GB/T 20234.1-2023: Download Full-PDF & Invoice in 9 seconds.
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Excerpt from above true-PDF:
GB/T 20234.1-2023
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.040.99
CCS T 35
Replacing GB/T 20234.1-2015
Connection set for conductive charging of electric vehicles -
Part 1: General requirements
ISSUED ON: SEPTEMBER 07, 2023
IMPLEMENTED ON: SEPTEMBER 07, 2023
Issued by: State Administration for Market Regulation;
Standardization Administration of the People's Republic of China.
Table of Contents
Foreword ... 4
Introduction ... 6
1 Scope ... 7
2 Normative references ... 7
3 Terms and definitions ... 9
4 Symbols and abbreviations ... 14
5 Rated values ... 15
5.1 Rated voltage (preferred value) ... 15
5.2 Rated current or duration maximum current (preferred value) ... 15
6 Requirements ... 16
6.1 General ... 16
6.2 Charging connection set ... 16
6.3 Charging coupler ... 27
6.4 Charging cable ... 37
6.5 In-cable device ... 38
7 Test methods ... 39
7.1 General provisions ... 39
7.2 Appearance and structure ... 40
7.3 Temperature cycling ... 40
7.4 Alternating heat and humidity ... 41
7.5 Grounding measures ... 42
7.6 Insulation resistance and dielectric strength ... 43
7.7 Connection of charging cable ... 43
7.8 Thermal management system ... 44
7.9 Liquid cooling device ... 45
7.10 Temperature monitor ... 47
7.11 Mechanical strength ... 48
7.12 Limited short-circuit current withstand... 52
7.13 Vehicle crushing ... 52
7.14 Type and size ... 53
7.15 Locking device ... 53
7.16 Switching elements ... 57
7.17 Plug-in and pull-out force ... 57
7.18 Protection against electric shock ... 58
7.19 Terminals and heads ... 58
7.20 Aging resistance of rubber and thermoplastic materials ... 60
7.21 Protection level ... 60
7.22 Divisive ability ... 60
7.23 Normal operation (service life) ... 61
7.24 Temperature rise ... 63
7.25 Screws, current-carrying parts and connections ... 67
7.26 Creepage distances, clearances and sealant penetration distances ... 67
7.27 Heat resistance, flame resistance and tracking resistance ... 67
7.28 Corrosion and rust resistance ... 67
7.29 Resistance to vibration and mechanical shock ... 67
7.30 Offset operation ... 68
7.31 Contact durability ... 68
7.32 Charging cable ... 69
7.33 In-cable device ... 71
8 Inspection rules ... 72
Annex A (informative) Thermal management system product data sheet ... 80
Annex B (normative) Reference test tool for temperature rise test ... 82
B.1 General ... 82
B.2 Requirements ... 82
Bibliography ... 87
Connection set for conductive charging of electric vehicles -
Part 1: General requirements
1 Scope
This document specifies the technical requirements for voltage and current ratings,
appearance, structure, environmental adaptability, electrical performance, and
mechanical performance of connection set for conductive charging of electric vehicles.
It describes the test conditions, test methods, inspection items and other inspection
requirements for connection set for conductive charging of electric vehicles.
The document is applicable to AC charging connection set with a frequency of 50 Hz,
a rated voltage not exceeding AC 690 V, and a rated current not exceeding 250 A for
conductive charging of electric vehicles, as well as DC charging connection set with
rated voltage not exceeding DC 1500 V and rated current (duration maximum current)
not exceeding 1000 A.
This document does not apply to the charging connection set that uses standard plugs
and sockets that comply with GB/T 1002 and GB/T 2099.1 for the plug and socket-
outlet.
When the charging connection set specified in this document is used for electric
vehicles in special places such as water conservancy, mining, construction sites,
agricultural operations, or other fields other than road vehicles, additional requirements
may be required in terms of the installation location, operating conditions, usage
methods, environmental adaptability, etc. of the charging connection set.
2 Normative references
The following referenced documents are indispensable for the application of this
document. For dated references, only the edition cited applies. For undated references,
the latest edition of the referenced document (including any amendments) applies.
