QC/T 911-2023Power supply vehicles (English PDF)

3.1 Power supply vehicle

The special vehicle that is equipped with a generator set, optional uninterruptible power supply system, transmission lines and other devices, and is used to provide power.

3.2 Compartment

The compartment body that is used to protect the generator set and related accessories in the power supply vehicle.

3.3 Ventilation system

The ventilation device that provides combustion and cooling air to the generator set (including engine and generator) in the compartment.

3.4 Rated output

The rated power mentioned in this Document is the basic power of the generator set specified in 14.3.3 of GB/T 2820.1-2022.

3.5 Uninterruptible power system

A power system that is composed of a combination of converters, switches and energy storage systems to maintain load power continuity when the input power fails.

NOTE: Energy storage systems can be divided into mechanical energy storage systems and rechargeable energy storage systems (such as batteries).

3.6 Rechargeable energy storage system

An energy storage system that is rechargeable and provides electrical energy.

EXAMPLE: Such as lithium-ion batteries, capacitors, etc.

3.7 Battery management system

A system that monitors battery status (temperature, voltage, current, state of charge, etc.) and provides communication interfaces and protection for the battery.

3.8 Delay time

The uninterruptible power supply operates at rated capacity and the time it takes for the voltage of the rechargeable energy storage system to drop to the discharge cut-off voltage.

4.1 General

4.1.1 The power supply vehicle shall comply with the requirements of this Document and be manufactured in accordance with the product drawings and technical documents approved by the manufacturer's prescribed procedures.

4.1.2 Purchased and outsourced parts shall comply with the provisions of relevant standards and have certificates of conformity from the manufacturer. They can only be used after passing the inspection. All self-made parts can be assembled only after passing the inspection.

4.2 Environmental conditions

4.2.1 Environmental conditions for the rated power output of the power supply vehicle: Altitude is 0m; ambient temperature is 25°C; and relative humidity is 30%.

4.2.2 The power supply vehicle shall be able to output the corrected specified power and work reliably under the following conditions. The conditions shall be specified in the product technical documents:

---The altitude does not exceed 4000m.

--- The low-temperature lower limits of the ambient temperature are: -40°C, -25°C, -10°C, 5°C; the high-temperature upper limits are: 40°C, 45°C, 50°C; the lower limit value and upper limit value of the ambient temperature are each one of the above data.

--- Maximum relative humidity does not exceed 90% (25°C).

---The rainfall shall not exceed 8mm/h.

4.2.3 When the power supply vehicle is running, the working site shall be able to ensure that the longitudinal (front and rear) horizontal inclination of the power supply vehicle is no more than 6°; and the transverse (left and right) horizontal inclination is no more than 5°.

4.2.4 When the actual environmental conditions are worse than those specified in 4.2.1, for non-supercharged and mechanically supercharged diesel engine units; the power is converted into electrical power after converting the diesel engine power under test conditions according to the provisions of GB/T 6072.1; but the maximum electrical power shall not exceed the rated power of the generator. For units using other prime movers, the power correction method shall be in accordance with the provisions of the product technical documents.

4.3 Whole vehicle

4.3.13 Power supply vehicles with a rated power greater than 20kW shall be equipped with a generator set starting battery voltage detection device. When the generator set starting battery voltage is too low, there shall be an alarm indication.

4.3.14 A power supply vehicle with a rated power greater than 20kW shall be equipped with an AC 220V or AC 380V charging device. After being connected, the starting battery can be charged to the generator set.

4.3.15 Power supply vehicles with a rated power greater than 20kW should be equipped with a camera with night vision function inside the compartment to monitor internal conditions from outside the compartment.

4.3.16 For power supply vehicles with a length of the whole vehicle greater than 6m, the cab shall be equipped with a reversing monitoring system.

4.3.17 The starting capability of the power supply vehicle shall meet the following requirements:

--- Normal temperature start: When the ambient temperature of the power vehicle generator set is greater than 10°C, the unit shall be able to start successfully within 3 starts. The starting battery capacity of the generator set shall meet the requirements for the unit to be successfully started five times continuously.

