TC charger HK-MF-108-32 On-Board Charger Instruction Manual

Specification Manual
Model:HK-MF-108-32, HK-MF-72-40, HK-MF-48-40
Name：3.3KW On-board Charger
Version：V1.0
Issue Date：2021.1

HK-MF-108-32 On-Board Charger

Overview

1.1 Subject
HK-MF full-sealed On-board Charger 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 is as the battery charger of new energy vehicle. This product not only has the advantages of high efficiency, small size, high stability, long- lifetime but also has the performance of high protection level, high reliability, more protection functions, it is an ideal power supply solution for electrical vehicle. Thermal sensor is built-in the 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 the excellent working under the complicated operation condition.
1.2 Main Features
1.2.1 Support UDS diagnosis, with CAN wake-up function
1.2.2 Full-sealed process, can reliably work in the temperature of -40℃~60℃
1.2.3 Built-in thermal sensor, shut off when temperature up to 90℃
1.2.4 Protection level with IP67

Charger Technical Specification

2.1 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
2.2 Charger regulatory requirements and reference standards
The design and manufacture of this product must meet the related requirements of vehicle which applicable regulations and standards in China, reference standards as following:

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

| Condition| Requirement
---|---|---
Grounding resistance test| @25A/AC| ≤100mΩ
Input insulation test| @1000V/DC| ≥20MΩ
Output insulation test| @1000V/DC| ≥20MΩ
Input withstand test| @2000V/AC 1min| Leak current≤15ma
Output withstand test| @2000V/AC 1min| Leak current≤10ma
Input to Output withstand test| @2000V/AC 1min| Leak current≤10ma

Charger Electrical Performance

4.1 Input

4.2 Output

0A in 500ms

4.3 Low Voltage Output

4.4 Control Interface

| 12V wake-up input| ≤10mA
---|---|---
12V wake-up signal output| Max 0.2A
12V CV| Sleep current≤1mA，peak current≤5A
CAN Communication| yes
Baud rate| Optional for 125Kbps、250Kbps、500Kbps
Terminal resistance| Not available

4.5 Other

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

Charger Protection Functions

±5V
Output low-voltage protection| Stop output when below the lowest voltage ±5V
Over-temperature protection| Power start to decrease when internal temperature rise to 85℃, shut off when rise 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

Electrical Interface Definition

The interfaces in the charger can be grouped into two categories, one category is low voltage interface, the other is high voltage interface.
Low voltage interface includes control connector
High voltage interface includes AC220V input and DC output
Connectors can be appointed by customer if quantity order is more than 5000pcs.
7.1 Low Voltage Signal Connector and Pins Definition P/N: 348302001 Brand: Molex

7.2 High Voltage Connectors and Pins Definition
7.2.1 AC Input P/N: HVSL633023A Brand: Amphenol

Pin| Function| Rated current| Definition| Wire cross-sectional area| Mating connector
---|---|---|---|---|---
1| Input AC N line| 16A| (N)| 2.5~4mm²| P/N: HVSL633063
2| Input AC PE| 地线 PE
3| Input AC L line| (L)
A| /| | /|
B| |

7.2.2 OBC Output
P/N: HVSL362022A Brand: Amphenol

Pin| Function| Rated Current| Definition| Wire cross-sectional area| Mating connector
---|---|---|---|---|---
1| Positive output| 40A| /|

6mm²

| P/N: HVSL362062
2| Negative output| /
A| /| /| /| /
B| /| /

Software requirements

8.1 CAN communication

Mechanical requirements

9.1 Size and weight

| Length（mm）| Width（mm）| Height（mm）| GW（KG）
---|---|---|---|---
Fan-cooled| 264.5±3| 252±3| 100±3| ≤5

9.2 Appearance 9.3 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

12.1 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 reference
Nameplate sample is as following: 12.2 Package
The packing box shall be provided with 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:

12.3 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. 12.4 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.
12.5 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, insulating shoes Insulating clothing, live maintenance and detection are strictly prohibited

• During the replacement of fuses and contactors, barbaric operation is strictly prohibited to avoid damaging the product and causing potential safety hazards

• Three core cable with grounding wire shall be selected for AC power supply, and the grounding wire

• Please unplug the power plug if there is abnormal sound or smell during the operation of the charger

• Please keep away from fire sources and inflammables 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 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
Tiecheng Information Technology Co., Ltd
5/F, A, No.108 Xiangyuan Rd, Gongshu District, Hangzhou 310015, China

References

• 铁城信息科技有限公司

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