1、UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULFEBRUARY 27, 20151UL 2734CONNECTORS AND SERVICE PLUGS FOR USE WITH ON-BOARDELECTRICAL VEHICLE (EV) CHARGING SYSTEMSIssue No. 3February 27, 2015The First and Second Issues were titled the Outline
2、of Investigation forConnectors for Use with On-Board Electrical Vehicle (EV) ChargingSystems.Summary of TopicsThis is the Third issue of the Outline of Investigation for Connectors andService Plugs for Use with On-Board Electrical Vehicle (EV) ChargingSystems. This issue expands the scope to also co
3、ver on-board electricvehicle (EV) service plugs.COPYRIGHT 2015 UNDERWRITERS LABORATORIES INC.UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULFEBRUARY 27, 2015UL 27342No Text on This PageUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPROD
4、UCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULCONTENTSINTRODUCTION1 Scope .42 Components 53 Units of Measurement .54 Undated References 65 Glossary .6CONSTRUCTION6 General 66.1 All devices .66.2 Service plugs 77 Environmental Protection 78 Fluid Compatibility 7PERFORMANCE9 General 810 Latching Tes
5、t 811 Fluid Compatibility Test .912 No-Load Endurance Test .9RATINGS13 General .9MARKINGS14 General 10APPENDIX AStandards for ComponentsA1FEBRUARY 27, 2015 UL 2734 3UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULINTRODUCTION1 Scope1.1 This ou
6、tline covers connectors of an on-board electric vehicle (EV) charging system. Connectors areintended to interconnect both communication and power circuit conductors rated up to 30 amperes andup to 600 volts ac or dc, within an on-board vehicle charging system.1.2 This outline also covers on-board el
7、ectric vehicle (EV) service plugs. Service plugs are not intendedfor operation under load, and are rated 400 amperes or less, maximum 600 V ac/dc. The pilot contactsincorporated in a service plug are intended for use in the control circuit of magnetic motor controllers andsimilar devices, and are ra
8、ted to switch control circuit loads with continuous current ratings of 10 amperesor less, maximum 600 V ac/dc.1.3 For the purpose of this outline, connectors consist of mating devices intended for factory assembly tocopper or copper alloy conductors.1.4 These devices are intended to be mounted inter
9、nal to the vehicle and are not accessible to theoperator or in locations where they may be subjected to mechanical abuse.1.5 A service plug is intended for EV service personnel use only.1.6 This outline does not cover:a) Plugs, receptacles, and couplers for electric vehicles covered by the Standard
10、for Plugs,Receptacles and Couplers for Electric Vehicles, UL 2251;b) Plugs, receptacles, and cable connectors, of the pin and sleeve type covered by theStandard for Plugs, Receptacles, and Cable Connectors, of the Pin and Sleeve Type, UL 1682;c) Devices molded integrally with flexible cord or cable
11、that are covered by the Standard forCord Sets and Power-Supply Cords, UL 817;d) Attachment plugs, cord connectors, and receptacles that are covered by the Standard forAttachment Plugs and Receptacles, UL 498;e) Single and multi-pole connectors, which may include 3 or more pilot contacts, intended fo
12、rconnection to copper conductors, for use in data, signal, control and power applications withinand between electrical equipment, where exposed, that are covered by the Standard forComponent Connectors for Use in Data, Signal, Control and Power Applications, UL 1977;f) Devices intended for use in ha
13、zardous (Classified) locations that are covered by theStandard for Explosion-Proof and Dust-Ignition-Proof Electrical Equipment for Use in Hazardous(Classified) Locations UL 1203;g) Devices consisting of wiring terminals and supporting blocks intended for the connection ofwiring that are covered by
14、the Standard for Terminal Blocks, UL 1059;h) Devices such as modular jacks and plugs that are intended for use with telecommunicationsnetworks, that are covered by the Standard for Information Technology Equipment Safety - Part1: General Requirements, UL 60950-1, and the Standard for Communications-
15、CircuitAccessories, UL 1863;FEBRUARY 27, 2015UL 27344UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULi) Devices such as wire connectors and soldering lugs that are covered by the Standard forWire Connectors, UL 486A-486B; the Standard for Spli
16、cing Wire Connectors, UL 486C; or theStandard for Equipment Wiring Terminals for Use with Aluminum and/or Copper Conductors, UL486E; orj) Devices such as quick-connect terminals that are covered by the Standard for ElectricalQuick-Connect Terminals, UL 310.2 Components2.1 Except as indicated in 2.2,
17、 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 this outline.2.2 A component is not required to comply with a specific requirement that:a) Invol
