QC/T 1175-2022High voltage contactor for electric vehicles (English PDF)

3.1 Contactor

A non-manually operated mechanical switching device, that has only one rest position and can make, carry and break current, under normal circuit conditions (including overload operating conditions).

3.2 Contact resistance

The resistance value between the closed contacts, which are measured from the two terminals of the contact assembly.

3.3 Contact rated voltage

a) Operation mode 1: The contactor coil's end connector is normally connected, BUT no power is supplied;

b) Operation mode 2: The coil end of the contactor supplies power, BUT the contact does not supply power;

c) Operation mode 3: The coil end of the contactor supplies power, AND the contacts supply power.

Note: Contact power supply generally means that the contactor's contacts pass a constant rated current, without requirements for the voltage. If there are special circumstances, the contact power supply situation can be determined, through negotiation, between the supplier and the buyer. The coil power supply refers to the supply of test voltage to the contactor coil's control circuit.

5.1 Working environment

Unless otherwise specified, the contactor shall work normally under the following environmental conditions:

a) Working environment temperature: -40 °C ~ 85 °C;

b) Relative humidity: 5% ~ 95%;

5.4.3 Requirements for make time and release time

Carry out the test according to 6.4.3. The make time of the contactor shall be less than 50 ms; the release time shall be less than 30 ms.

5.4.4 Coil short-term overvoltage requirements

Carry out the test according to 6.4.4. During the test, the contactor shall work normally.

After the test, the contactor shall meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10.

5.4.5 Coil long-term overvoltage requirements

Carry out the test according to 6.4.5. During the test, the contactor shall work normally.

After the test, the contactor shall meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10.

5.4.6 Voltage drop requirements

Carry out the test according to 6.4.6. Within the operating voltage range of the coil, the contactor shall work normally. Outside the operating voltage range of the coil, the contactor can be disconnected. After the test, the contactor shall meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10.

5.4.7 Coil reverse voltage requirements

Carry out the test according to 6.4.7. The contactor shall meet the following requirements:

a) Contactor with circuit board: When a reverse voltage is applied to the coil end, the circuit board of the contactor shall not be damaged. When the forward test voltage is applied after the test, the contactor shall comply with the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10;

b) Contactor without circuit board: The contactor shall work normally during the test.

The contactor shall comply with the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10.

5.4.8 Requirements for contact voltage drop/contact resistance

Carry out the test in accordance with 6.4.8. The contact voltage drop/contact resistance of the contactor, before and after the test, shall meet the values, which are negotiated and determined between the supplier and the purchaser.

5.4.9 Requirements for insulation resistance

Carry out the test according to 6.4.9. Before the test, the insulation resistance of the contactor shall be greater than 1000 Mohm. After the test, the insulation resistance of the contactor shall be greater than 50 Mohm.

5.4.10 Requirements for power frequency withstand voltage

Carry out the test according to 6.4.10. During the test, the contactor shall have no defects, such as flashover, arcing, or insulation breakdown. The leakage current of the contactor shall not exceed 0.5 mA.

5.4.11 Requirements for anti-short-circuit current capability

Carry out the test according to 6.4.11. During the test, the contactor shall be free from smoke, explosion, fire, appearance damage.

5.4.12 Requirements for ultimate breaking capacity

Carry out the test according to 6.4.12. The contactor shall be able to break safely at least once, that is, the contactor has no adhesion, smoke, fire, explosion, appearance damage.

5.4.13 Electrical life requirements

Carry out the test according to 6.4.13. During the test, the contactor shall work normally.

After the test, the contactor shall meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10, 5.4.14.

5.4.14 Temperature rise requirements

Carry out the test in accordance with 6.4.14. If there is no special requirement, the temperature rise of the contactor contact and the shell shall not exceed 60 K. After the life test, the temperature rise test shall be carried out, under high temperature conditions.

It is required that the maximum temperature of the contactor's contact and the shell shall not exceed 150 °C. After the test, the contactor shall meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10.

5.5 Environmental adaptability

5.5.1 Low temperature requirements

Carry out the test according to 6.5.1. During the test, the contactor shall work normally.

