Tc Charger HK-LF-312-20 6.6kW Board Charger High Voltage Instruction Manual

Tc Charger HK-LF-312-20 6.6kW Board Charger High Voltage

Tiecheng Information Technology Co., Ltd

• 5/F, A, No.108 Xiangyuan Rd, Gongshu District, Hangzhou 310015, China

V1.0

| ****

Draft

| ****

Tianxiang Pan

| ****

Lizhen Tang

| ****

Hongbin Zhang

| ****

2021.1.1

Overview

Subject

HK-LF full-sealed on-board OBC is a product specially designed for new energy vehicle by Tiecheng Information Technology Co., Ltd according to China standard QC/T895-2011 Conductive On-board Charger for Electric Vehicle, which function as the battery charger of new energy vehicle This product not only have the advantages of high efficiency, small size, high stability, long- lifetime but also have the performance of high protection level, high reliability, more protection functions, it is a ideal power supply solution for the electrical vehicle. The thermal sensor is a built-in charger, has the function of over-temperature, and can auto-recovery when temperature decreased. With the process of full-sealing, achieve the protection level of IP67, which make sure excellent working under the complicated operation condition.

Main Features

1. Support UDS diagnosis, with CAN wake-up function
2. Full-sealed process can reliably work in the temperature of -40℃~60℃
3. Built-in thermal sensor, shut off when temperature up to 90℃
4. Protection level with IP67

Charger Technical Specification

Environmental Specification

• Working environmental temperature

Storage environmental temperature

• Humidity：relative humidity 5%~95%，no condensation
• Altitude：≤5000m
• Working noisy： max when working ≤65dB， meet China standard QTC 895-2011

Charger regulatory requirements and reference standards
The design and manufacture of this product must meet the related requirements of the vehicle which applicable regulations and standards in China, reference standards as follows:

895-2011

| The conductive on-board charger of electrical vehicle| /
2| GB/T

30512-2014

| Prohibited substances requirement| /
3| GB/T

18387-2008

| Limits and measurement methods for electromagnetic field

the emission intensity of electric vehicles, broadband, 9kHz~30MHz

| /
4| GB/T

18384-2015

| Safety requirements of electrical vehicle| /
5| GB/T

18487-2015

| Electric vehicle conductive charging system| /
6| GB/T

28382-2012

| Technical specifications for all-electric passenger vehicles| /

7

| GB/T 14023-2011| Limits and methods of measurement for radio disturbance characteristics of vehicles, ships, and installations driven by internal

combustion engines

|

/

23| GB/T

18655-2018

| EMC technical requirements for electronic components and

subsystems of passenger vehicles

| /

24

| GB/T 18655-2010| Limits and measurement methods for the radio disturbance characteristics of vehicles, ships, and internal combustion engines

used to protect vehicle-mounted receivers

|

/

Charger Safety Regulations Specification

Charger Electrical Performance

Input

Input

| Input voltage range| AC 90~265V
---|---|---
Frequency| 47~63Hz
Input Current| ≤32A
Power Factor| ≥0.98 @ ≥1650W
Efficiency| ≥93% full loading
Stand-by power consumption| ≤5W
Starting inrush current| ≤48A

Output

Output

| Output voltage range| 400-680V| 200-450V
Max output current| 14A| 20A
Output power| 6600W@220VAC；3300W@110VAC
Output way| CV/CC
Efficiency| ≥94%
CV accuracy| ±1%
CC accuracy| ±2%
Ripple voltage coefficient| ±5%
Output voltage rising time| ＜5S，overshoot＜10%
Shut off response time| Current decreased below 10% in 300ms and decreased to

0A in 500ms

Low Voltage Output

Low voltage Output

| Output way| CV
---|---|---
Output voltage| 12V
Nominal current| 5.5A
CV accuracy| ±2%
Output Power| ≤66W
Ripple voltage coefficient| ≤1%

Control Interface

Other

direction
Noisy| ≤65dB  （Class A）
MTBF| 150000H

Charger Protection Functions

Protectio n     unctions

| Input over-voltage protection| AC270±5V
---|---|---
Input low-voltage protection| AC85±5V
Output over-voltage

protection

| Stop output when exceeding the highest voltage ±5V
Output low-voltage

protection

| Stop output when below the lowest voltage ±5V
Over-temperature protection| Power starts to decrease when internal temperature rise to 85℃, and shut off when rises to 90℃
Output short circuit

protection

| Stop output
Output polarity reverse

protection

| yes
Grounding protection| ≤100mΩ
CAN Communication

protection

| Automatically stop output when CAN communication fails
Power-off protection| Yes

Function block diagram

Control Interface

• The interfaces in the charger can be grouped into two categories, one category is low voltage interface, and the other is high voltage interface.
• Low voltage interface includes control connector
• High voltage interface includes AC220V input, DC output, and HIVL
• Connectors can be appointed by the customer if the quantity order is more than 5000pcs.

