1、UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULAUGUST 6, 20121UL 458AOUTLINE OF INVESTIGATIONFORPOWER CONVERTERS/INVERTERS FOR ELECTRIC LAND VEHICLESIssue Number 2August 6, 2012Summary of TopicsThe second issue of the Outline of Investigation
2、 for Power Converters/Inverters for Electric Land Vehicles, UL 458A, has been issued to reviseparagraph 1.1 and Table 30.1 so the requirements cover fixed andstationary power converters, and accessories having a nominal rating of1000 V or less.COPYRIGHT 2012 UNDERWRITERS LABORATORIES INC.UL COPYRIGH
3、TED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULAUGUST 6, 2012UL 458A2No Text on This PageUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULCONTENTSINTRODUCTION1 Scope .62 Glossary .63 Components 94
4、General 94.1 Units of measurement .94.2 Undated references 10CONSTRUCTION5 General .106 Frame and Enclosure 107 Enclosures Used For Protected Environments .137.1 General 137.2 Environmental considerations .138 Accessibility of Uninsulated Live Parts, Film-Coated Wire, and Moving Parts 148.1 General
5、148.2 User servicing .168.3 Serviceman servicing 179 Assembly .1710 Protection Against Corrosion .1811 Supply Connections .1811.1 Permanently-connected converters or inverters 1811.2 Cord connection .2111.3 Bushings 2212 Low-Voltage DC Connections and Wiring 2312.1 General .2313 Secondary Circuits 2
6、414 Live Parts 2515 Internal Wiring 2615.1 General .2615.2 Tubing 2615.3 Protection of wiring .2715.4 Electrical connections .2715.5 Separation of circuits .2815.6 Barriers .2916 Insulating Materials .2917 Transformers .3017.1 General .3017.2 Coil insulation 3018 Resistors 3219 Switches and Controll
7、ers 3220 Overload-Protective Devices .3220.1 General .3220.2 Overcurrent-overtemperature protection .3321 Fuses and Fuseholders 3422 Receptacles 3423 Lampholders .3424 Capacitors .35AUGUST 6, 2012 UL 458A 3UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISS
8、ION FROM UL25 Transient Voltage Surge Suppressors .3526 Printed Wiring 3527 Spacings 3527.1 General .3527.2 Insulation barriers 3928 Grounding .4029 Bonding of Internal Parts 4129.1 General .4129.2 Bonding conductor .42PERFORMANCE30 General .4331 Leakage Current Test .4332 Power Input Test .4633 Cap
9、acitor Voltage Measurement Test .4734 Output Voltage and Current Test .4735 Temperature Test .4735.1 Normal 4736 External Surface Temperature Limits Test .5137 Dielectric Voltage-Withstand Test .5238 Induced Potential Test .5239 Testing on Transformer Insulating Materials 5340 Strain Relief Test .53
10、41 Overload Test 5342 Overcurrent Protection Calibration Test 5443 Battery Charger Overcharge Test .5444 Abnormal Operation Test 5544.1 General .5544.2 Output short-circuit .5744.3 Switch position .5744.4 Component malfunction .5744.5 Rectifier and capacitor short-circuit test .5744.6 Vibration test
11、 5844.7 Surge protectors .5844.8 Specific value overload .5844.9 Flanged bobbin transformer abnormal test .5944.10 Blocked fan 6145 Evaluation of Reduced Spacings on Printed Wiring Boards 6145.1 General .6145.2 Dielectric voltage-withstand test 6145.3 Shorted trace test 6146 Burnout Test .6246.1 Gen
12、eral .6246.2 Relay and solenoid burnout 6246.3 Transformer burnout 6247 Gasket Tests .6348 Atomized Water Test 6449 Label Adhesion Test 65AUGUST 6, 2012UL 458A4UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULMANUFACTURING AND PRODUCTION TESTS5
13、0 Dielectric Voltage-Withstand Test .6651 Grounding Continuity Test .67RATING52 General .68MARKING53 Details .6854 Content 69INSTRUCTIONS55 Instruction Manual 7156 Important Safety Instructions .7257 Assembly Instructions .7858 Operating Instructions .7859 Maintenance Instructions 7860 Moving and St
14、orage Instructions 78APPENDIX AStandards for ComponentsA1AUGUST 6, 2012 UL 458A 5UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULINTRODUCTION1 Scope1.1 These requirements cover fixed and stationary power converters, and accessories having a no
15、minalrating of 1000 V or less, direct and alternating current. These converters are intended for use withinelectric vehicle land vehicles where not directly exposed to outdoor conditions, and are intended to beemployed in accordance with the National Electrical Code, NFPA 70.1.2 These requirements a
16、lso cover fixed, stationary and portable power inverters having a dc input anda 120 or 240 V ac output. These inverters are intended for use within electric vehicle land vehicles wherenot directly exposed to outdoor conditions, and are intended to be employed in accordance with theNational Electrica
17、l Code, NFPA 70.1.3 These requirements also cover converters/inverters that are additionally intended to charge batteries.1.4 This outline does not cover fixed and stationary power converters, power-converter systems, andaccessories intended for use within land vehicles which are not electric vehicl
