GB/T 20234.1-2023 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 properties, mechanical properties, etc. of the connection sets for conductive charging of electric vehicles, and describes the inspection requirements for test conditions, test methods, inspection items, etc. of the connection sets for conductive charging of electric vehicles.
This document is applicable to AC charging connection sets (with a frequency of 50Hz, a rated voltage not exceeding AC 690V and a rated current not exceeding 250A) and DC charging connection sets [with a rated voltage not exceeding DC 1,500V and a rated current (duration maximum current) not exceeding 1,000A] for conductive charging of electric vehicles.
This document is not applicable to the use of standard plugs and socket-outlets conforming to GB/T 1002 and GB/T 2099.1 for the charging connection sets.
When the charging connection sets specified in this document are used in electric vehicles in special scenarios such as water conservancy, mines, construction sites and agricultural operations, or in other fields other than road vehicles, additional requirements may be required in terms of installation location, operating conditions, use mode and environmental adaptability of the charging connection sets.
2 Normative references
The following documents contain provisions which, through reference in this text, constitute provisions 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
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 2423.7 Environmental testing - Part 2: Test methods - Test Ec: Rough handling shocks, primarily for equipment-type specimens
GB/T 2423.22 Environmental testing - Part 2: Tests methods - Test N: Change of temperature
GB/T 2951.11 Common test methods for insulating and sheathing materials of electric and optical cables - Part 11: Methods for general application - Measurement of thickness and overall dimensions - Tests for determining the mechanical properties
GB/T 2951.12 Common test methods for insulating and sheathing materials of electric and optical cables - Part 12: Methods for general application - Thermal ageing methods
GB/T 3956 Conductors of insulated cables
GB/T 4208 Degrees of protection provided by enclosure (IP code)
GB 4943.1 Audio/video, information and communication technology equipment - Part 1: Safety requirements
GB/T 5013.4 Rubber insulated cables of rated voltages up to and including 450/750V - Part 4: Cords and flexible cables
GB/T 5023 (all parts) Polyvinyl chloride insulated cables of rated voltages up to and including 450/750V
GB/T 5461 Edible salt
GB/T 5462 Industrial salt
GB/T 5563 Rubber and plastics hoses and hose assemblies - Hydrostatic testing
GB/T 11918.1-2014 Plugs, socket-outlet and couplers for industrial purposes - Part 1: General requirements
GB/T 11918.4-2014 Plugs, socket-outlets and couplers for industrial purposes - Part 4: Switched socket-outlets and connectors with or without interlock
GB/T 14048.5 Low-voltage switch gear and control gear- Part 5-1: Control circuit devices and switching element - Electromechanical control circuit devices
GB/T 15092.1 Switches for appliances - Part 1: General requirements
GB/T 16895.3-2017 Low-voltage electrical installations - Part 5-54: Selection and erection of electrical equipment - Earthing arrangements and protective conductors
GB/T 16935.1 Insulation coordination for equipment within low-voltage systems - Part 1: Principles requirements and tests
GB/T 18487.1 Electric vehicle conductive charging system - Part 1: General requirements
GB/T 19596 Terminology of electric vehicles
GB/T 20234.2 Connection set for conductive charging of electric vehicles - Part 2: AC charging coupler
GB/T 20234.3 Connection set for conductive charging of electric vehicles - Part 3: DC charging coupler
GB/T 28046.3-2011 Road vehicles - Environmental conditions and testing for electrical and electronic equipment - Part 3: Mechanical loads
GB/T 28046.4-2011 Road vehicles - Environmental conditions and testing for electrical and electronic equipment - Part 4: Climatic loads
GB/T 28957.1 Road vehicles - Test dust for filter evaluation - Part 1: Silicon dioxide test dust
GB/T 29317 Terminology of electric vehicle charging/battery swap infrastructure
GB/T 33594 Charging cables for electric vehicles
3 Terms and definitions
For the purposes of this document, the terms and definitions given in GB/T 11918.1-2014, GB/T 18487.1, GB/T 19596 and GB/T 29317 and the following apply.
