QC/T 895-2011Conductive on-board chargers for electric vehicles (English PDF)

3.1 On-board charger

Refers to a device that installed on the electric automobile, and can converted the power of the public grid into direct current required by the on-board energy storage device and can charge the on-board energy storage device.

3.2 Charging efficiency

The percentage of the ratio of the on-board charger DC output power and the AC input active power.

3.3 Total harmonic distortion (THD)

The square-root of sum of squares of the ratio of the 2-th "C 40-th harmonic current component AND the fundamental current.

3.4 Output voltage tolerance

The percentage of the RATIO of the DEVIATION between the on-board charger's actual output voltage value and output voltage pre-set value AND output voltage pre-set value.

3.5 Output current tolerance

The percentage of the RATIO of the DEVIATION between the on-board charger's actual output current value and output current pre-set value AND output current pre-set value.

3.6 Charging coupler

Other components except for the cable and the cable control box (if any) in the charging connecting apparatus, including the power supply interface and vehicle interface.

5.1 Rated input voltage, rated input current

The on-board charger input voltage and current levels are shown in Table 1.

5.2 Recommended values of output voltage

It is recommended to divide the on-board charger output voltage levels into 6 in accordance with Table 2.

6.1 General provisions

6.1.1 The outer surface of on-board charger shall be smooth, without obvious scratches, deformation and other defects. The surface coating shall be uniform.

6.1.2 Nameplate and markings installation shall be upright and fixed, with clear handwriting.

6.1.3 Parts shall be securely tightened. There shall be no rust, burrs, cracks and other defects and damages.

6.1.4 The strength and stiffness of the on-board charger structure shall conform to the requirements of 6.5 in GB/T 15139-1994.

6.2 Environmental Requirements

6.2.1 Humidity

Relative Humidity is 5% - 95%, non-condensing, non-frosting.

6.2.2 Temperature

The on-board charger operating temperature and storage temperature range shall comply with the requirements of Table 3

6.3 Input voltage and frequency

6.3.1 Input voltage range

Within the range of ± 15% of the rated input voltage, the on-board charger shall be able to work normally.

6.4 Functional requirements

6.4.1 Charging Function

6.4.2 Voltage-limiting and current-limiting characteristics

6.4.3 Protection functions

6.4.4 Low voltage power supply function

For the on-board charger with a low-voltage auxiliary power, the low voltage auxiliary power supply shall provide a DC voltage with a nominal value of 12V or 24V, and the DC voltage ripple factor shall be less than 1%.

6.5 High voltage electrical performance requirements

6.5.4 Ripple coefficient of voltage. The on-board charger voltage ripple factor shall be ± 5%.

6.5.1 Starting surge starting current

The starting surge current of the on-board charger (on-board charger input current) shall not exceed 150% of the maximum value of the working input current.

6.5.2 Output voltage tolerance

When the on-board charger is running in a state of constant voltage output, the deviation between its output voltage and the set voltage shall be ± 1%.

6.5.3 Output current error

When the on-board charger is running in a state of constant current output, the deviation between its output current value and the set current value shall be ± 5%.

6.5.5 Power factor and charging efficiency

6.6 Electrical safety requirements

6.6.1 Insulating property

On-board charger insulation performance shall meet the following provisions.

6.7 Electromagnetic compatibility

6.7.1 Electromagnetic immunity

Electromagnetic immunity of on-board charger during operation shall meet requirements in 11.3.1 of GB/T 18487.3-2001.

6.7.2 Electromagnetic disturbance

Electromagnetic immunity generated during the operation of on-board charger shall meet requirements in 11.3.1 of GB/T 18487.3-2001.

6.7.3 Harmonic current

6.8 Environmental performance requirements

6.8.1 Vibration resistance performance

Sweep vibration test shall be conducted on on-board charger according to 7.8.1. After the test, parts shall be free of damage, fasteners shall be free of loosening, and normal operation shall be assured.

6.8.4 IP Protection class On-board charger

IP protection class shall comply with the provisions of 3.6 in QC/T413-2002.The specific protection class shall be set in accordance with the requirements of the body layout, and the minimum shall not be less than IP20B.

6.8.5 Salt mist resistance

On-board charger shall be able to withstand salt mist test prescribed in 7.9.5, and to operate normally after test and standing.

6.9 Noise

Maximum operating noise of on-board charger and its cooling system measured in accordance with 7.9 shall not exceed 65dB (level A).

6.10 Durability

Conduct the test according to requirements of 7.10, normal operation of the product shall be assured during the test.

7.1 Test conditions

7.1.1 Environmental conditions

Without special provisions, the test shall be carried out under the following environmental conditions.

7.1.2 Measuring instruments and meters

Measuring instruments and meters specified in Table 4 are recommended, accuracy of measuring instruments and meters shall be more than 3 times higher than the accuracy of the test sample parameters.