GB/T 261, Determination of flash point -- Pensky-Martens closed cup method
GB/T 1002, Single phase plugs and socket-outlets for household and similar
purposes -- Types, basic parameters and dimensions
GB/T 2099.1, Plugs and socket-outlets for household and similar purposes -- Part
1: General requirements
3.10 in-cable device
An equipment or set that performs a specific electrical function on a cable assembly.
NOTE: In-cable device includes in-cable function boxes that implement control and protection
functions on the cable assembly, and in-cable chargers that convert AC power from the external
power supply into DC power required by the power battery.
3.11 locking device
A device that keeps the charging coupler in the normal connection position and prevents
the charging coupler from being accidentally disconnected. It is equipped to prevent the
phase line, neutral line and DC contacts of the charging coupler from being charged
before normal plugging. It prevents the phase line, neutral line and DC contacts of the
charging coupler from being disconnected when powered, or prevent the phase line,
neutral line and DC contacts of the charging coupler from being powered before being
pulled out.
NOTE: It is divided into mechanical locking device with manual locking/unlocking and electronic
locking device with electronically controlled locking/unlocking.
3.12 rated current
In the absence of forced air convection and other specified conditions, the manufacturer
specifies the maximum operating current for sustainable operation of the naturally
cooled charging connection set.
NOTE: For charging connection sets with positive cooling function, it refers to the maximum
operating current that can continue to operate after the positive cooling function is turned off.
3.13 duration maximum current
Under specific positive cooling conditions, the manufacturer specifies the maximum
operating current for sustainable operation of the positively cooled charging connection
set.
3.14 short time maximum current
Within a specified period of time, the operating current can be greater than the rated
current (or duration maximum current) of the charging connection set without causing
deterioration and damage to the charging connection set.
3.15 positive cooling
A method of using gas, liquid or solid cooling medium to forcefully dissipate heat from
the charging connection set through heat conduction, thereby reducing the temperature.
NOTE: Common positive cooling methods are divided into gas medium cooling and liquid medium
6 Requirements
6.1 General
6.1.1 Appropriate measures shall be taken for the charging connection set in material
selection, design, production, packaging, storage, transportation, installation, etc., so
that the product has normal functions and meets the expected use needs.
6.1.2 Charging connection sets shall have appropriate product performance. When used
in normal operation, the product shall work normally during its normal life span. When
misused, the product shall not cause leakage, short circuit, fire or other safety accidents.
It shall not cause harm or adverse effects to surrounding people, vehicles, equipment
and the environment. When charging equipment or electric vehicles experience
overload, short circuit or other faults in the charging circuit, it shall not cause serious
accidents such as melting or burning of the charging connection set.
6.1.3 The charging connection set shall comply with the climatic and environmental
conditions of the charging site. Product durability shall meet the application
requirements of electric vehicles and charging equipment.
6.1.4 The charging connection set shall be easy for personnel to operate and use,
facilitate regular maintenance and maintenance, and meet the needs of product use
management such as recycling and storage of electric vehicles and charging equipment.
6.1.5 The charging connection set shall adopt appropriate structure and measures. Avoid
dismantling or modifying it by non-professionals unless it is seriously damaged.
6.2 Charging connection set
6.2.1 Appearance requirements
6.2.1.1 The casing of the plug, socket-outlet, vehicle connector, vehicle inlet or charging
cable shall be marked with the name or trademark of the manufacturer, product model,
rated voltage, rated current (except charging cables) and protection level information.
The vehicle inlet shall be marked with rated current and duration maximum current.
The vehicle connector with a thermal management system shall be marked with the
duration maximum current and may not be marked with the rated current.
6.2.1.2 The contacts of rewirable plugs, socket-outlets, vehicle connectors and vehicle
inlets shall be marked with the following symbols. These symbols shall be located close
to the terminal concerned. They shall not be marked on screws, removable washers or
other removable parts:
- For three phases, L1, L2, and L3 represent phase lines, N represents neutral line,
and represents protective grounding;
- For single phase, L1 represents phase line, N represents neutral line, and
represents protective grounding;
- DC+ and DC- represent direct current electrodes;
- CP stands for controlled guidance;
- CC stands for connection confirmation;
- S+ and S- represent communication contacts;
- A+ and A- represent low voltage auxiliary power electrodes.