3.1
charging connection set
assembly or device that conductively connects an electric vehicle to an electric vehicle charging equipment (or external power supply)
Note 1: It has the functions of connecting and disconnecting circuits, and realizing the transmission of electric energy, low-voltage auxiliary power supply, control signals or communication data.
Note 2: Charging connection set includes charging coupler, charging cable, in-cable device and protective cap accessories. See Figure 1 for the schematic diagram of charging connection set.
Key:
1——Electric vehicle charging equipment or external power supply;
2——Socket-outlet; 5——In-cable device; 8——Vehicle inlet;
3——Plug; 6——Charging cable; 9——Vehicle coupler;
4——Plug and socket-outlet; 7——Vehicle connector; 10——Electric vehicle.
The product style in the figure is for illustration only and does not represent the actual product structure.
Figure 1 Schematic diagram of charging connection set
3.2
charging coupler
part for connecting and disconnecting the circuit connection between the electric vehicle and the electric vehicle charging equipment (or external power supply)
Note: It is a part of the charging connection set, which includes plug and socket-outlet and vehicle coupler.
3.3
plug and socket-outlet
assembly consisting of a plug and a socket-outlet, which is capable of connecting a cable to an electric vehicle charging equipment or an external power supply
Note: It corresponds to the plug and socket-outlet defined in GB/T 11918.1-2014.
3.4
socket-outlet
part of plug and socket-outlet that is connected and fixedly installed with an external power supply cable or electric vehicle charging equipment
Note: It corresponds to the socket-outlet defined in GB/T 11918.1-2014.
3.5
plug
movable part of plug and socket-outlet that is connected to the charging cable
Note: It corresponds to the plug in GB/T 11918.1-2014.
3.6
vehicle coupler
assembly consisting of a vehicle connector and a vehicle inlet, which is capable of connecting a charging cable to an electric vehicle
Note: It corresponds to the appliance coupler defined in GB/T 11918.1-2014.
3.7
vehicle inlet
part of the vehicle coupler that is fixedly installed on the electric vehicle and connected with the on-board charger or on-board rechargeable energy storage system by means of a conductor
Note: It corresponds to the appliance input defined in GB/T 11918.1-2014.
3.8
vehicle connector
movable part of the vehicle coupler that is connected to the charging cable
Note: It corresponds to the connector defined in GB/T 11918.1-2014.
3.9
cable assembly
flexible cable for connecting an electric vehicle to an electric vehicle charging equipment (or external power supply), which is equipped with additional assemblies (plug and/or vehicle connector)
Note 1: For connection mode A: the cable assembly is a flexible cable fixed to the vehicle at one end and equipped with a plug at the other end; for connection mode B: the cable assembly is a flexible cable equipped with a plug at one end and a vehicle connector at the other end; for connection mode C: the cable assembly is a flexible cable fixed to an external power supply or electric vehicle charging equipment at one end and equipped with a vehicle connector at the other end.
Note 2: The cable assembly is part of the charging connection set. The cable assembly for connection mode B includes the cable assembly with in-cable device.
3.10
in-cable device
equipment or device that undertakes specific electrical functions on the cable assembly
Note: The in-cable devices include in-cable function box that performs control and protection functions on the cable assembly and in-cable charger that converts alternating current (AC) from an external power supply to direct current (DC) required by traction battery on the cable assembly.
3.11
locking device
device that keeps the charging coupler in the normal connection position and prevents it from being accidentally disconnected, with the function of preventing the phase line, neutral line and DC contact of charging coupler from becoming energized before normal plug-in and from being disconnected when energized, or keeping them uncharged before being pulled out.
Note: There are mechanical locking devices for manual locking/unlocking and electronic locking devices for electronically controlled locking/unlocking.
