BS ISO 25981-2008 Road vehicles - Connectors for the electrical connection of towing and towed vehicles - Connectors for electronically monitored charging systems with 12 V or 24 V.pdf

1、BRITISH STANDARDBS ISO 25981:2008Road vehicles Connectors for the electrical connection of towing and towed vehicles Connectors for electronically monitored charging systems with 12 V or 24 V nominal supply voltageICS 43.040.10g49g50g3g38g50g51g60g44g49g42g3g58g44g55g43g50g56g55g3g37g54g44g3g51g40g5

2、3g48g44g54g54g44g50g49g3g40g59g38g40g51g55g3g36g54g3g51g40g53g48g44g55g55g40g39g3g37g60g3g38g50g51g60g53g44g42g43g55g3g47g36g58Incorporating corrigendum December 2008 National forewordThis British Standard is the UK implementation of ISO 25981:2008, incorporating corrigendum December 2008.The UK par

3、ticipation in its preparation was entrusted to Technical Committee AUE/16, Electrical and electronic equipment.A list of organizations represented on this committee can be obtained on request to its secretary.This publication does not purport to include all the necessary provisions of a contract. Us

4、ers are responsible for its correct application.Compliance with a British Standard cannot confer immunity from legal obligations.BS ISO 25981:2008This British Standard was published under the authority of the Standards Policy and Strategy Committee on 29 February 2008 BSI 2009Amendments/corrigenda i

5、ssued since publicationDate Comments 31 August 2009 Implementation of ISO corrigendum December 2008, figure 1 replacedISBN 978 0 580 65711 5Reference numberISO 25981:2008(E)INTERNATIONAL STANDARD ISO25981First edition2008-02-01Road vehicles Connectors for the electrical connection of towing and towe

6、d vehicles Connectors for electronically monitored charging systems with 12 V or 24 V nominal supply voltage Vhicules routiers Raccords pour les connexions lectriques des vhicules tracteurs et des vhicules tracts Raccords pour systmes de charge contrls lectroniquement tension dalimentation nominale

7、de 12 V ou 24 V ii iiiForeword ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standards is normally carried out through ISO technical committees. Each member body interested in a

8、 subject for which a technical committee has been established has the right to be represented on that committee. International organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the International Electrotechnical Commissio

9、n (IEC) on all matters of electrotechnical standardization. International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2. The main task of technical committees is to prepare International Standards. Draft International Standards adopted by the technical co

10、mmittees are circulated to the member bodies for voting. Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. ISO shall no

11、t be held responsible for identifying any or all such patent rights. ISO 25981 was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 3, Electrical and electronic equipment. BS ISO 25981:2008blank1Road vehicles Connectors for the electrical connection of towing and towed vehic

12、les Connectors for electronically monitored charging systems with 12 V or 24 V nominal supply voltage 1 Scope This International Standard specifies dimensional characteristics, contact allocation, tests and requirements of 7-pole connectors for electrical connections of electronically monitored char

13、ging systems of towing and towed vehicles. The electronic monitoring system is designed to detect 12 V and 24 V nominal supply voltage and to limit the current to 50 A. This is a connector without breaking capacity. This electrical connection is intended for use with separable truck-trailer combinat

14、ions in order to connect an additional battery pack of the trailer with the generator of the truck using an electronically monitored charging system. Additional battery packs in trailers are basically used with tailgate lifts, electrical forklifts or other technical equipment with high current consu

15、mption. This International Standard further specifies a park socket used to receive and store the plug when it is disconnected. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For

16、undated references, the latest edition of the referenced document (including any amendments) applies. ISO 1185, Road vehicles Connectors for the electrical connection of towing and towed vehicles 7-pole connector type 24 N (normal) for vehicles with 24 V nominal supply voltage ISO 3731, Road vehicle

17、s Connectors for the electrical connection of towing and towed vehicles 7-pole connector type 24 S (supplementary) for vehicles with 24 V nominal supply voltage ISO 4009, Commercial vehicles Location of electrical and pneumatic connections between towing vehicles and trailers ISO 4091,Road vehicles

18、Connectors for the electrical connection of towing and towed vehicles Definitions, tests and requirements ISO 4141-3, Road vehicles Multi-core connecting cables Part 3: Construction, dimensions and marking of unscreened sheathed low-voltage cables ISO 7638-1,Road vehicles Connectors for the electric