6.2.1.3 The shell of the in-cable device shall be marked with the manufacturer's name
or trademark, product model, rated voltage, rated current and protection level
information. There shall be high voltage warning signs. If the in-cable device is only
suitable for areas with an altitude of 2000 m and below, it shall also be marked with the
altitude warning statement or warning sign of GB 4943.1.
6.2.1.4 The markings of the charging connection set shall be clear and wear-resistant.
They shall comply with the requirements of 7.6 in GB/T 11918.1-2014.
6.2.1.5 For cable assemblies containing cables and a plug or vehicle connector, wire
terminal or end identification information shall be provided to guide wiring and
installation. Unwired ends of cable assemblies shall be marked with conductor
identification for connection to rewirable terminals.
6.2.1.6 When using connection method B, the plug and the vehicle connector shall have
clearly visible distinguishing marks.
6.2.1.7 The accessible surface of the charging connection set shall be free of burrs,
foreign matter, flash and similar sharp edges.
6.2.2 Environmental conditions
6.2.2.1 The normal working environment temperature that the charging connection set
shall be able to withstand is -30℃~+50℃.
6.2.2.2 Charging connection sets shall be able to withstand overheating of contacts and
terminals. High and low temperature tolerance tests shall be carried out in accordance
with 7.3.2. After the test, the final test temperature rise of the charging connection set
shall comply with the requirements of 6.3.13. The deviation from the initial test
temperature rise is not greater than ±5 K. Insulation resistance and dielectric strength
shall meet the requirements of 6.2.5. The protection level shall meet the requirements
grounding conductor shall not be cracked, damaged or melted.
NOTE: The DC charging connection set is usually not directly electrically connected to the DC
grid, but it does not rule out the application of direct electrical connection to the DC grid.
6.2.5 Insulation resistance and dielectric strength
The insulation resistance and dielectric strength of the charging connection set shall
meet the requirements of Chapter 19 of GB/T 11918.1-2014. Among them, the
insulation resistance shall not be less than 100 MΩ.
6.2.6 Connection of charging cable
6.2.6.1 The connection between the plug and/or the vehicle connector and the charging
cable shall comply with the requirements of 23.1 in GB/T 11918.1-2014.
6.2.6.2 Non rewirable plugs and/or vehicle connectors shall be provided with charging
cables matching their ratings or duration maximum current in accordance with the
manufacturer's specifications. Non-rewirable plugs and/or vehicle connectors shall be
tested as cable assemblies. The connection between the rewirable plug and/or the
vehicle connector and the charging cable shall meet the requirements of 23.2.2 in GB/T
11918.1-2014.
6.2.6.3 The plug and/or vehicle connector equipped with a charging cable shall meet
the requirements of 23.3 in GB/T 11918.1-2014. After testing of components using
liquid medium cooling cables, the sealing parts shall not show cracks or damage that
could lead to leakage of the medium.
6.2.7 Thermal management system
6.2.7.1 The charging connection set may be equipped with a thermal management
system. The thermal management system shall be able to provide positive cooling and
other functions for the charging connection set through heat conduction, heat radiation,
etc. The charging connection set manufacturer shall refer to Annex A to provide product
data sheets related to the thermal management system.
6.2.7.2 After the thermal management system is turned on, it shall be able to reduce the
temperature of the charging connection set. According to the manufacturer's
instructions, perform an positive cooling function test on the charging connection set
with a thermal management system.
6.2.7.3 The thermal management system shall be able to meet the requirements of the
charging connection set at the duration maximum current and maximum operating
temperature. The thermal management system shall continue to operate stably for at
least 168 h. Under duration maximum current, three consecutive readings after the
temperature stabilizes show that the temperature rise shall not exceed 2 K.
6.2.7.4 When the thermal management system uses liquid medium to provide positive
a pressure relief valve), leakage monitoring (only for non-insulating liquid medium),
etc.