--- Low-temperature start: When the power supply vehicle is used in low-temperature environments, it shall be equipped with low-temperature start devices. The low-temperature starting device can ensure that the generator set of a power supply vehicle with a power of no more than 250kW under the lower limit temperature of the environment shall be able to start smoothly within 30 min; and shall have the ability to work with the specified load within 3 min after successful start. For power supply vehicles with a power greater than 250kW, the starting time and load working time of the generator set at low temperatures shall be in accordance with the provisions of the product technical documents.

4.3.18 The continuous operation capability of the power supply vehicle under rated working conditions shall meet the following requirements:

--- Under the conditions of 4.2.1 environmental conditions and sufficient fuel supply, the power supply vehicle can continuously operate normally at rated power output for no less than 12 h (including 1 h of operation at 10% overload);

--- Under the environmental conditions of 4.2.1, the power supply vehicle can continue to operate at rated power output for no less than 4 h after a single fuel filling.

4.3.19 For a power supply vehicle equipped with an uninterruptible power supply system, the uninterruptible power supply system can replace the unit to provide power to the load before the generator set is started and operates stably. Its uninterruptible power supply system shall meet the requirements of 4.8.

4.4 Safety requirements

4.4.1 The operation safety of the power supply vehicle shall comply with the provisions of GB 7258.

4.4.2 The outer dimensions, axle load and mass parameters of the power supply vehicle shall comply with the provisions of GB 1589.

4.4.3 The power supply vehicle shall adopt a power supply system with neutral point insulation.

4.4.4 The insulation resistance of each electrical circuit to ground and between circuits in the power supply system of the power vehicle shall meet the following requirements:

--- In hot state (the generator set operates at rated power for 1 h), the insulation resistance shall be no less than 0.5 Mohm;

--- In cold state (the generator set is left standing for 8 h), the insulation resistance shall be no less than 10 Mohm.

4.4.5 The withstand voltage values of each independent electrical circuit to ground and between circuits in the electrical system of the power supply vehicle shall comply with the relevant provisions of 4.13.3 of GB/T 2819-1995.

4.4.6 The power supply vehicle shall be equipped with a special vehicle body grounding device, and the grounding device shall be marked with prescribed symbols or graphics. The grounding device includes an insulated sheathed grounding wire with a length of no less than 10m and a cross-sectional area of no less than 25 mm2, and a grounding rod with a length of no less than 900mm and a diameter of no less than 16mm.

4.4.7 The vehicle chassis, generator set casing, energy storage device casing, fuel tank, compartment, and distribution cabinet shall be reliably connected through yellow/green two-color wires; and the resistance between each connection point shall be no greater than 0.5 ohm.

4.4.8 The power output junction box of the power supply vehicle shall be able to be closed and locked under operating conditions; and the exposed live parts such as copper bars shall be equipped with an insulating protective cover.

4.4.9 Near the power output end of the power supply vehicle, there must be a functional switch for emergency stop of the power supply equipment. This functional switch also has the function of preventing mis-operation.

4.4.10 The cab and compartment of the power supply vehicle shall be equipped with one set of fire extinguishers of no less than 2 kg, respectively, which shall be installed securely and easy to use.

4.5 Protective measures

4.5.1 Overload protection

The power supply vehicle shall have overload protection measures. When the load current exceeds the specified overload current value, the overload protection device shall act reliably within the specified time. The overload protection requirements are specified in the product technical documents.

4.5.2 Short-circuit protection

The power supply vehicle shall have short-circuit protection measures. When a short circuit occurs at the power output end (including single-phase, two-phase and three-phase short circuit); the protection measures shall be able to act quickly and reliably so that the power supply vehicle is not damaged.

4.5.3 Voltage protection

The generator set of the power supply vehicle shall have two protection measures, namely, low voltage over-limit and high-voltage over-limit. When the voltage of the generator set exceeds the limit due to internal or external reasons, the protective measures shall act reliably; and the protection requirements shall be in accordance with the provisions of the product technical documents. For power supply vehicle equipped with uninterruptible power supplies, their uninterruptible power supply systems shall also have voltage protection functions.