Low Voltage Connector and Pins Definition

Molex

| 10| 12V 5A Output Positive|
11| CAN-H|
12| CAN-L|
13| HVIL positive|
14| HVIL negative|
17| GND|
Others| NA|
Socket| 348302001
Plug| 334722006

High Voltage Connectors and Pins Definition

AC Input

AMPHENOL

| 1| （N）
2| （PE）
3| （L）
A\B| NC
Socket P/N：| HVSL633023A
Plug P/N:| HVSL633063A106I

OBC Output

TE

| 1| Positive
2| Negative
A、B| HVIL
Socket P/N:| 2103124-5
Plug P/N:| 2103177-5

Software requirements

CAN communication

2

| CAN bus communication

protocol

| Comply with CAN2.0B specification| ****

/

3| Terminating resistor| No terminating resistor| /

Mechanical requirements

Size and weight

Appearance

Appearance requirements

The surface of the part should be smooth, free from defects such as delamination, rust, cracks, spots, burrs, deformation, and hand-accessible bumps. The connecting parts are complete, the parts are securely fastened, and there are no defects and damages such as rust, burrs, and cracks. The connector sheath and pins should be intact and free of damage, and the components must be fastened.

Installation size

Installation requirements

Nameplate, Package, Transport, and Storage

Nameplate

• Require information in the nameplate shall be traceable
• The basic parameters of the nameplate include model, rated voltage, rated power, production date, serial number, etc.

High Voltage Label for the reference Nameplate sample is as follows

Package
The packing box shall be provided with the product name, model, manufacturer identification, inspection certificate of the manufacturer’s quality department, manufacturing date, etc; There is a list of accessories in the packing box:

Transportation
The product shall be transported in a firm packing box, which shall comply with the provisions of relevant national standards and shall be marked with “handle with care” and “moisture-proof”. The packaging box containing the product can be transported by various means of transportation. Direct rain and snow and mechanical impact shall be avoided during transportation.

Storage

• The products shall be stored in the packing box when not in use. The ambient temperature of the warehouse shall be -10-40 ℃ and the relative humidity shall not be greater than 80%. There shall be no harmful gas, flammable, explosive products, and corrosive chemicals in the warehouse, and there shall be no strong mechanical vibration, impact, and strong magnetic field. The packing box shall be at least 20cm above the ground and at least 50cm away from the wall, heat source, window, or air inlet, The storage period under the specified conditions is generally 2 years, and the inspection shall be carried out again after more than 2 years.
• The product shall be stored in a ventilated and dry place. At the same time, high-temperature sources, fire sources, and chemicals must be avoided. Store neatly to avoid throwing.

Safe Guide

Warning: remind the user that the operation is dangerous

• It is strictly prohibited to disassemble and refit the on-board charger for repair or commissioning
• Do not place the parts in the rain
• Please confirm that the housing is intact before installation. If it is damaged, please replace it immediately or contact the after-sales service department
• All plugs and sockets shall be connected firmly. If they are damaged or loose, please replace them immediately
• It is strictly prohibited to plug and unplug the connector when the product is powered on, otherwise, personal injury may be caused
• It is strictly prohibited to open the product shell during the power-on operation of the product, otherwise, personal injury may be caused
• It is strictly forbidden to touch the high-voltage live parts of the product with bare hands. Please wear insulating gloves, and insulating shoes Insulating clothing, live maintenance, and detection are strictly prohibited
• During the replacement of fuses and contactors, the barbaric operation is strictly prohibited to avoid damaging the product and causing potential safety hazards
• Three core cables with grounding wire shall be selected for the AC power supply and the grounding wire
• Please unplug the power plug if there is an abnormal sound or smell during the operation of the charger
• Please keep away from fire sources and inflammable and explosives when the battery is normally charged
• Do not charge damaged or non-rechargeable batteries

Note: remind the user that the following operations are important operations of the product.

• Do not block the air inlet and outlet of the charger to prevent overheating
• Please make sure that the output cable is not too long to avoid the impact of line voltage drop on charging
• Please disconnect the power cord and charging plug when moving the charger
• The battery voltage must be consistent with the nominal voltage of the charger
• Avoid the collision, compression, pulling, twisting, or shaking the charging cable
• The product should be placed in a safe, ventilated, dust-free and rain-free environment
• Please pack and store if not used for a long time.

www.tccharger.com.

References

• 铁城信息科技有限公司

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