QC/T 1200-2023 English PDF (QCT1200-2023)

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QC/T 1200-2023: Cable assembly for conducting charging of electric vehicles with a charger
QC/T 1200-2023
QC
AUTOMOBILE INDUSTRY STANDARD
ICS 43.040
CCS T 35
Cable assembly for conducting charging of electric vehicles
with a charger
ISSUED ON. DECEMBER 20, 2023
IMPLEMENTED ON. JULY 01, 2024
Issued by. Ministry of Industry and Information Technology of PRC
Cable assembly for conducting charging of electric vehicles
with a charger
1 Scope
This document specifies the technical requirements, test methods, marking, packaging,
transportation, storage requirements for the cable assembly for conductive charging of
electric vehicles with chargers (hereinafter referred to as "portable DC chargers").
This document is applicable to the cable assembly for conductive charging of electric
vehicles with chargers for single-phase AC power supply circuits, which have an input
rated voltage not exceeding 250 VAC and an input rated current not exceeding 10 A.
This document, based on the relevant industry standards of various types of non-on-
board chargers, combines the application conditions such as transportation and use with
vehicles, to make more stringent definitions of functions and performance.
2 Normative references
The contents of the following documents constitute essential clauses of this document
through normative references in the text. Among them, for dated references, only the
version corresponding to that date applies to this document; for undated references, the
latest version (including all amendments) applies to this document.
GB/T 1002-2021 Single phase plugs and socket-outlets for household and similar
purposes - Types, basic parameters and dimensions
GB/T 2099.1-2021 Plugs and socket-outlets for household and similar purposes -
Part 1.General requirements
GB/T 2423.5-2019 Environmental testing - Part 2.Test methods - Test Ea and
guidance. Shock
GB/T 3956 Conductors of insulated cables
GB/T 4207-2022 Method for the determination of the proof and the comparative
tracking indices of solid insulating materials
GB/T 4208 Degrees of protection provided by enclosure (IP code)
GB/T 5023.1 Polyvinyl chloride insulated cables of rated voltages up to and
including 450/750 V - Part 1.General requirements
GB/T 33594-2017 Charging cables for electric vehicles
GB/T 34657.1-2017 Interoperability test specifications of electric vehicle
conductive charging - Part 1.Supply equipment
GB/T 34658-2017 Conformance test for communication protocols between off-
board conductive charger and battery management system for electric vehicle
GB 50057-2010 Code for design protection of structures against lightning
NB/T 33001-2018 Specification for electric vehicle off-board conductive charger
NB/T 33008.1-2018 Inspection and test specifications for electric vehicle charging
equipment - Part 1.Off-board charger
3 Terms and definitions
The following terms and definitions, which are defined in GB/T 19596-2017, GB/T
18487.1, GB/T 20234.1-2023, NB/T 33001-2018, as well as the following terms and
definitions, apply to this document.
3.1
Portable DC charger
A dedicated device that can be carried by a person or transported with an electric
vehicle, connected to an AC power source through a standard plug, cable and socket,
converts its electrical energy into DC power, connects to the vehicle through a
vehicle plug by conduction, charges the on-board energy storage device.
3.2
Function box
The control function, power conversion unit, safety function are integrated in a
suitable housing, which constitutes a part of the portable DC charger.
3.3
Standard plug/socket-outlet
Plug and socket that comply with GB/T 1002 and GB/T 2099.1.
3.4
Connection set for power
A device that can connect a cable to a power source or electric vehicle power supply
secondary operation or a special unlocking device to open the locking state between the
connection devices.
6.1.3 The charging cable assembly in the portable DC charger shall comply with the
relevant requirements of Chapter 6 of GB/T 33594-2017.
6.1.4 For charging cable assemblies in portable DC chargers, for devices with cables
longer than 7.5 m, relevant management and storage measures shall be taken to ensure
that the length of the cable that can be freely moved when not in use does not exceed
7.5 m.
6.2 Communication protocol
The communication protocol of the portable DC charger shall comply with the relevant
provisions of GB/T 27930 and the relevant requirements of GB/T 34658.