3.12
rated current
maximum operating current specified by the manufacturer for sustainable operation of a naturally cooled charging connection set under specified conditions such as no forced air convection
Note: For charging connection sets with positive cooling function, it refers to the maximum operating current in sustainable operation after the positive cooling function is turned off.
Foreword III
Introduction V
1 Scope
2 Normative references
3 Terms and definitions
4 Symbols and abbreviations
5 Ratings
5.1 Rated voltage (preferred values)
5.2 Rated current or duration maximum current (preferred values)
6 Requirements
6.1 General
6.2 Charging connection set
6.3 Charging coupler
6.4 Charging cables
6.5 In-cable device
7 Test methods
7.1 General requirements
7.2 Appearance and structure
7.3 Temperature cycling
7.4 Cyclic damp heat
7.5 Earthing measures
7.6 Insulation resistance and dielectric strength
7.7 Connection of charging cable
7.8 Thermal management system
7.9 Liquid cooling device
7.10 Temperature monitor
7.11 Mechanical strength
7.12 Conditional short-circuit current withstand
7.13 Vehicle rolling
7.14 Types and dimensions
7.15 Locking device
7.16 Switching elements
7.17 Insertion-withdrawal force
7.18 Protection against electric shock
7.19 Terminal and terminal end
7.20 Resistance to ageing of rubber and thermoplastic materials
7.21 Degree of protection
7.22 Breaking capacity
7.23 Normal operation (service life)
7.24 Temperature rise
7.25 Screws, current-carrying parts and connections
7.26 Creepage distance, electrical clearance and distance through sealing compound
7.27 Heat resistance, flame resistance, and tracking resistance
7.28 Corrosion resistance and rust resistance
7.29 Vibration and mechanical shock resistance
7.30 Offset operation
7.31 Contact durability
7.32 Charging cables
7.33 In-cable device
8 Inspection rules
Annex A (Informative) Product data sheet of thermal management systems
Annex B (Normative) Reference test tools for temperature rise tests
B.1 General
B.2 Requirements
Bibliography
GB/T 20234.1-2023 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 properties, mechanical properties, etc. of the connection sets for conductive charging of electric vehicles, and describes the inspection requirements for test conditions, test methods, inspection items, etc. of the connection sets for conductive charging of electric vehicles.
This document is applicable to AC charging connection sets (with a frequency of 50Hz, a rated voltage not exceeding AC 690V and a rated current not exceeding 250A) and DC charging connection sets [with a rated voltage not exceeding DC 1,500V and a rated current (duration maximum current) not exceeding 1,000A] for conductive charging of electric vehicles.
This document is not applicable to the use of standard plugs and socket-outlets conforming to GB/T 1002 and GB/T 2099.1 for the charging connection sets.
When the charging connection sets specified in this document are used in electric vehicles in special scenarios such as water conservancy, mines, construction sites and agricultural operations, or in other fields other than road vehicles, additional requirements may be required in terms of installation location, operating conditions, use mode and environmental adaptability of the charging connection sets.
