- When the frequency is greater than 60 Hz, the constant acceleration is 10 m/s² (1.0 g);

-- number of sweep-frequency cycles: 10.

6.2.1.4 Drop test

e) If the enclosure of the testing equipment is made of metal material, contact discharge should be used for direct discharge; if the enclosure of the testing equipment is made of insulating material, air discharge should be used for direct discharge.

f) The number of discharges at each test point: more than 10 times for positive and negative polarities; the interval between discharges is at least 1 s.

g) The testing equipment is in working condition.

6.4 Electromagnetic compatibility test

6.4.2 Power frequency magnetic field immunity test

The test shall be carried out in accordance with the provisions of GB/T 17626.8-2006, and the test shall be carried out under the following conditions:

a) severity: grade 5, continuous magnetic field 100 A/m;

b) magnetic field duration: 60 s;

c) magnetic field frequency: 50 Hz;

d) magnetic field directions: X, Y, Z;

e) inspection methods: immersion method and proximity method;

f) testing equipment in working condition.

6.4.3 Electrical fast transient/burst immunity test

The test shall be carried out in accordance with the provisions of GB/T 17626.4-2018, and the test shall be carried out under the following conditions:

a) Use a coupling/decoupling network to directly couple the disturbance test voltage to the input port and output port.

1) severity: grade 3;

2) test voltage: 2 kV;

3) repetition frequency: 5 kHz or 100 kHz;

4) duration: 1 min;

5) number of voltage applications: 3 times each for positive and negative polarities;

6) testing equipment in working condition.

6.5 Measurement performance test

6.5.4.3 External power frequency magnetic field impact test

Under the reference conditions of 6.5.1, test the basic error of the testing equipment.

Then, apply the power frequency magnetic field specified in 5.4.2; keep the reference conditions for other quantities, and test the error again; calculate the influence quantity. The result shall meet the requirements in Table 3.

6.5.4.4 Radiated radio-frequency electromagnetic field impact test

Under the reference conditions of 6.5.1, test the basic error of the testing equipment.

Then, apply the radio frequency electromagnetic field according to the requirements of 7.5.3 in GB/T 17215.211-2006; keep other quantities under the reference conditions, and test the error again; calculate the influence quantity. The result shall meet the requirements of Table 3.

6.5.4.5 Immunity impact test to conducted disturbances induced by radio-

frequency fields Under the reference conditions of 6.5.1, test the basic error of the testing equipment.

Then, according to the requirements of 7.5.5 in GB/T 17215.211-2006, apply the RF field induction of severity grade 3; keep the reference conditions for other quantities, and test the error again; calculate the influence quantity. The results shall meet the requirements of Table 3.

6.5.5 Clock requirement test

The testing equipment and the standard clock tester record their indication time at the same time. Calculate the clock indication error deltat of the testing equipment according to Formula (2).

Where: t - the display time of the standard clock tester, in seconds (s); t' - the display time of the testing equipment under test, in seconds (s). The test results shall meet the requirements of 5.5.4.

6.5.6 Control guide measurement test

Apply voltage to detection point 1 and detection point 2 of the testing equipment from the charging interface (or other equivalent interface) to make the voltage meet the requirements of 5.5.5; check the display value of the testing equipment, and compare it with the applied voltage. The results shall meet the requirements for uncertainty of measurement in 5.5.5.

6.6 Interface test

6.6.1 Power interface test

Measure the power interface size and check whether it meets the requirements specified in 5.6.1.

Use S+ and S- as CAN communication lines, and set the test communication rate to 250 kbit/s. See Appendix A for specific requirements. Before the test, it shall be confirmed that the load communication function is normal.

Carry out at least two tests, i.e., load connection establishment (see Appendix A.4.2) and version reading (see Appendix A.4.8). The communication process and protocol content shall meet the protocol requirements.

6.6.2 Power pulse input interface test

Use a DC voltage source to output low-level and high-level voltage signals, and check the pulse detection of the testing equipment, which shall comply with the regulations in 5.6.2.

6.6.3 Power pulse output interface test

Use a measuring device to detect the low-level and high-level voltage signals of the power pulse output interface, which shall comply with the provisions of 5.6.3.

6.6.4 Auxiliary interface test

Use a measuring device to test the auxiliary interface. The auxiliary interface of the testing equipment shall comply with the provisions of 5.6.4.

6.7 Functional requirements

6.7.1 Control guide circuit simulation test

Use a multimeter to check the testing equipment; adjust the testing equipment control guide resistance R4 in the upper and lower limit range; use a standard voltmeter to measure the CC1 loop voltage adjustment range, which shall meet the requirements of 5.7.1 for control guide circuit simulation function.

6.7.2 Connection loop on-off state simulation test

Use a multimeter to check each loop of the testing equipment interface, which shall meet the requirements of 5.7.2 for connection loop on-off state simulation function.

6.7.3 Signal acquisition test

Check the testing equipment acquisition interface, which shall meet the signal acquisition function requirements of 5.7.3.

6.7.4 Insulation state simulation test

Use a multimeter and an insulation tester to check the testing equipment, which shall meet the insulation state simulation function requirements of 5.7.4.

6.7.5 Battery voltage simulation test

Adjust the upper and lower limits of the output voltage of the testing equipment, and measure it with a standard voltmeter, which shall meet the requirements of 5.7.5 for battery voltage simulation function.

6.7.6 Vehicle BMS simulation test

Use a testing equipment to test the consistency and interoperability of the standard sample pile communication protocol; save all messages and analyze the data frame format, content, cycle and timing; verify the execution of each test case, which shall meet the requirements of 5.7.6 for vehicle BMS simulation function.

7.1 Inspection classification

The inspection of the testing equipment is divided into type inspection and ex-factory inspection.

7.2 Type inspection

In any of the following cases, type inspection shall be carried out:

a) before the finalization and identification of new products;

b) before the finalization and identification of products transferred to the factory for production;

c) after formal production, if there are major changes in design, process materials, and components, which may affect product performance;

d) when the production, which has been suspended for one year or more, is resumed;

e) when the national technical supervision agency or the technical testing department entrusted puts forward type inspection requirements;

f) when the ex-factory inspection result is significantly different from the inspection of the previous batch of products;

g) when it is stipulated in the contract. The type inspection items are shown in Table 9. […]