ChinaAutoRegs|GB/T 41589-2022英文版翻译《电动汽车模式2充电的缆上控制与保护装置（IC-CPD）》

In-Cable Control and Protection Device for Mode 2 Charging of Electric Road Vehicles (IC-CPD)

CONTENTS

Foreword I

Introduction

1 Scope 1

2 Normative References 2

3 Terms and Definitions 5

3.1 Terms and definitions relating to plugs and socket-outlets 5

3.2 Terms and definitions relating to terminals 5

3.3 Terms and definitions relating to residual current functions 6

3.4 Terms and definitions relating to tests 10

3.5 Terms and definitions relating to construction 10

4 Classification 11

4.1 Classification according to the power supply mode 11

4.2 Classification according to the construction 11

4.3 Classification according to the method of connecting the cable(s) 11

4.4 Classification according to the protective conductor path 11

4.5 Classification according to behavior in case of open protective conductor 12

4.6 Classification according to the usage 12

5 Characteristics of IC-CPDs 12

5.1 Requirements for characteristics 12

5.2 Rated quantities and other characteristics 13

5.3 Standard and preferred values 14

6 Marking and other product information 15

6.1 Data to be marked on the IC-CPD 15

6.2 Information to be provided to the end-user 16

7 Standard conditions for installation and operation 17

7.1 Standard conditions 17

7.2 Installation conditions 17

8 Requirements for construction and operation 17

8.1 Mechanical design 17

8.2 Pluggable electrical connections of pluggable IC-CPDs according to 4.3.4 18

8.3 Construction 19

8.4 Electrical performance 22

8.5 Protection against electric shock 24

8.6 Dielectric properties 25

8.7 Temperature rise 25

8.8 Operating characteristics 25

8.9 Mechanical and electrical endurance 26

8.10 Performance at short-circuit currents 26

8.11 Resistance to mechanical vibration and mechanical impact 26

8.12 Resistance to heat 26

8.13 Resistance to abnormal heat and to fire 26

8.14 Performance of the test function 26

8.15 Behavior in case of loss of the supply voltage 27

8.16 Resistance of IC-CPDs against unwanted tripping due to surge currents to earth resulting from impulse voltages 27

8.17 Control pilot function controller 27

8.18 Reliability 27

8.19 Resistance to tracking 27

8.20 Electromagnetic compatibility (EMC) 27

8.21 Behavior of the IC-CPD at low ambient air temperature 27

8.22 Operation with supply failure and hazardous live protective conductor conditions 27

8.23 Verification of a standing current in the protective conductor in normal service conditions 27

8.24 Behavior at specific environmental conditions 27

8.25 Resistance to vibration and shock 28

9 Tests 28

9.1 General requirements 28

9.2 Test conditions 29

9.3 Test of indelibility of marking 29

9.4 Protection against electric shock 30

9.5 Test of dielectric properties 30

9.6 Temperature-rise test 34

9.7 Verification of the operating characteristic 34

9.8 Verification of mechanical and electrical endurance 40

9.9 Verification of the behavior of the IC-CPD under overcurrent conditions 42

9.10 Verification of resistance to mechanical shock and impact 47

9.11 Test of resistance to heat 48

9.12 Resistance of insulating material to abnormal heat and to fire 49

9.13 Verification of the self-test 49

9.14 Verification of the behavior of IC-CPDs in case of failure of the supply voltage 50

9.15 Verification of the limiting values of the non-operating current under overcurrent conditions 50

9.16Verification of IC-CPD resistance against unwanted tripping due to surge currents to earth resulting from impulse voltages

9.17 Verification of reliability 51

9.18 Verification of resistance to ageing 53

9.19 Resistance to tracking 53

9.20 Test on pins provided with insulating sleeves 54

9.21 Test of mechanical strength of non-solid pins of plugs 54

9.22 Verification of the effects of strain on the conductors 54

9.23 Verification of the torque exerted by IC-CPDs on fixed socket-outlets 54

9.24 Tests of the cord anchorage 54

9.25 Flexing test of non-rewirable IC-CPDs 54

9.26 Verification of the electromagnetic compatibility (EMC) 55

9.27 Tests replacing verifications of creepage distances and clearances 56

9.28 Verifications for single electronic components used in IC-CPDs 57

9.29 Chemical loads 59

9.30 Heat test under solar radiation 59

9.31 Resistance to ultra-violet (UV) radiation 59

9.32 Damp and salt mist test for marine and coastal environments 59

9.33 Hot damp test for tropical environments 60

9.34 Vehicle drive-over 60

9.35 Low temperature storage test 61

9.36 Vibration and shock test 61

Annex A (Normative) Test sequences and number of samples to be submitted for verification of conformity to this document 81

Annex B (Normative) Routine tests 86

Annex C (Normative) Determination of clearances and creepage distances 87

Annex D (Informative) Switched-protective conductor (SPE) application 91

Annex E (Informative) Example of IC-CPD for mode 2 charging 93

Annex F (Informative) Types of IC-CPD according to construction and assembly 94

Annex G (Informative) Methods for determination of short-circuit power factor 95

Bibliography

1 SCOPE

This document applies to the in-cable control and protection devices (hereafter referred to as IC-CPDs) for mode 2 charging of electric vehicles, including control and safety functions.

