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Posted By Topic: Electric car standards

Rhino
Sep 07 2017 13:51

What are the relevant standards, procedures when installing a car charger into an electric car, input is 230VAC. output to charge batt is 110V-400VDC
   

AlecK
Sep 07 2017 14:09

Worksafe have published a 3-part guide for EV charging
   

JonoQC
Sep 07 2017 14:24

Rhino: You mean actually removing/replacing the on-board charger itself?

If it's for an existing vehicle, there will be a service manual that details the procedure. Each vehicle differs slightly, but there will normally be a way to safely isolate the battery pack.

As an example, in the Nissan Leaf it's a link under a cover in the footwell between the rear seats that separates the pack into 2 banks of 200V each and leaves it open circuit.

Most EVs that I've worked on have in-pack contactors so the 400V pack is effectively disconnected as long as the 12V system is down, but I wouldn't rely solely on that.

Aside from that, I don't know what the relevant standards/testing requirements would be outside any other appliance repair/maintenance? Anyone have any suggestions beyond testing and tagging to 5762?
   

Rhino
Sep 07 2017 16:07

Yes i mean installing the Car charger inside the car, it came with in its box two female plug ends, one for 230V input and the other for 400V output DC , so these plugs will need to be terminated to Cable by an electrician, however they are plugs i havnt seen before and thought they would need to be complaint, the chargers manual says it meets standards etc but no specific standard numbers ...
   

JonoQC
Sep 07 2017 16:31

Do you have a link to the charger itself?

There are a few different families of plugs/sockets that are commonly used for connections to the vehicle wiring. Normally the charger has sockets or flying leads on it which will connect to the vehicle wiring which heads off to the charging port socket (SAE J1772 socket or similar) and the battery pack directly, or a distribution box.

I don't think there will be any specific compliance requirements for the connectors/cabling within the vehicle other than being rated appropriately and fit for purpose as the vehicle itself would end up being considered an appliance, rather than a connectable installation. That's where things get fuzzy for me, though, so any other opinions would be welcomed.

Is this a repair to an existing EV or a retrofit of an ICE vehicle?
   

Rhino
Sep 07 2017 16:50

http://www.tccharger.com/Product/T38/73.html

Name
3,3kw HK-J

Retro fit car
   

JonoQC
Sep 07 2017 17:20

Ok, those aren't any of the connectors I'm familiar with, but then I'm more often working in the OEM space than the retrofit space these days.

I don't think you'll find any relevant standards within NZ. My understanding is that there aren't really any standards internationally, either, with most of the auto OEMs mostly publishing their own for the vehicle wiring.

I'd approach it as wiring an appliance, make sure everything is rated appropriately and fit for purpose (specifically protected from movement/vibration based damage) and then test the components as installed to 5762.

Not entirely sure what you're after here, but it's pretty common for the vehicle wiring to be some form of flex, sometimes with a shielding braid connected to ground. You can buy pre-made cables from various places around as well (we've had to do that to source some of the more oddball cable) from places like EV West.
   

Rhino
Sep 08 2017 08:54

The charger came with plugs and crimps to go inside the plugs, they are steel plugs female. didnt come with cable and just found it abit tricky using flexible cable . i see EV west has replacement sockets that are plastic and look alot easier and safer to wire up thanks. can this also be done by an auto electrician? there is 230Vac and 400VDC , so i dont think so?
   

pluto
Sep 08 2017 09:53

I would strongly suggest you rule the Electric Vehicle rules availsble from the WorkSafe NZ website to see if you are complying with requirements.

From the limited information you have given it does appear what you are proposing will NOT comply with EC the requirements, electric vehicles are potentially leathal if you gets anything wrong.
   

pluto
Sep 08 2017 09:56

typo in first line it should read

I would strongly suggest you READ the Electric Vehicle rules availsble from the WorkSafe NZ website to see if you are complying with ALL requirements.
   

JonoQC
Sep 08 2017 15:24

pluto: Those requirements are all dealing with the EVSE side of the charging, correct? I didn't see anything there that was specific to the actual wiring/fitout of the EV itself.
   

JonoQC
Sep 08 2017 15:30

Rhino: The EV West gear is often the same plugs/sockets you'll find in something like a Leaf, BMW i3, Ioniq, etc. They can be a bit finnicky to deal with if you don't get the proper crimp tooling, but they'll make up the cables to spec or you can normally make do adequately.

I definitely wouldn't go with an auto-electrician for any of this work. I'd be looking for someone local who has a practising license andexperience with this kind of fitout. Worst case, someone licensed with a good understanding of the rules and keen to try their hand at something new would likely suffice.

pluto is right in that getting it wrong can be lethal, but it would be nice to at least see an attempt to figure out the 'proper' way to go about things.