18、es. Fixed and stationarypower converters, power-converter systems, and power inverters and power-inverter systems accessoriesintended for use within land vehicles other than electric vehicle land vehicles are covered under theStandard for Power Converters/Inverters and Power Converter/Inverter Syste
19、ms for Land Vehicles andMarine Crafts, UL 458.2 Glossary2.1 For the purpose of this outline the following definitions apply.2.2 ACCESSIBLE PART A part located so that it can be contacted by a person, either directly or bymeans of a probe or tool during user servicing, or that is not recessed the req
20、uired distance behind anopening.2.3 BARRIER A partition for the insulation or isolation of electric circuits, for the isolation of electricarcs, or for isolation of moving parts or hot surfaces. In this respect, a barrier may serve as a portion ofan enclosure or as a functional part.2.4 BRANCH CIRCU
21、IT That portion of the wiring system beyond the final overcurrent protectingdevice on the power-distribution panel protecting the circuit to the output.2.5 CLASS 2 TRANSFORMER A step-down, isolation type transformer having a secondary voltageof not more than 30 Vrms (42.4 peak) under any condition o
22、f loading including open circuit andcomplying with the applicable requirements in the Standard for Low Voltage Transformers Part 1:General Requirements, UL 5085-1 and the Standard for Low Voltage Transformers Part 3: Class 2and Class 3 Transformers, UL 5085-3.2.6 CONTROL CIRCUIT A circuit that carri
23、es electric signals directing the performance of acontroller that, in turn, governs power delivered to a motor or other load in the equipment. A controlcircuit does not carry main power current.2.7 ENCLOSURE That portion of a unit that reduces the accessibility and unintentional contact of apart tha
24、t may involve a risk of fire, electric shock or injury to persons, or reduces the risk of propagationof flame, sparks, and molten metal initiated by an electrical disturbance occurring within.AUGUST 6, 2012UL 458A6UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT
25、 PERMISSION FROM UL2.8 FIELD-WIRING LEAD Any lead to which a supply, load or other wire is intended to be connectedby an installer.2.9 FIELD-WIRING TERMINAL Any terminal to which a supply or other wire is intended to beconnected by an installer in the field is a field-wiring terminal unless the wire
26、 is provided as part of theproduct and a pressure terminal, connector, soldering lug, soldered loop, crimped eyelet, or othermeans for making the connection is factory-assembled to the wire.2.10 FIXED UNIT A unit that is intended to be permanently connected electrically.2.11 LIMITED-ENERGY CIRCUIT A
27、 circuit having a voltage not exceeding 1000 V and the energylimited to 100 VA by a secondary winding of a transformer, or a fixed impedance.2.12 LIVE PART Denotes metal or conductive parts that, during intended use, have a potentialdifference with respect to ground or any other conductive part.2.13
28、 LOW-VOLTAGE, LIMITED ENERGY CIRCUIT A circuit involving an alternating voltage of notmore than 30 Vrms (42.4 Vpeak) or a direct voltage of not more than 60 V and supplied by:a) An inherently limiting Class 2 transformer;b) A non-inherently limiting Class 2 transformer and an overcurrent protective
29、device that is:1) Not of the automatic reclosing type;2) Trip-free from the reclosing mechanism; and3) Not readily interchangeable with a device of a different rating;c) A combination of an isolated transformer secondary winding and a fixed impedance thatcomplies with all the performance requirement
30、s for an energy-limiting Class 2 transformer orpower source;d) A dry-cell battery that is isolated from the primary circuit and having output characteristics nogreater than those of an energy-limiting Class 2 transformer or power source; ore) A combination of a rechargeable battery and a fixed imped
31、ance that complies with all of theperformance requirements for an energy-limiting Class 2 transformer or power source.2.14 PRESSURE TERMINAL CONNECTOR A field wiring terminal that accomplishes the connectionof one or more conductors by means of pressure without the use of solder. A pressure terminal
32、connector may be the barrel and set screw type, crimp type barrel, or clamping plate and screw type.2.15 PRIMARY CIRCUIT Wiring and components that are conductively connected to a branch circuitor an alternating-current motor generator set installed separately from, or included as, a part of apower-
33、converter or power-inverter system.2.16 PRINTED WIRING BOARD The finished combination of a pattern of conductive paths either on,in, or both on and in (multilayer) a sheet of insulating material, including printed components, and thebase material.2.17 PROTECTED ENVIRONMENT Areas internal to the equi