This document applies to the portable devices performing simultaneously the functions of detecting the residual current, of comparing this residual current value with the residual operating current value and of opening the protected circuit when the residual current exceeds this value.

The IC-CPD in compliance with this document:

 has a control pilot function controller that meets the requirements of Annex A in GB/T 18487.1-2015;

 checks supply conditions and prevents charging in case of supply faults under specified conditions;

 may have a switched protective conductor.

These IC-CPDs are intended for use in TN- and TT-systems. The use of IC-CPDs in IT systems may be limited.

Residual currents with frequencies different from the rated frequency, DC residual currents and specific environmental situation are under consideration.

This document is applicable to IC-CPDs performing the safety and control functions as required in GB/T 18487.1 for mode 2 charging of electric vehicles.

This document is applicable to IC-CPDs for single-phase circuits not exceeding 250V and with a maximum rated current not exceeding 16A.

This document is applicable to IC-CPDs to be used in AC circuits only, with preferred values of rated frequency 50Hz, 60Hz or 50/60Hz. The IC-CPDs specified in this document are not intended to be used to supply electric energy towards the connected grid.

This document is applicable to IC-CPDs having a rated residual operating current not exceeding 30 mA and are intended to provide additional protection for the circuit downstream of the IC-CPD in situations where it cannot be guaranteed that the electrical installation is equipped with a residual current device (RCD) with I∆n ≤ 30 mA.

The IC-CPD consists of:

 a plug for connection to a socket-outlet in the fixed installation;

 one or more subassemblies containing the control and protection features;

 a cable between the plug and the subassemblies (optional);

 a cable between the subassemblies and the vehicle connector (optional);

 a vehicle connector for connection to the electric vehicle.

For plugs for household and similar use, GB/T 2099.1-2021 applies, where the types, basic parameters and dimensions shall be in line with GB/T 1002.

Plugs, vehicle connectors and cables which are part of the IC-CPD are not required to be tested according to this document. These parts are tested separately according to their specific product standard.

The switching contacts of the IC-CPD are not required to provide isolation, as isolation can be ensured by disconnecting the plug.

The IC-CPD may have a non-replaceable integral fuse in the phase(s) and/or neutral current path.

The IC-CPD is not considered to be a protective device for use in fixed installations.

2 NORMATIVE REFERENCES

The following normative documents contain provisions which, through normative reference in this text, constitute essential provision of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendment) applies.

GB/T 1002 Single phase plugs and socket-outlets for household and similar purposes—Types, basic parameters and dimensions

GB/T 1043 (all parts) Plastics—Determination of charpy impact properties [ISO 179 (all parts)]

Note: GB/T 1043.1-2008, Plastics – Determination of charpy impact properties – Part 1: Non-instrumented impact test (ISO 179-1:2000, IDT)

GB/T 1043.2-2018, Plastics—Determination of charpy impact properties – Part 2: Instrumented impact test (ISO 179-2:1997, IDT)

GB/T 1043.1 Plastics – Determination of charpy impact properties – Part 1: Non-instrumented impact test (GB/T 1043.1-2008, ISO 179-1:2000, IDT)

GB/T 2099.1-2021 Plugs and socket-outlets for household and similar purposes—Part 1: General requirements (IEC 60884-1:2013, MOD)

GB/T 2423.1 Environmental testing – Part 2: Test methods – Tests A: Cold (GB/T 2423.1-2008, IEC 60068-2-1:2007, IDT)

GB/T 2423.4 Environmental testing for electric and electronic products – Part 2: Test method – Test Db: Damp heat, cyclic (12h+12h cycle) (GB/T 2423.4-2008, IEC 60068-2-30:2005, IDT)

GB/T 2423.5 Environmental testing—Part 2: Test methods—Test Ea and guidance: Shock (GB/T 2423.5-2019, IEC 60068-2-27:2008, IDT)