19、al connection of towing and towed vehicles Part 1: Connectors for braking systems and running gear of vehicles with 24 V nominal supply voltage ISO 7638-2,Road vehicles Connectors for the electrical connection of towing and towed vehicles Part 2: Connectors for braking systems and running gear of ve

20、hicles with 12 V nominal supply voltage BS ISO 25981:20082 ISO 12098, Road vehicles Connectors for the electrical connection of towing and towed vehicles 15-pole connector for vehicles with 24 V nominal supply voltage IEC 60512-13-5, Connectors for electronic equipment Tests and measurements Part 13

21、-5: Mechanical operation tests Test 13e: Polarizing and keying method 3 Terms and definitions For the purposes of this document, the terms and definitions given in ISO 4091 apply. 4 Dimensions 4.1 General Details not specified are at the manufacturers discretion. The contacts shall be floating and s

22、hall align to the datum position when plug and socket are engaged. 4.2 Plug Dimensions of the plug shall be as in Figure 1. The locking lever design shall take into consideration the space required for screws used to fasten the socket (see section B-B in Figure 2). 4.3 Socket Dimensions of the socke

23、t shall be as in Figure 2. The cover is shown in opened position. It shall close automatically when the plug is disconnected. 4.4 Park socket Dimensions of the park socket shall be as in Figure 3. The cover is shown in closed position. It shall close automatically when the plug is disconnected. BS I

24、SO 25981:20083BS ISO 25981:2008Dimensions in millimetres aDimension refers to the locking lever in its locked position. bPlug housing with 7 bushings and coding. cThe sealing ring shall be mounted such that it cannot become detached under normal use. dCentre of cover rest. eSee ISO 4141-3 for correc

25、t sealing. fOther housing designs are permitted in compliance with the maximum distance of 58 mm for the locking lever. gMinimum space required for the ejection from the socket hSpring tube. iContact numbers. jContact bushing with 6,0 mm2terminal for contacts 1 to 4 and 1,0 mm2terminal for contacts

26、5 to 7. Figure 1 Dimensions 4 Dimensions in millimetres Figure 2 (continued) BS ISO 25981:20085Key X contacts 1 to 4 with 6,0 mm2terminal and 23,5 mm length Y contacts 5 to 7 with 1,0 mm2terminal and 19,5 mm length aThe sealing ring shall be mounted such that it cannot become detached under normal u

27、se. bFor existing products for which the cable outlet is mounted from the rear, the outside diameter of the outlet may be larger with the vehicle manufacturers agreement. However, to ensure socket exchangeability, it is recommended to allow for future applications that the maximum outside diameter b

28、e 54 mm over a maximum length of 75 mm. See ISO 4141-3 for correct sealing. cSpring loaded ejector optional. dReference point for engaged locking lever. eOpening angle of cover 120 min. fThis area shall be smooth and burr free. gMinimum space required for screws used to fasten the socket. Figure 2 S

29、ocket BS ISO 25981:20086 Dimensions in millimetres aThe sealing ring shall be mounted such that it cannot become detached under normal use. bOpening angle 120 min. cReference point for engaged locking lever. Figure 3 Park socket BS ISO 25981:200875 Application of the connector 5.1 General The connec

30、tion shall be used only for those road vehicles that are equipped with an electronic monitoring device which recognises the system voltage, and which is able to prevent damages caused by wrong system voltage. NOTE Annex A specifies the minimum functionality of the electronic monitoring device. Coile

31、d cable assemblies shall be fitted to: the tractor, in the case of an articulated vehicle (the coiled cable may be connected to the electrical on-board network of the towing vehicle, with or without the connection; see Figure 4); the trailer, in the case of a drawbar-trailer combination therefore, t

32、he trailer towing vehicle (drawbar tractor) shall be fitted with a socket mounted at the rear of the vehicle; see Figure 4. 5.2 Connector positions and free space The positions of the connectors shall comply with those specified for a 7-pin S connector (see ISO 3731) in accordance with ISO 4009. Fre

33、e space around the connector shall comply with ISO 4009. If this connector is used, the optional 7-pin N connector (see ISO 1185) shall be replaced by the 15-pin connector conforming to ISO 12098. Key 1 socket 2 park socket 3 plug aSee 5.1. Figure 4 Electrical connection positions BS ISO 25981:20088