6.2.8.2 The liquid cooling device shall be able to reduce the medium temperature in the
medium pipeline by increasing the liquid cooling medium transmission flow or heat
dissipation power according to the ambient temperature, operating current and contact
temperature status of the charging connection set. Reduce or control the temperature of
the charging connection set. Referring to the test method in 7.24, under any working
condition where the ambient temperature does not exceed 40°C and the charging current
is not greater than the duration maximum current, the contact temperature of the
charging connection set shall not exceed 90°C.
6.2.8.3 The charging connection set manufacturer shall provide operating instructions
for the liquid cooling medium, which shall include the rated pressure of the liquid
cooling medium, the maximum allowable pressure of the liquid cooling medium, and
the type of liquid cooling medium. In addition, the cable type, conductor cross-sectional
area, maximum temperature of the liquid cooling medium, minimum flow rate of the
liquid cooling medium, and minimum capacity of the liquid cooling medium may also
be included. The manufacturer of the charging connection set shall provide information
on the operating current in the event of cooling pipe failure and heat exchanger failure.
6.2.8.4 Environmentally friendly cooling medium shall be used in accordance with the
requirements for chemical classification and labeling. Any leaks that occur shall be
collected, stored in equipment and kept isolated from the environment. The cooling
medium used shall also meet biodegradable requirements.
6.2.8.5 All liquid cooling medium sealing components shall be able to withstand the
action of the liquid cooling medium and the thermal environment. After the non-
metallic parts undergo the liquid medium and air oven aging treatment in 7.9.3, the
tensile strength and ultimate elongation shall not be less than 60% of the control
specimen.
6.2.8.6 Liquid cooling devices can use different types of liquid cooling medium.
Different types of liquid cooling medium shall not be mixed. The liquid cooling
medium model of the liquid cooling device shall not be changed at will. A warning shall
be provided in the product instructions or data sheet: Failure to use the cooling medium
specified by the charging connection set manufacturer may result in leakage or material
deterioration.
6.2.8.7 If liquid cooling medium leaks onto exposed electrical components inside the
charging connection set, it shall not cause a fire. The minimum flash point of liquid
cooling medium shall not be lower than 135°C.
6.2.8.8 The liquid cooling device shall not leak liquid medium and reduce the insulation
performance during normal operation. Carry out the durability test according to the test
method of 7.9.4. Liquid medium shall be operated at the maximum pressure the device
can produce. The sealing components of the liquid cooling device shall be able to
withstand the maximum pressure that the device can generate (pressure protection
devices such as closing pressure relief valves and pressure monitoring devices) or the
maximum allowable pressure of the design of the device. The total pressure of the
pressure test is the larger of the two and increases by 0.1 MPa. The device shall not leak,
explode or rupture.
NOTE: When the liquid cooling device is in normal use, use methods such as pressure relief valves
and pressure monitoring to avoid failures that exceed the maximum allowable pressure of the liquid
cooling device.
6.2.8.9 Conduct insulation resistance and dielectric strength tests on the cooling
medium of the liquid device according to 6.2.5. If the liquid cooling medium and the
contacts are separated by insulating material, insulation resistance and dielectric
strength tests are carried out between the liquid medium and the contacts. If the liquid
medium is in direct contact with the contacts, the liquid cooling medium and the
contacts are considered to be the same conductor. Separate insulation resistance and
dielectric strength tests are not performed on liquid cooling medium. Insulation
resistance and dielectric strength tests shall be carried out on contacts containing liquid
cooling medium.
6.2.9 Temperature monitor
6.2.9.1 The charging connection set shall have a temperature monitor function. AC
charging socket-outlets with a rated operating current greater than 16 A, vehicle inlets
and vehicle connectors with connection mode C shall have a temperature monitor
function. Vehicle connectors and vehicle inlets used for DC charging shall have
temperature monitor functions. The temperature monitor device shall be able to reflect
the temperature changes at key locations such as charging connection sets such as DC±
and phase line contacts and terminal ends.
6.2.9.2 The thermal management system of the charging connection set shall have a
temperature monitor function. For liquid cooling devices, the temperature monitor
device shall be able to monitor the temperature of the liquid medium inlet and/or outlet
in the liquid medium pipeline.