6.3 Electrical insulation performance
6.3.1 Insulation resistance
The insulation resistance of the portable DC charger shall comply with the relevant
requirements of 7.6.1 of NB/T 33001-2018.
6.3.2 Dielectric strength
The dielectric strength of the portable DC charger shall comply with the relevant
requirements of 7.6.2 of NB/T 33001-2018.
6.3.3 Impact withstand voltage
The impact withstand voltage of the portable DC charger shall comply with the relevant
requirements of 7.6.3 of NB/T 33001-2018.
6.4 Safety requirements
6.4.1 Grounding requirements
a) The housing of the portable DC charger shall be made of non-metallic materials.
When metal materials (including metal screws or nuts) are used, electrical
isolation between the metal material and the internal live parts shall be ensured;
b) The grounding requirements shall meet the relevant requirements of 7.5.4 c) in
NB/T 33001-2018.The working ground and protective ground shall be connected
to the ground conductor separately.
c) When the grounding continuity of the power supply circuit is detected to be
disconnected, the portable DC charger shall stop charging within 100 ms or not
allow charging to start.
6.4.2 Electrical isolation requirements
Electrical isolation protection measures shall be taken between the power input and DC
output of the portable DC charger; the electrical isolation requirements of double
insulation or reinforced insulation shall be met.
6.4.3 Disconnection requirements
The portable DC charger shall have at least a power disconnection device at the DC
output position.
6.4.4 Residual current protection
The residual current protection of portable DC chargers shall at least meet the relevant
requirements of GB/T 18487.1.
6.4.5 Output overload protection
The portable DC charger shall have an output overload protection function. When the
actual output current is greater than or equal to 9 A and lasts for 5 s, the output shall be
cut off within 5 s; when the output current is greater than or equal to 10 A, the portable
DC charger shall cut off the output within 100 ms and cannot automatically resume
charging, meeting functional status D.
6.4.6 Output short circuit protection
The portable DC charger shall have an output short circuit protection function. When
an output short circuit occurs in the output circuit, the short circuit current value shall
refer to the relevant requirements of GB/T 18487.1.The equipment shall cut off the
output within 100 ms without causing open flames or burning.
6.4.7 Overtemperature protection
The portable DC charger shall have an overtemperature protection function. When the
temperature exceeds its set value, the portable DC charger shall enter the over-
temperature protection state; the functional state level shall not be lower than level D.
When the temperature returns to normal, it shall be able to charge normally. The specific
temperature value and response time shall be subject to the manufacturer's agreed
requirements.
6.4.8 Lightning protection
The portable DC charger shall be equipped with a surge protector or applied to a power
supply circuit equipped with a surge protector. The installation and type selection of the
equipment shall be based on the installation site and meet the requirements of 6.4 in
GB 50057-2010.When lightning protection measures must be taken for equipment
application, a surge protection device shall be installed between the conductor and the
Perform the test in accordance with 7.7.3.During and after the test, the product shall be
able to work normally, the appearance shall be intact, the functional status shall reach
level A.
6.5.4 High temperature storage
Perform the test in accordance with 7.7.4.After the test, return to normal temperature,
the appearance shall be intact, the functional status shall reach level C.
6.5.5 High temperature operation
Perform the test in accordance with 7.7.5.During and after the test, the product shall be
able to work normally, the appearance shall be intact, the functional status shall reach
level A.
6.5.6 Temperature cycle
Perform the test in accordance with 7.7.6.After the test, return to normal temperature,
the appearance shall be intact, the functional status shall reach level A.
6.5.7 Temperature shock
Perform the test in accordance with 7.7.7.After the test, return to normal temperature,
the appearance shall be intact, the functional status shall reach level C.
6.5.8 Damp heat cycle
Perform the test in accordance with 7.7.8.After the test, return to normal temperature,
the appearance shall be intact, the functional status shall reach level A.
6.5.9 Salt spray
Perform the test in accordance with 7.7.9.After the test, the appearance shall be free of
corrosion, the functional status shall reach level C.
6.5.10 High altitude
Perform the test in accordance with 7.7.10.After the test, the appearance shall be intact;
the functional status shall reach level A and meet the requirements of 5.1.