2 Normative references
The following documents contain provisions which, through reference in this text, constitute provisions 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
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 2423.7 Environmental testing - Part 2: Test methods - Test Ec: Rough handling shocks, primarily for equipment-type specimens
GB/T 2423.22 Environmental testing - Part 2: Tests methods - Test N: Change of temperature
GB/T 2951.11 Common test methods for insulating and sheathing materials of electric and optical cables - Part 11: Methods for general application - Measurement of thickness and overall dimensions - Tests for determining the mechanical properties
GB/T 2951.12 Common test methods for insulating and sheathing materials of electric and optical cables - Part 12: Methods for general application - Thermal ageing methods
GB/T 3956 Conductors of insulated cables
GB/T 4208 Degrees of protection provided by enclosure (IP code)
GB 4943.1 Audio/video, information and communication technology equipment - Part 1: Safety requirements
GB/T 5013.4 Rubber insulated cables of rated voltages up to and including 450/750V - Part 4: Cords and flexible cables
GB/T 5023 (all parts) Polyvinyl chloride insulated cables of rated voltages up to and including 450/750V
GB/T 5461 Edible salt
GB/T 5462 Industrial salt
GB/T 5563 Rubber and plastics hoses and hose assemblies - Hydrostatic testing
GB/T 11918.1-2014 Plugs, socket-outlet and couplers for industrial purposes - Part 1: General requirements
GB/T 11918.4-2014 Plugs, socket-outlets and couplers for industrial purposes - Part 4: Switched socket-outlets and connectors with or without interlock
GB/T 14048.5 Low-voltage switch gear and control gear- Part 5-1: Control circuit devices and switching element - Electromechanical control circuit devices
GB/T 15092.1 Switches for appliances - Part 1: General requirements
GB/T 16895.3-2017 Low-voltage electrical installations - Part 5-54: Selection and erection of electrical equipment - Earthing arrangements and protective conductors
GB/T 16935.1 Insulation coordination for equipment within low-voltage systems - Part 1: Principles requirements and tests
GB/T 18487.1 Electric vehicle conductive charging system - Part 1: General requirements
GB/T 19596 Terminology of electric vehicles
GB/T 20234.2 Connection set for conductive charging of electric vehicles - Part 2: AC charging coupler
GB/T 20234.3 Connection set for conductive charging of electric vehicles - Part 3: DC charging coupler
GB/T 28046.3-2011 Road vehicles - Environmental conditions and testing for electrical and electronic equipment - Part 3: Mechanical loads
GB/T 28046.4-2011 Road vehicles - Environmental conditions and testing for electrical and electronic equipment - Part 4: Climatic loads
GB/T 28957.1 Road vehicles - Test dust for filter evaluation - Part 1: Silicon dioxide test dust
GB/T 29317 Terminology of electric vehicle charging/battery swap infrastructure
GB/T 33594 Charging cables for electric vehicles
3 Terms and definitions
For the purposes of this document, the terms and definitions given in GB/T 11918.1-2014, GB/T 18487.1, GB/T 19596 and GB/T 29317 and the following apply.
3.1
charging connection set
assembly or device that conductively connects an electric vehicle to an electric vehicle charging equipment (or external power supply)
Note 1: It has the functions of connecting and disconnecting circuits, and realizing the transmission of electric energy, low-voltage auxiliary power supply, control signals or communication data.
Note 2: Charging connection set includes charging coupler, charging cable, in-cable device and protective cap accessories. See Figure 1 for the schematic diagram of charging connection set.
Key:
1——Electric vehicle charging equipment or external power supply;
2——Socket-outlet; 5——In-cable device; 8——Vehicle inlet;
3——Plug; 6——Charging cable; 9——Vehicle coupler;
4——Plug and socket-outlet; 7——Vehicle connector; 10——Electric vehicle.
The product style in the figure is for illustration only and does not represent the actual product structure.
Figure 1 Schematic diagram of charging connection set
3.2
charging coupler
part for connecting and disconnecting the circuit connection between the electric vehicle and the electric vehicle charging equipment (or external power supply)
Note: It is a part of the charging connection set, which includes plug and socket-outlet and vehicle coupler.
3.3
plug and socket-outlet
assembly consisting of a plug and a socket-outlet, which is capable of connecting a cable to an electric vehicle charging equipment or an external power supply
Note: It corresponds to the plug and socket-outlet defined in GB/T 11918.1-2014.
3.4
socket-outlet
part of plug and socket-outlet that is connected and fixedly installed with an external power supply cable or electric vehicle charging equipment
Note: It corresponds to the socket-outlet defined in GB/T 11918.1-2014.
3.5
plug
movable part of plug and socket-outlet that is connected to the charging cable
Note: It corresponds to the plug in GB/T 11918.1-2014.
3.6
vehicle coupler
assembly consisting of a vehicle connector and a vehicle inlet, which is capable of connecting a charging cable to an electric vehicle
Note: It corresponds to the appliance coupler defined in GB/T 11918.1-2014.