GB/T 2423.7 Environmental testing—Part 2: Test methods—Test Ec: Rough handling shocks, primarily for equipment—type specimens (GB/T 2423.7-2018, IEC 60068-2-31:2008, IDT)

GB/T 2423.17 Environmental testing—Part 2: Test methods—Test Ka: Salt mist (GB/T 2423.17-2008, IEC 60068-2-11:1981, IDT)

GB/T 2423.24 Environmental testing—Part 2: Test methods—Test S: Simulated solar radiation at ground level and guidance for solar radiation testing and weathering (GB/T 2423.24-2013, IEC 60068-2-5:2010, IDT)

GB/T 2423.56 Environmental testing—Part 2: Test methods—Test Fh: Vibration, broadband random and guidance (GB/T 2423.56-2018, IEC 60068-2-64:2008, IDT)

GB/T 2424.2 Environmental Testing for electric and electronic products — Guidance for damp heat tests (GB/T 2424.2-2005, IEC 60068-3-4:2001, IDT)

GB/T 4207 Method for the determination of the proof and the comparative tracking indices of solid insulating materials (GB/T 4207-2012, IEC 60112:2009, IDT)

GB/T 4208-2017 Degrees of protection provide by enclosure (IP code) (IEC 60529:2013, IDT)

GB 4343.1 Electromagnetic compatibility requirements for household appliances, electric tools and similar apparatus—Part 1: Emission (GB 4343.1-2018, CISPR 14-1:2011, IDT)

GB/T 5013 (all parts) Rubber insulated cables – Rated voltages up to and including 450/750V [IEC 60245 (all parts)]

Note: GB/T 5013.1-2008, Rubber insulated cables of rated voltages up to and including 450/750V – Part 1: General requirements (IEC 60245-1:2003, IDT)

GB/T 5013.2-2008, Rubber insulated cables of rated voltages up to and including 450/750V – Part 2: Test methods (IEC 60245-2:1998, IDT)

GB/T 5013.3-2008, Rubber insulated cables of rated voltages up to and including 450/750V – Part 3: Heat resistant silicone insulated cables (IEC 60245-3:1994, IDT)

GB/T 5013.4-2008, Rubber insulated cables of rated voltages up to and including 450/750V – Part 4: Cords and flexible cables (IEC 60245-4:2004, IDT)

GB/T 5013.5-2008, Rubber insulated cables of rated voltages up to and including 450/750V – Part 5: Lift cables (IEC 60245-5:1994, IDT)

GB/T 5013.6-2008, Rubber insulated cables of rated voltages up to and including 450/750V – Part 6: Arc welding electrode cables (IEC 60245-6:1994, IDT)

GB/T 5013.7-2008, Rubber insulated cables of rated voltages up to and including 450/750V – Part 7: Heat resistant ethylene-vinyl acetate rubber insulated cables (IEC 60245-7:1994, IDT)

GB/T 5013.8-2013, Rubber insulated cables – Rated voltages up to and including 450/750V – Part 8: Cords for applications requiring high flexibility (IEC 60245-8:2004, IDT)

GB/T 5023 (all parts) [IEC 60227 (all parts)]

Note: GB/T 5023.1-2008, Polyvinyl chloride insulated cables of rated voltages up to and including 450/750V – Part 1: General requirements (IEC 60227-1:2007, IDT)

GB/T 5023.2-2008, Polyvinyl chloride insulated cables of rated voltages up to and including 450/750V – Part 2: Test methods (IEC 60227-2:2003, IDT)

GB/T 5023.3-2008, Polyvinyl chloride insulated cables of rated voltages up to and including 450/750V – Part 3: Non-sheathed cables for fixed wiring (IEC 60227-3:1997, IDT)

GB/T 5023.4-2008, Polyvinyl chloride insulated cables of rated voltages up to and including 450/750V – Part 4: Sheathed cables for fixed wiring (IEC 60227-4:1997, IDT)

GB/T 5023.5-2008, Polyvinyl chloride insulated cables of rated voltages up to and including 450/750V – Part 5: Flexible cables (cords) (IEC 60227-5:2003, IDT)

GB/T 5023.6-2006, Polyvinyl chloride insulated cables of rated voltages up to and including 450/750V – Part 6: Lift cables and cables for flexible connections (IEC 60227-6:2001, IDT)

GB/T 5023.7-2008, Polyvinyl chloride insulated cables of rated voltages up to and including 450/750V – Part 7: Flexible cables screened and unscreened with two or more conductors (IEC 60227-7:2003, IDT)

GB/T 5169.10 Fire hazard testing for electric and electronic products—Part 10: Glowing/hot-wire based test methods—Glow-wire apparatus and common test procedure (GB/T 5169.10-2017, IEC 60695-2-10:2013, IDT)