34、 5.3 Contact allocation The contact allocation shall be in accordance with Table 1. Table 1 Contact allocation Contact No. Function 1 Plus charging current; switched on electronically 2 Plus charging current; switched on electronically 3 Minus charging current 4 Minus charging current 5 Switched on

35、minus, if platform is closed (control pin for switching on charging current and feedback signal for systems following quiescent current principle) 6 Switched on minus, if platform is opened (control pin for switching on charging current and feedback signal for systems following operating current pri

36、nciple) 7 Switched on minus for feedback signal, if tailgate lift of trailer is opened 5.4 Contact designation The contact designation numbers shall be permanently marked on the inside of the socket cover and on the terminal faces of both plug and socket. The character size shall not be less than 2

37、mm. However, where limited space is available, a smaller size may be used on the terminal face. 5.5 Terminals The terminals on the rear side of the pins and tubes shall be capable of accepting cables with the following nominal cross-sectional areas: contacts 1, 2, 3 and 4: 6 mm2; contacts 5, 6 and 7

38、: 1 mm2. Terminals accepting cables with different cross-sectional area shall be as agreed between manufacturer and user. 5.6 Connecting cable The connecting cable shall meet the requirements of the applicable parts of ISO 4141. 5.7 Colouring of plug and socket As a minimum requirement, the cover of

39、 the socket and the insert of the plug shall be coloured light grey. 6 Tests and specific requirements 6.1 General Connectors conforming to this International Standard shall be tested as specified in ISO 4091 and shall fulfil the requirements of ISO 4091 unless otherwise specified in subclauses 6.2

40、to 6.5. BS ISO 25981:200896.2 Mismating test 6.2.1 Purpose It shall be impossible to make contact between any tube or pin of the plugs and sockets conforming to this International Standard and the pins and tubes of connectors conforming to ISO 7638-1, ISO 7638-2 and ISO 12098 without excessive force

41、. 6.2.2 Test procedure The mismating test shall be applied in accordance with IEC 60512-13-5. 6.2.3 Requirement No pins shall come into contact up to the minimum allowable force of 1 000 N. 6.3 Connection and disconnection The connection and disconnection forces shall not exceed 35 N when tested in

42、accordance with ISO 4091. 6.4 Endurance Carry out the endurance test as specified in ISO 4091, but with 10 000 cycles. 6.5 Mechanical strength of mounting features The mounting features shall be able to withstand a minimum mounting torque of 15 Nm for fastening the socket. BS ISO 25981:200810 Annex

43、A (normative) Minimum functionality of the monitoring device A.1 General The described connector shall be used in combination with an additional electronic monitoring device in order to protect the complete charging system against damage by overvoltage, misuse and electrical arcing. A.2 Minimum func

44、tionalities The minimum functionalities are as described below. Two control pins (pin 5 and 6) are provided to signalize the electronic monitoring device whether a trailer cable is connected or not. For a correct charging function, one of these wires shall be connected to minus (e.g. in the battery

45、box of the trailer). This coded connection shall not only result in a turn-on signal for charging of the additional battery pack but, in addition, the feedback system of the platform at the trailer is determined (see Table 1). With a hybrid operation (i.e. the towing vehicle and trailer have tailgat

46、e lifts from different tailgate manufacturers with different feedback systems), the correct coding of pin 5 or 6 shall result in a correct switching principle of the feedback signal in the drivers cabin. In this way, it is possible to combine trailers with different minus feedbacks from all tailgate

47、 manufacturers with a towing vehicle that is equipped with a comparable electronic monitoring device (with trucks, the feedback signal is always minus operating current principle). The electronic monitoring device shall be able to diagnose initially the systems voltage of each of the battery packs t

48、hat are to be connected. In the case of different system voltages (12V/24V), no coupling of the battery packs shall take place. When the plug is engaged, the electronic monitoring device shall connect the battery packs after a time delay in order to prevent electrical arcing at the contacts. When th

49、e plug is separated, the shorter pins of the plug initially disconnect the ground signal; in this way, the electronic monitoring device shall shut off the charging current within milliseconds before the contacts of the charging current pins are disconnected, in order to prevent electrical arcing at the contacts. The electronic monitoring device shall disconnect the charging system if the charging current exceeds 50 A. If a short-circuit occurs, the electronic monitoring device shall also disconn