4.5.4 Speed protection

The generator set of the power supply vehicle shall have a speed over-limit protection function. The speed over-limit includes two states, namely, too low speed and too high speed. When the speed over-limit state exceeds the specified time limit, the protection measures shall be able to act quickly and reliably. The protection requirements are based on the provisions of product technical documentation.

4.5.5 Temperature protection

The generator set of the power supply vehicle shall have high temperature protection measures. When the ultra-high temperature operation of the generator set exceeds its specified time limit, the protection measures shall be taken quickly to ensure that the power supply vehicle is not damaged. For power supply vehicle equipped with uninterruptible power supply, the uninterruptible power supply system shall also have temperature protection function.

4.5.6 Engine protection

In the event of a malfunction that may cause damage to the unit's prime mover, the generator set of power supply vehicle shall have a protection or alarm function.

4.8.4 Uninterruptible power supply host and installation requirements

4.8.4.1 The uninterruptible power supply host output shall have the function of preventing polarity reversal; and shall be able to issue corresponding abnormality alarms when the phase sequence connection is abnormal.

4.8.4.2 The uninterruptible power supply host shall pass YD 5083 and YD 5096 certification; and its earthquake resistance capability shall reach Level-8 and above magnitude.

4.8.4.3 When installing the uninterruptible power supply host, the vibration and impact under vehicle driving conditions shall be fully considered; and corresponding vibration reduction and anti-impact measures shall be set up.

4.8.5 Rechargeable energy storage system and installation requirements

4.8.5.1 The safety design of rechargeable energy storage systems shall meet the relevant requirements of GB 18384.

4.8.5.2 The battery pack of the rechargeable energy storage system must meet the relevant requirements of GB 38031.

4.8.5.3 The battery energy of the rechargeable energy storage system shall not be greater than 120 kW·h.

4.8.5.4 The rechargeable energy storage system shall be equipped with a battery management system; and the battery management system shall meet the relevant requirements of 5.2, 5.3, 5.4, 5.5, 5.7, 5.14, 5.15, 5.16, 5.17, and 5.19 in GB/T 34131-2017. It has related functions such as display, storage, and wave recording. It can monitor each battery in the vehicle in real time (temperature, voltage, current, state of charge, installation and fixation status, etc.); and can automatically disconnect the protection switch and alarm when abnormality occurs.

4.8.5.5 Each battery pack in the rechargeable energy storage system shall be products produced by the same manufacturer with the same structure and chemical composition, and meet the following requirements:

--- The difference between the maximum and minimum static open circuit voltages between fully charged batteries in the battery module shall be no greater than 0.05V;

--- The difference between the maximum, minimum and average capacity of each battery in the battery module shall not exceed ±1% of the average.

4.8.5.6 The charging and discharging process of the rechargeable energy storage system battery shall be professionally monitored through the uninterruptible power supply host, and charging by an external charger is not allowed.

4.8.5.7 The battery pack of the power supply vehicle equipped with uninterruptible power supply must be installed and placed in separate compartments from the generator set.

4.8.5.8 The battery installation shall be equipped with shock-absorbing devices and compression devices, which shall be installed securely and not move or fall when driving.

4.8.5.9 The distance between the battery installation position and the rear of the compartment shall be no less than 400mm. The installation height of the battery pack on the vehicle shall meet the requirements of 4.7.1 of GB 38032-2020. The battery shall be able to avoid direct collision with the outside.

4.8.5.10 The battery shall be installed with waterproof and dustproof measures, and shall be convenient for disassembly, assembly and maintenance.

4.9 Compartment

4.9.1 The compartment frame shall have sufficient strength and stiffness, and its dimensional error shall meet the following requirements:

a) For compartment length less than or equal to 5000mm, the limit deviation is ±8mm; for compartment length above 5000mm, the limit deviation is ±10mm.

b) Width: The limit deviation is ±8mm.

c) Height on the longitudinal center plane: the limit deviation is ±6mm.

d) The difference between the two diagonals of the door frame shall be no greater than 3mm.

e) The parallelism tolerance between door frames and columns is 3mm.