18、ves 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.2.3 A component shall be used in accordance with its rating established for the intended conditions ofuse.2.4 Specific component
19、s 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.3 Units of Measurement3.1 In addi
20、tion to being stated in the inch/pound units that are customary in the USA, each of therequirements in this outline is also stated in units that make the requirement conveniently usable incountries employing the metric system (practical SI). Equivalent - although not necessarily exactlyidentical - r
21、esults are to be expected from applying a requirement in USA or metric terms. Equipmentcalibrated in metric units is to be used when a requirement is applied in metric terms.FEBRUARY 27, 2015 UL 2734 5UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION F
22、ROM UL4 Undated References4.1 Any undated reference to a code or standard appearing in the requirements of this outline shall beinterpreted as referring to the latest edition of that code or standard5 Glossary5.1 SERVICE PLUG A disconnect device that is used when performing repairs on the high volta
23、gehybrid/electric vehicle circuits.CONSTRUCTION6 General6.1 All devices6.1.1 Connectors and service plugs complying with these requirements are acceptable for use ascomponents in an end product where the acceptability of the combination is to be determined.6.1.2 The acceptability of a connector or s
24、ervice plug in any particular application depends on its abilityto be used under the conditions that prevail in actual service. For a particular application, a connector orservice plug may be affected by the requirements for the equipment in which it is used, and it may benecessary to additionally e
25、valuate features or performance characteristics that are not specified in thisoutline.6.1.3 Connectors and service plugs shall comply with the insulating material, current carrying parts,grounding and dead metal parts, assembly, and spacing requirements in the Standard for ComponentConnectors for Us
26、e in Data, Signal, Control and Power Applications, UL 1977, except as modified below:a) Insulating Materials: The Electrical RTI and Mechanical Strength Without Impact (Str) RTIvalues of the insulating material shall not be lower than the temperature measured during theTemperature Test of UL 1977. T
27、he Electrical and Mechanical Strength Without Impact (Str) RTIvalues are determined at the nominal insulating material thickness separating live parts or liveparts of opposite polarity and grounded dead metal parts.b) Assembly: Connectors and service plugs shall have a mechanical means, such as a la
28、tch,that prevents unintentional separation when mating halves are fully engaged in the matedcondition. The latch shall comply with the Latching Test specified in Section 10.c) Spacings: Spacings between live parts of different circuits shall be judged based upon thehighest voltage involved.6.1.4 All
29、 gasket material shall comply with the Standard for Gaskets and Seals, UL 157.FEBRUARY 27, 2015UL 27346UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL6.2 Service plugs6.2.1 A service plug shall be constructed in a manner that restricts the co
30、nnector from being eitherinserted or withdrawn under traction motor loading conditions.6.2.2 The service plug shall break all ungrounded supply conductors.6.2.3 The housing of a service plug shall be orange in color.6.2.4 The terminals of a service plug shall comply with the requirements in the Stan
31、dard for WireConnectors, UL 486A-486B, as appropriate.6.2.5 A service plug shall comply with the No-Load Endurance Test, Section 12.6.2.6 The pilot contacts of a service plug (switching means) shall comply with the applicable requirementsfor auxiliary devices in the Standard for Industrial Control E
32、quipment, UL 508.7 Environmental Protection7.1 Connectors and service plugs that are identified with an environmental enclosure rating shall complywith the applicable requirements for each environmental classification in accordance with the Standard forEnclosures for Electrical Equipment, Environmen
33、tal Considerations, UL 50E, (Type Rating) and/or theStandard for Degrees of Protection Provided by Enclosures (IP Code), IEC 60529.7.2 Connectors and service plugs rated for any degree of moisture protection shall not permit theentrance of water when subjected to the tests associated with their clas
34、sifications. Water shall not enterthe mated pairs, and shall not reach live parts.8 Fluid Compatibility8.1 Connectors and service plugs that are identified with a Fluid Compatibility Rating as shown in Table8.1 shall comply with the Fluid Compatibility Test, Section 11.Table 8.1Fluid compatibility -