7.1.3 On-board charger basic states

7.2 Environmental test

7.2.1 Humidity test

The test shall be carried out according to provisions of 3.11 in QC/T413-2002 for two cycles, during test process; on-board charger shall be in operating state under temperature of 0-45oC.

7.2.2 Temperature test

7.3 Input voltage and frequency test

7.3.1 Voltage fluctuation range test

Start up the on-board charger to make it run at rated load condition; respectively, adjust on-board charger input voltage to 85%, 100% and 115% of the rated value, and continuously run at each input voltage for 1min.

7.3.2 Frequency fluctuation test

Adjust the on-board charger input voltage to the rated voltage, start up on-board charger to make it run at rated load; respectively adjust on-board charger to make it at input frequency of 49Hz and 51 Hz, and continuously run at each frequency for 1 min.

7.4 Function requirements test

7.4.1 Charging function test

Under the voltage and frequency range condition specified in 6.3, start on-board charger, the on-board charger output rated power.

7.4.2 Voltage-limiting and current-limiting characteristics test

7.4.3 Protection function test

7.4.3.1 Overvoltage protection test

7.4.3.2 Under-voltage protection test

7.4.3.3 Short circuit protection test

7.4.3.5 Reverse-connection protection test

Connect the output positive pole of the on-board charger to the negative pole of the capacitive load, and connect the output negative pole of the on-board charger to the positive pole of the capacitive load, and under the voltage and frequency conditions specified in the 6.3, start up on-board charger.

7.4.4 Low voltage power supply function test

At the low-voltage auxiliary power output terminal, connect adjustable resistive load circuit (adjustable resistive load must meet adjustment requirement of the low-voltage auxiliary power from no load to full load), and connect the oscilloscope at the output; start on-board charger, read and record the maximum peak "C peak shown on the oscilloscope and the DC output average voltage, and obtain the ripple coefficient values through calculation.

7.5 High voltage electrical performance requirements test

7.5.1 Starting surge current test

At nominal input voltage and rated input frequency, start up the on-board charger to make it work at rated load, and use the oscilloscope to measure input current peaks during such start-up process.

7.5.5 Power factor and charging efficiency test

At nominal input voltage and rated frequency, start up on-board charger to make it work in the full load condition; use power meter to measure the power factor of the on-board charger, record input active power and DC output power of the on-board charger, and obtain the charging efficiency of the on-board charger through calculation.

7.5.6 Output response time test

At rated input voltage and rated frequency, start up on-board charger to make it operate in constant voltage output mode; after using the oscilloscope to measure and confirm that the on-board charger has fully started up, the rise time of the output voltage, output voltage rise peak and stable value, output voltage rise time and the calculated overshoot shall meet the requirements of 6.5.6; after the on-board charger receives the shutdown command, fall time of the output current shall meet the requirements of 6.5.6.

7.6 Electrical safety test

7.8 Environmental performance test

7.8.1 Vibration test

When the on-board charger is at non-working state, make it withstand scanning frequency vibration test from the following three directions - up and down, left and right, front and rear; 8h test time for each direction, and scanning frequency vibration test conditions shall comply with the requirements of Table 6.

8.1 General provisions

On-board charger shall be checked and qualified before delivery, and attached with documents or labels to prove the product quality.

8.2 Inspection type

The inspection of on-board charger is classified into ex-factory inspection and type inspection.

8.2.1 Ex-factory inspection

Visual inspection shall comply with the provisions as specified in 6.1 and performance test shall comply with the provisions as specified in Table 8 when make delivery inspection.

8.2.2 Type inspection

8.2.2.1 Type inspection shall be conducted under one of the following conditions.

8.2.2.2 The products conducted with type inspection shall be randomly selected from products that are qualified in the factory inspection and shall be able to cover the whole production process, totally 12 samples, all of which shall accomplish the performance test; after qualified they will be divided into 6 groups, 2 samples for each group. Test items and test sequence of each group of samples shall comply with provisions as specified in Table 9.

9.1 Marking

9.1.1 Product marking

9.2 Packaging

9.2.1 Product package shall consider the following items.

9.2.2 Packing carton shall be firm, products shall be motionless in the carton, free of mechanical damage in transportation, handling and stacking process and packaging carton can be moisture proof, corrosion prevention, shake proof and dust prevention.

Technical documents accompanied with packaging carton shall include the packing list, product factory quality certification, product operation instruction and prepared attachments list. Outside the packaging carton shall be marked.

9.3 Storage and custody Product

storage and custody shall be maintained under clean, dry and well-ventilated environment of 5 oC to 40 oC. It shall avoid sun, fire-roasted, water immersion, and putting together with corrosive substances.

9.4 Handling and transportation

Shock and vibration of products suffered during in carrying shall be limited to a minimum. […]