6.2.9.3 The temperature monitor device of the DC charging connection set shall be able
to monitor the temperature of the DC+ and DC- contacts, respectively. The temperature
monitor device of the cable assembly shall be able to provide the charging equipment
with temperature data of the DC± contacts of the vehicle connector. The temperature
monitor device of the vehicle inlet shall be able to provide the vehicle with temperature
data of the DC± contacts of the vehicle inlet.
6.2.9.4 The temperature monitor device shall comply with the insulation resistance and
dielectric strength requirements of 6.2.5. During the test, the signal line of the
temperature monitor device and the PE line are short-circuited. The test is conducted
between the PE line and the live parts.
6.2.9.5 The temperature monitor accuracy of the temperature monitor device shall not
be greater than ±5°C. The collected signals can be compensated and calibrated
according to the manufacturer's instructions according to the installation position and
thermal conductivity of the temperature monitor device on the charging connection set.
During the test, after the measured temperature data is stable, the consistency is
compared with the calibration value provided by the manufacturer.
6.2.9.6 The manufacturer shall provide the function value of the temperature monitor
device in the product instructions for use of the charging connection set. The action
value shall be a value before the contact reaches 90°C.
NOTE: The action value is used for temperature monitor data calibration of charging equipment or
electric vehicles.
6.2.9.7 The temperature monitor device shall be durable in normal use. When
performing the limit conditions and endurance tests specified in 7.3, 7.8, and 7.9, the
temperature monitor device shall meet the functional requirements.
6.2.10 Mechanical strength
6.2.10.1 The charging connection set shall have sufficient mechanical strength and be
able to withstand the stress exerted during installation and use.
6.2.10.2 Socket-outlets and vehicle inlets shall have sufficient mechanical strength.
After withstanding the impact that occurs during normal use, the protection level
indicated by the mark shall be maintained. After the socket-outlet and vehicle inlet are
subjected to the pendulum ball impact test according to 7.11.2, they shall meet the
requirements of 24.2.3 in GB/T 11918.1-2014 and the following requirements:
a) There shall be no separation of parts.
b) There shall be no movement, looseness or deformation that affects the function
and use of the component.
c) The sealing parts of the liquid cooling device shall not be cracked or damaged
causing leakage.
d) The protection level shall comply with 6.3.10.
e) The specimen shall not show the following damage:
1) Live parts do not comply with 6.3.7.1.
2) The integrity of the enclosure is compromised and it cannot provide adequate
mechanical protection for internal components.
c) Rupture or damage to the integrity of the liquid cooling device resulting in leakage;
d) Affection of the operation, functionality and installation of charging connection
sets;
e) The charging connection set cannot relieve the stress on the charging cable (if
any);
f) Creepage distances and clearances between DC+ and DC-, live parts and
accessible metal or grounded metal do not comply with 6.3.15;
g) Dielectric strength does not comply with 6.2.5;
h) Other damage that may increase the risk of fire or electric shock.
6.2.12.2 The plug and vehicle connector shall be subjected to the vehicle rolling test
according to the method of 7.13.2. They shall meet the requirements of 6.2.12.1 or
visual observation shall reveal that they are damaged or ruptured and cannot continue
to be used.
6.2.12.3 The charging cable shall be able to withstand vehicle crushing. After
conducting the vehicle crushing test according to the method in 7.13.3, the following
damage shall not occur:
a) Appearance and structural damage such as damage to the insulation layer or sheath;
b) Insulation resistance and dielectric strength do not meet the requirements of 6.2.5;
c) Open circuit or short circuit of low-voltage conductors such as signal lines;
d) The integrity of the cooling channels of liquid medium cooled charging cables
can develop cracks or damage that can lead to leaks.
6.2.12.4 If the cable length between the standard plug (in compliance with GB/T 1002
and GB/T 2099.1) and the in-cable device is greater than 300 mm, the in-cable device
shall be able to withstand being crushed by a vehicle. After the test, the following
damage shall not occur:
a) The charging function does not meet the requirements of 6.5.1;
b) The protection level does not meet the requirements of 6.5.2;
c) Other faults affecting safety protection occur.
6.2.13 Surface temperature
The surface temperature of the cable assembly shall not exceed the specified value
during normal use. Carry out the test according to the method of 7.24. The surface
temperature shall meet the following requirements:
......