35、 conditioning and requirementsTest fluid Test temperature, C (F) Optional marking codeName FluidEngine oil* ASTM D 471, IRM-902 50 3 (122 5.4) OGasoline* ASTM D 471, Ref. Fuel C 25 5 (73 9.0) GEthanol Blend* per ATB77 23 5 (73 9.0) EDiesel fuel* 90% ASTM D 471, IRM-903 +10% p-xylene23 5 (73 9.0) DPo
36、wer steering fluid* ASTM D 471, IRM-903 50 3 (122 5.4) SAuto transmission fluid* Dexron IV, SAE J311 50 3 (122 5.4) TEngine coolant* 50% Distilled Water + 50%ethylene glycol50 3 (122 5.4) ABattery acid * H2SO4 Specific gravity =1.260 .00523 5 (73 9.0) CBrake fluid* DOT 3 23 5 (73 9.0) BNote: Solutio
37、ns are determined by percent of volume. Exposures marked by * are optional.FEBRUARY 27, 2015 UL 2734 7UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULPERFORMANCE9 General9.1 Connectors and service plugs shall comply with the performance requir
38、ements in the Standard forComponent Connectors for Use in Data, Signal, Control and Power Applications, UL 1977, based uponthe assigned electrical rating. Connectors and service plugs shall also comply with the Latching Testdescribed in Section 10.10 Latching Test10.1 The latch mechanism of a connec
39、tor or service plug shall not open or experience breakage of eitherthe enclosure or latching means when both the male and female interconnect is subjected to the LatchingTest specified in 10.2 and 10.3.10.2 Three mated pairs of connectors or a service plug are to be tested. The latching mechanism sh
40、allbe operated to latch the connector or service plug halves together. The latching mechanism shall then beoperated to release the connector or service plug halves, and the mating connector or service plug halvesshall be physically separated. This sequence shall be repeated for a total of 10 cycles.
41、10.3 Following the 10th cycle, the latching mechanism is to be operated to lock the connector or serviceplug in place. A static pull of 30 lbf (133 N) is to be applied to the connector or service plug for 1 minutein a direction perpendicular to the plane of the connectors mated face or service plug
42、mated half.10.4 Each device is then to be subjected to a 50 - 60 Hz essentially sinusoidal potential equal to twicethe rated voltage plus 1000 V applied between live parts of opposite polarity and between live parts andgrounding or dead metal parts. An insulated body is to be wrapped in foil. The te
43、st voltage is to beincreased at a uniform rate and as rapidly as is consistent with its value being correctly indicated by avoltmeter, and maintained at the test potential for 1 minute.Exception: For DC rated devices, when tested using AC equipment, each device is to be subjected to a50 - 60 Hz esse
44、ntially sinusoidal potential equal to the sum of twice the rated voltage plus 1000 V, dividedby 1.414. When tested using DC equipment, each device is to be subjected to a potential of twice therated voltage plus 1000 V.FEBRUARY 27, 2015UL 27348UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRO
45、DUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL11 Fluid Compatibility Test11.1 A connector or service plug shall not exhibit deterioration such as cracking, breaking, warping, ordielectric voltage breakdown after being subjected to the Fluid Compatibility Test specified in 11.2 11.4.11.2 One repre
46、sentative device consisting of mated halves is to be tested. A new representativemated-pair shall be used for each fluid tested.11.3 Mated halves with approximately 12-inch (30.5-cm) conductor leads shall be immersed in the fluidshown in Table 8.1 for a period of 20 (+1, -0) hours.11.4 After removal
47、 from the fluid, excess fluid is to be removed from the representative mated halves andthen the mated halves are to be conditioned for 4 hours at room temperature. After conditioning, eachconnector shall be visually examined for cracking, breaking, and warping.11.5 Upon completion of the visual exam
48、ination, the representative mated halves shall be subjected to aDielectric Voltage-Withstand Test as described in the Standard for Component Connectors for Use inData, Signal, Control and Power Applications, UL 1977.12 No-Load Endurance Test12.1 A service plug shall be completely inserted and withdr
49、awn in the intended manner to permit itsoperation, either manually or mechanically, and the mechanism shall be locked and unlocked after eachcomplete insertion. The duration of the test shall be 250 cycles. One cycle is considered to be full insertionfollowed by locking followed by unlocking followed by withdrawal. The cycle rate shall be no greater than10 per minute. During this test, there shall be no mechanical or visible damage to any of the parts,including the locking mechanism. These devices shall be marked in accordance with 14.4.RATINGS13