After the test, the contactor shall meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10, 5.4.14.

5.5.2 High temperature requirements

Carry out the test according to 6.5.2. During the test, the contactor shall work normally.

After the test, the contactor shall meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10, 5.4.14.

5.6.2 Mechanical vibration requirements

Carry out the test according to 6.6.2. The contactor in the test shall meet the following requirements:

a) In the operation mode 1 when the contact is opened, the contactor shall not be closed instantaneously (the single closing time of the open contact shall not exceed 10 µs);

b) In the operation mode 2 when the contact is closed, the contactor shall not be disconnected instantaneously (the single disconnection time of the closed contact shall not exceed 10 µs).

After the test, the contactor shall have no mechanical damage and meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10, 5.4.14.

5.6.3 Mechanical shock requirements

Carry out the test according to 6.6.3. The contactor in the test shall meet the following requirements:

a) In the operation mode 1 when the contact is opened, the contactor shall not be closed instantaneously (the single closing time of the open contact shall not exceed 10 µs);

b) In the operation mode 2 when the contact is closed, the contactor shall not be disconnected instantaneously (the single disconnection time of the closed contact shall not exceed 10 µs).

After the test, the contactor shall have no mechanical damage and meet the requirements of 5.4.2, 5.4.3, 5.4.8, 5.4.9, 5.4.10, 5.4.14.

5.6.4 Sound level requirements

The test shall be carried out according to 6.6.4. The limit value of the contactor's sound level test shall be determined, through negotiation between the supplier and the purchaser.

5.7 Electromagnetic compatibility

5.7.1 General requirements

Contactors with electronic circuits shall meet the technical requirements, which are specified in 5.7.2 ~ 5.7.8.

5.7.2 Conducted disturbance requirements

Conduct the test according to 6.7.1. If there is no special requirement, the conduction disturbance of the contactor shall comply with the limit values of level 3, which are specified in Table 5 and Table 6 in GB/T 18655-2018.

5.7.3 Radiation disturbance requirements

Conduct the test in accordance with 6.7.2. If there is no special requirement, the radiation disturbance of the contactor shall comply with the limit values of level 3, which is specified in Table 7 in GB/T 18655-2018.

5.7.4 Transient conducted disturbance requirements

Conduct the test according to 6.7.3. If there is no special requirement, the transient conduction disturbance of the contactor shall comply with the limit value requirements of level 3, in C.2 and C.3 of GB/T 21437.2-2008.

5.7.5 Transient conduction immunity requirements for power lines

Carry out the test according to 6.7.4. If there is no special requirement, the contactor shall work normally, during and after the test.

5.7.6 Electrical fast transient burst immunity requirements

Carry out the test according to 6.7.5. If there is no special requirement, the contactor shall work normally, during and after the test.

5.7.7 Radiated immunity requirements

Carry out the test according to 6.7.6. If there is no special requirement, the contactor shall work normally, during and after the test.

5.7.8 Electrostatic discharge requirements

Carry out the test according to 6.7.7. If there is no special requirement, the contactor shall work normally, during and after the test.

6.1 General test conditions

6.1.1 Standard atmospheric conditions of test

Unless otherwise specified, all tests shall be carried out, under the following environmental conditions:

a) Room temperature: 23 °C ± 5 °C;

6.4.2 Pick-up and release voltage test

6.4.2.1 The contactor is tested under the conditions of operation mode 2.

6.4.2.2 Type tests are carried out at 85 °C, 23 °C, -40 °C, respectively. The exit-factory inspections are carried out at 23 °C.

6.4.2.3 The pick-up voltage test process is as follows:

a) Place the contactor in the temperature box before the test. The test can be carried out, after the temperature of the contactor is consistent with the test environment temperature (deltaT <= ±2 °C);

b) Adopt the method of increasing voltage: Start the low-voltage power supply and adjust the voltage, starting from 0 V and increasing at 0.1 V stepwise voltage, until it is detected that the moving and static contacts are connected;

c) Increase voltage by step-up method: First adjust the voltage of the low-voltage power supply to the voltage, which is shown in Table 2; then start the low-voltage power supply after connecting the contactor coil.