4.9.14 The design of the compartment shall meet the requirements of rated power output of the power supply vehicle and the continuous operation capability under rated working conditions.

4.10 Electrical circuit layout

4.10.1 The power cables of the generator set arranged in the compartment must have dedicated wiring channels. The wiring channel shall have the functions of cable protection, insulation and water accumulation prevention.

4.10.2 The control cables and communication cables of the generator set must have dedicated wiring channels independent of the power cables. The wiring channel shall have the functions of cable protection, insulation and water accumulation prevention.

4.10.3 The output end of the generator set and the output end of the power supply vehicle must be marked with the name of the phase line that complies with national standards. Both ends of the power cable arranged in the box must have color markings of no less than 150mm in length. The A phase wire is marked with yellow color, the B phase wire is marked with green color, the C phase wire is marked with red color, and the neutral wire N is marked with brown or light blue color; and the grounding wire is marked with a special grounding conductor.

4.10.4 The power supply output end of the power supply truck is arranged from left to right or from top to bottom in order of A, B, C and N phases (viewed from the terminals). There must be clear letter identification on the terminals.

4.10.5 Power cables should be cables that meet the requirements of TB/T 1484.1; and their oil resistance reaches Level-III standards. At the same time, the cable has certain wear resistance, temperature resistance and flame-retardant properties. The cable carrying capacity shall be able to meet the maximum output current of the power supply vehicle. The outer surface of the cable shall have continuous markings such as nominal cross-section and voltage level that are not easy to erase.

4.10.6 The control wires of the power supply vehicle shall be reasonably and neatly laid out, firmly connected, and easy to maintain. The internal wire numbers, colors, and cross-sections are consistent with the instructions.

4.10.7 For power vehicles equipped with uninterruptible power supply, the battery circuit of the battery connection cable of the uninterruptible power supply system should be provided with no less than two obvious disconnection points.

4.11 Instruments and indications

4.11.1 The power supply vehicle shall be able to display the main operating parameters of the generator set and the uninterruptible power supply system, including voltage, current, frequency, etc. The display accuracy level of voltage, current, and frequency is no less than Level-1.0, and corresponding alarms can be issued when parameters are abnormal.

4.11.2 The power supply vehicle shall have an alarm device for abnormal oil pressure of the generator set; and the water-cooled generator set shall also have an alarm device for abnormal water temperature in the water tank.

4.11.3 The power supply vehicle shall have an indication and alarm device for the fuel quantity of the generator set.

4.11.4 The instruments and indicator lights of the power supply vehicle shall be placed in a position that is convenient for observation.

5.1 Test conditions and test preparation

The test conditions and test preparation of the power supply vehicle shall be carried out in accordance with the provisions of GB/T 12534.

5.2 Basic performance test

The basic performance test of the power supply vehicle is carried out in accordance with the provisions of QC/T 252.

5.3 Special performance test

5.3.1 Phase sequence inspection

According to Method-208 in GB/T 20136-2006, connect the power output terminals to the corresponding terminals of the phase sequence indicator; start the generator set and the uninterruptible power supply system respectively; and check whether the phase sequence complies with the markings.

5.3.2 Start performance test

According to Method-206 in GB/T 20136-2006, when the generator set is started at normal temperature and cold, the unit shall be able to start successfully. For units equipped with low-temperature starting devices, it is necessary to confirm whether the low-temperature starting device is working properly according to Method-207 in GB/T 20136-2006. For power supply vehicles used in low-temperature environments, when starting the generator set under the lower limit of ambient temperature, the unit shall be able to start successfully within 30 min.

5.3.3 Insulation resistance measurement

According to Method-101 in GB/T 20136-2006, when the ambient temperature is 15°C~35°C and the relative air humidity is 45%~75%, let the generator set stand for 8 h.