GB/T 5169.11 Fire hazard testing for electric and electronic products—Part 11: Glowing/hot-wire based test methods—Glow-wire flammability test method for end-products (GWEPT) (GB/T 5169.11-2017, IEC 60695-2-11:2014, IDT)

GB/T 6346.14 Fixed capacitors for use in electronic equipment—Part 14: Sectional specification—Fixed capacitors for electromagnetic interference suppression and connection to the supply mains (GB/T 6346.14-2015, IEC 60384-14:2005, IDT)

GB 8898 Audio, video and similar electronic apparatus – Safety requirements (GB 8898-2011, IEC 60065:2005, MOD)

GB/T 9286 Paints and varnishes—Cross-cut test (GB/T 9286-2021, ISO 2409:2020, IDT)

GB/T 9341 Plastics – Determination of flexural properties (GB/T 9341-2008, ISO 178:2001, IDT)

GB/T 11918 (all parts) Plugs, fixed or portable socket-outlets and appliance inlets for industrial purposes [IEC 60309 (all parts)]

Note: GB/T 11918.1-2014, Plugs, fixed or portable socket-outlets and appliance inlets for industrial purposes—Part 1: General requirements (IEC 60309-1:2012, MOD)

GB/T 11918.2-2014, Plugs, socket-outlets and couplers for industrial purposes―Part 2: Dimensional compatibility and interchangeability requirements for pin and contact-tube accessories (IEC 60309-2:2012, MOD)

GB/T 11918.4-2014, Plugs, socket-outlets and couplers for industrial purposes―Part 4: Switched socket-outlets and connectors with or without interlock (IEC 60309-4:2012, MOD)

GB/T 11918.5-2020, Plugs, socket-outlets and couplers for industrial purposes—Part 5: Dimensional compatibility and interchangeability requirements for plugs, socket-outlets, ship connectors and ship inlets for low-voltage shore connection systems (LVSC) (IEC 60309-5:2017, MOD)

GB/T 11918.1-2014 Plugs, fixed or portable socket-outlets and appliance inlets for industrial purposes—Part 1: General requirements (IEC 60309-1:2012, MOD)

GB/T 16422.2-2014 Plastics―Methods of exposure to laboratory light sources―Part 2：Xenon-arc sources (ISO 4892-2:2006, IDT)

GB/T 16895.10-2010 Low-voltage electrical installations – Part 4-44: Protection for safety – Protection against voltage disturbances and electromagnetic disturbances (IEC 60364-4-44:2007, IDT)

GB/T 16935.1-2008 Insulation coordination for equipment within low-voltage systems – Part 1: Principles, requirements and tests (IEC 60664-1:2007, IDT)

GB/T 16935.3 Insulation coordination for equipment within low-voltage systems—Part 3: Use of coating, potting or moulding for protection against pollution (GB/T 16935.3-2016, IEC 60664-3:2010, IDT)

GB/T 18487.1-2015 Electric vehicle conductive charging system—Part 1: General requirements

GB/T 18499-2008 Residual current operated protective devices (RCD) for household and similar use – Electromagnetic compatibility (IEC 61543:1995, IDT)

GB/T 20234.1-2015 Connection set of conductive charging for electric vehicles—Part 1: General requirements

GB/T 20234.2-2015 Connection set for conductive charging of electric vehicles—Part 2: AC charging coupler

GB/T 28046.5-2013 Road vehicles – Environmental conditions and testing for electrical and electronic equipment – Part 5: Chemical loads (ISO 16750-5:2010, MOD)

GB/T 30789.3 Paints and varnishes—Evaluation of degradation of coatings—Designation of quantity and size of defects, and of intensity of uniform changes in appearance—Part 3: Assessment of degree of rusting (GB/T 30789.3-2014, ISO 4628-3:2003, IDT)

ISO 17409:2020 Electrically propelled road vehicles – Conductive power transfer – Safety requirements

IEC 60417 Graphical symbols for use on equipment

Note: GB/T 5465.2-2008, Graphical symbols for use on electrical equipment – Part 2: Graphical symbols (IEC 60417 DB:2007, IDT)

IEC 61249-2 (all parts) Materials for printed boards and other interconnecting structures

3 TERMS AND DEFINITIONS

For the purposes of this document, the following terms and definitions apply.

Note 1: The terms “voltage” and “current” used in this document imply RMS values, unless otherwise specified.

Note 2: In this document, the word “earthing” is used for “protective earthing”.

Note 3: The term “accessory” is used as a general term covering plugs, socket-outlets, vehicle connectors and vehicle couplers.

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