6.6 Temperature rise requirements
6.6.1 Surface temperature rise
The surface temperature of the portable DC charger shall comply with the relevant
provisions of GB/T 18487.1.
6.6.2 Internal temperature rise
The internal temperature rise of the portable DC charger shall comply with the relevant
provisions of 7.4 in NB/T 33001-2018.
6.6.3 Temperature rise of power supply connection device
The standard plug, power plug, power socket in the power supply connection device
shall be tested with reference to the test method in GB/T 20234.1; it shall meet the
following requirements.
a) The maximum allowable temperature of the gripping part of the plug and socket
shall not exceed 60 °C;
b) The temperature rise of the pin, contact, terminal position shall not exceed 50 K.
6.6.4 Temperature rise of charging connection device
It shall comply with the relevant provisions of 6.3.13 in GB/T 20234.1-2023.
6.7 Output requirements
6.7.1 Charging efficiency
The portable DC charger should adopt the weighted efficiency calculation method; the
number of efficiency value points shall be no less than 10.The efficiency value points
are determined through negotiation, between the equipment manufacturer and the
automobile manufacturer, according to the output voltage range.
Weighted efficiency preferred value. ≥ 92%.
The weighted efficiency reference algorithm is as follows; the weighting coefficient
and value point are determined by the manufacturer.
Where.
An. A is the weighting coefficient, and A1 + A2 +... + An = 1;
En. E is the actual efficiency value; En represents the efficiency measured value of
the n-th efficiency value point.
Note. The efficiency test shall not calculate the loss of the input/output cable.
6.7.2 Output response requirements
In the charging state, the portable DC charger shall be able to quickly respond to the
current reduction request of the battery management system; the response time shall not
be less than the requirements of Table 4.
Perform the test in accordance with 7.11.2.After the test, the IP level of the sample shall
not be reduced; the functional status shall reach level C.
6.10.3 Mechanical shock
Perform the test in accordance with 7.11.3.After the test, the IP level of the sample shall
not be reduced; the functional status shall reach level C.
6.10.4 Cable connection
The tension and torque values of the cables at both ends of the functional box, as well
as the maximum allowable displacement of the cables after the test, shall comply with
the requirements of Table 14 in GB/T 11918.1-2014.
Note. For vehicle plugs, cables required by the manufacturer and compatible with the rated
working value shall be provided; the cables shall be tested as cable assemblies.
6.10.5 Cable bending
Perform the test in accordance with 7.11.4.After the test, the cable shall not be broken,
pulled off or loose; the functional status level of the sample shall meet level A.
6.11 Durability
Perform the test in accordance with 7.12.The sample shall not be damaged during and
after the test; the functional status shall reach level A.
6.12 Aging resistance
Perform the test in accordance with 7.13.After the test, the IP level of the sample shall
not be reduced and meet the requirements of 5.1; the temperature rise shall meet the
requirements of 6.3.13 in GB/T 20234.1-2023.
6.13 Xenon lamp aging
Perform the test in accordance with 7.14.After the test, discoloration, loss of gloss,
cracking shall meet level 1; the remaining inspection items shall meet level 2.Among
them.
- Level 1.Discoloration ≥ level 3; loss of gloss, powdering ≤ level 1; cracking ≤
level 2 (S1) a.
- Level 2.Discoloration ≥ level 3 ~ 4; loss of gloss ≤ level 1; powdering level 0;
cracking ≤ level 1 (S1) a; bubbles and rust level 10; peeling, mildew, spots level 0
(S0); gold level 0; pinholes and adhesion ≤ level 1; no obvious change in orange
peel.
6.14 Vehicle rollover
The function box shall be tested in accordance with 7.15.After the test, the following
degree of severe cracking, breaking or deformation shall not occur.
- Except for the exposed terminals, the live parts and internal circuits can be touched
by the standard test wire;
- The integrity of the housing is damaged, so that the internal parts of the function
box cannot be fully protected by mechanical or environmental protection;
- The action, function or installation of the function box is damaged.
6.15 Abnormal heat resistance and flame resistance test of insulating materials
Carry out the glow-wire test in accordance with 7.16.Aft...