3.7
vehicle inlet
part of the vehicle coupler that is fixedly installed on the electric vehicle and connected with the on-board charger or on-board rechargeable energy storage system by means of a conductor
Note: It corresponds to the appliance input defined in GB/T 11918.1-2014.
3.8
vehicle connector
movable part of the vehicle coupler that is connected to the charging cable
Note: It corresponds to the connector defined in GB/T 11918.1-2014.
3.9
cable assembly
flexible cable for connecting an electric vehicle to an electric vehicle charging equipment (or external power supply), which is equipped with additional assemblies (plug and/or vehicle connector)
Note 1: For connection mode A: the cable assembly is a flexible cable fixed to the vehicle at one end and equipped with a plug at the other end; for connection mode B: the cable assembly is a flexible cable equipped with a plug at one end and a vehicle connector at the other end; for connection mode C: the cable assembly is a flexible cable fixed to an external power supply or electric vehicle charging equipment at one end and equipped with a vehicle connector at the other end.
Note 2: The cable assembly is part of the charging connection set. The cable assembly for connection mode B includes the cable assembly with in-cable device.
3.10
in-cable device
equipment or device that undertakes specific electrical functions on the cable assembly
Note: The in-cable devices include in-cable function box that performs control and protection functions on the cable assembly and in-cable charger that converts alternating current (AC) from an external power supply to direct current (DC) required by traction battery on the cable assembly.
3.11
locking device
device that keeps the charging coupler in the normal connection position and prevents it from being accidentally disconnected, with the function of preventing the phase line, neutral line and DC contact of charging coupler from becoming energized before normal plug-in and from being disconnected when energized, or keeping them uncharged before being pulled out.
Note: There are mechanical locking devices for manual locking/unlocking and electronic locking devices for electronically controlled locking/unlocking.
3.12
rated current
maximum operating current specified by the manufacturer for sustainable operation of a naturally cooled charging connection set under specified conditions such as no forced air convection
Note: For charging connection sets with positive cooling function, it refers to the maximum operating current in sustainable operation after the positive cooling function is turned off.
Contents of GB/T 20234.1-2023
Foreword III
Introduction V
1 Scope
2 Normative references
3 Terms and definitions
4 Symbols and abbreviations
5 Ratings
5.1 Rated voltage (preferred values)
5.2 Rated current or duration maximum current (preferred values)
6 Requirements
6.1 General
6.2 Charging connection set
6.3 Charging coupler
6.4 Charging cables
6.5 In-cable device
7 Test methods
7.1 General requirements
7.2 Appearance and structure
7.3 Temperature cycling
7.4 Cyclic damp heat
7.5 Earthing measures
7.6 Insulation resistance and dielectric strength
7.7 Connection of charging cable
7.8 Thermal management system
7.9 Liquid cooling device
7.10 Temperature monitor
7.11 Mechanical strength
7.12 Conditional short-circuit current withstand
7.13 Vehicle rolling
7.14 Types and dimensions
7.15 Locking device
7.16 Switching elements
7.17 Insertion-withdrawal force
7.18 Protection against electric shock
7.19 Terminal and terminal end
7.20 Resistance to ageing of rubber and thermoplastic materials
7.21 Degree of protection
7.22 Breaking capacity
7.23 Normal operation (service life)
7.24 Temperature rise
7.25 Screws, current-carrying parts and connections
7.26 Creepage distance, electrical clearance and distance through sealing compound
7.27 Heat resistance, flame resistance, and tracking resistance
7.28 Corrosion resistance and rust resistance
7.29 Vibration and mechanical shock resistance
7.30 Offset operation
7.31 Contact durability
7.32 Charging cables
7.33 In-cable device
8 Inspection rules
Annex A (Informative) Product data sheet of thermal management systems
Annex B (Normative) Reference test tools for temperature rise tests
B.1 General
B.2 Requirements
Bibliography