Note: Choose one of the two test methods to test; the double-coil contactor with energy-saving board and with driver board shall be tested, in step-up voltage increasing mode.

6.4.2.4 The release voltage test process is to slowly reduce the power supply voltage from the rated voltage of the coil, until the movable and static contacts are completely disconnected.

6.4.3 Make time and release time test

The make time and release time tests shall be carried out, according to the following requirements:

a) Apply the rated voltage to the coil end of the contactor; the load connected to the contact end does not exceed 12 V/1 A;

b) Use an oscilloscope to collect the voltage waveform, at both ends of the coil, as well as the voltage waveform, at both ends of the load;

c) The time difference -- between the voltage at both ends of the coil and the voltage at both ends of the load changing from low level to high level -- is the make time;

d) When the coil end of the contactor is powered off, the time difference -- between the voltage at both ends of the coil and the voltage at both ends of the load changing from high level to low level -- is the release time.

6.4.4 Coil short-term overvoltage test

6.4.4.1 The test object is a contactor, which has a coil rated voltage of 12 V.

6.4.4.2 The contactor is tested under the conditions of operation mode 2.

6.4.4.3 The coil short-term overvoltage test process is to place the contactor in a room temperature environment. Apply 2 times the rated voltage to the coil end, which lasts for 60s.

6.4.5 Coil long-term overvoltage test

6.4.5.1 The contactor is tested under the conditions of operation mode 2.

6.4.5.2 The test is carried out at 85 °C.

6.4.5.3 The coil long-term overvoltage test process is to place the contactor in the temperature box. Apply 1.5 times the rated voltage, to the coil end, after the temperature of the contactor remains consistent with the test environment temperature (deltaT <= ±2 °C) for 60 minutes.

6.4.6 Voltage drop-jumpback test

6.4.6.1 The contactor is tested under the conditions of operation mode 2.

6.4.6.2 The voltage drop-jumpback test process is as follows:

a) According to Figure 1, apply a test pulse to the coil end of the contactor, in which the supply voltage drops from Usmin to 0.95Usmin, at a 5% amplitude, maintaining for 5 s; then jump back to Usmin from 0.95Usmin, maintaining for at least 10 s. Repeat the above operations in sequence, until the power supply voltage drops from Usmin to 0 V, at a 5% amplitude; then jump the voltage back to Usmin;

b) Check the reset performance of the contactor.

6.7 Electromagnetic compatibility

6.7.1 Conducted disturbance test

The conducted disturbance test shall be carried out, according to the test method in 6.3 of GB/T 18655-2018.

6.7.2 Radiation disturbance test

The radiation disturbance test shall be carried out, according to the test method in 6.5 of GB/T 18655-2018.

6.7.3 Transient conducted disturbance test

The transient conduction disturbance test shall be carried out, in accordance with the test method in Chapter 4 of GB/T 21437.2-2008.

6.7.4 Power line transient conduction immunity test

The power line transient conduction immunity test shall be carried out, according to the test method 5.6 in GB/T 21437.2-2008; the test severity level shall be level III.

6.7.5 Electrical fast transient burst immunity test

The electrical fast transient burst immunity test shall be carried out, according to the test method in GB/T 17626.4-2018; the test level is level 3; the pulse repetition frequency is 5 kHz.

6.7.6 Radiated immunity test

The radiation immunity test shall be carried out, in accordance with the following requirements:

a) Carry out the radiation immunity test, according to the test method of GB/T 33014.2-2016; the test frequency range is 400 MHz ~ 2 GHz; the intensity level of test field is 30 V/m;

b) According to the test method of GB/T 33014.4-2016, conduct a large current injection test, on the power line and the signal line connected to the outside. The test frequency range is 1 MHz ~ 400 MHz; the injection current level is 60 mA;

c) Carry out the magnetic field immunity test, according to the test method of ISO 11452-8:2015; the test frequency range is 15 Hz ~ 150 kHz; the test level is level