34、pment that are resistant to entry ofcarbon dust, or other conductive contaminants, and the like.AUGUST 6, 2012 UL 458A 7UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL2.18 PROTECTED ENVIRONMENT ENCLOSURE A part or total enclosure of an applia
35、nce that isconstructed as defined in Section 7, Enclosures Used for Protected Environments, so as to maintain aprotected environment.2.19 RISK OF ELECTRICAL ENERGY HIGH CURRENT LEVELS The capability for damage toproperty or injury to persons, other than by electric shock, from available electrical e
36、nergy is consideredto exist, if between a live part and an adjacent dead metal part or between live parts of differentpolarity, there exists a potential of2Vormore and either an available continuous power level of 240VA or more, or a reactive energy level of 20 J or more. For example, a tool, or oth
37、er metal shortcircuiting a component may cause a burn or a fire if enough energy is available at the component tovaporize, melt, or more than warm the metal.2.20 RISK OF ELECTRIC SHOCK A risk of electric shock is considered to exist at any part if thepotential between the part and earth ground or an
38、y other accessible part is greater than 42.4 Vpeak acor 60 V dc, and the continuous current flow through a 1500 resistor connected across the potentialexceeds 5 mA.2.21 RISK OF FIRE A risk of fire is considered to exist at any component unless an investigation ofthe supply delivering power to that c
39、omponent complies with the criteria in Section 6, Frame andEnclosure.2.22 RISK OF INJURY TO PERSONS A condition that exists when stationary parts (such as sharpmetal edges and projections), moving parts (such as gears, chains, or linkages), falling objects,inadequate mechanical strength of material,
40、 or the physical instability of the equipment are such thatinjury to persons may result.2.23 SAFETY CIRCUIT Any primary or secondary circuit that is relied upon to reduce the risk of fire,electric shock, injury to persons, or electrical energy high current levels. For example, in someapplications, a
41、n interlock circuit is considered to be a safety circuit.2.24 SECONDARY CIRCUIT A circuit conductively connected to the secondary winding of anisolating power supply transformer.2.25 SERVICE PERSONNEL Trained persons having familiarity with the construction and operationof the equipment, and the ris
42、ks involved, who may periodically open an appliance to repair or maintainelectrical or mechanical components.2.26 STATIONARY UNIT Cord- and plug-connected units that are not fixed and are not movable. Astationary unit may have provision for attachment in accordance with this outline.2.27 SUPPLY CORD
43、, POWER A separable cord set or a length of flexible cord or cable, with oneend connected to the primary-circuit wiring of the unit and the other end connected to the attachmentplug for connection to branch circuit power.2.28 TOOL A screwdriver, coin, key, or any other object that may be used to ope
44、rate a screw latch,or similar fastening means.2.29 TRIP Denotes automatic interruption of the electric circuit to the load.2.30 UNIT For the purposes of this outline, a converter or inverter unless specified otherwise.2.31 USER SERVICING Any form of servicing that can be performed by personnel other
45、 than thosewho are trained to maintain the unit. Some examples of user servicing are:AUGUST 6, 2012UL 458A8UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULa) The installation of accessories by means of attachment plugs and receptacles, or by m
46、eansof separable connectors.b) The replacement of lamps and fuses, or the resetting of circuit breakers located in a useraccess area unless they are marked to indicate replacement or resetting by qualified personnelonly.c) The making of routine operating adjustments necessary to adapt the unit for d
47、ifferentintended functions.d) Routine cleaning.3 Components3.1 Except as indicated in 3.2, a component of a product covered by this outline shall comply with therequirements for that component. See Appendix A for a list of standards covering components generallyused in the products covered by the ou
48、tline.3.2 A component is not required to comply with a specific requirement that:a) Involves a feature or characteristic not required in the application of the component in theproduct covered by this outline, orb) Is superseded by a requirement in this outline.3.3 A component shall be used in accord
49、ance with its rating established for the intended conditions ofuse.3.4 Specific components are incomplete in construction features or restricted in performance capabilities.Such components are intended for use only under limited conditions, such as certain temperatures notexceeding specified limits, and shall be used only under those specific conditions.4 General4.1 Units of measurement4.1.1 Values stated without parentheses are the requirement. Values in parentheses are explanatory orapproximate information.AUGUS
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