UL 2202 CRD-2018 UL Standard for Safety Electric Vehicle (EV) Charging System Equipment - Section Paragraph Reference Supplement SB (New) Subject Liquid cooled high power charging.pdf

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1、UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULUNDERWRITERS LABORATORIES INC. CERTIFICATION REQUIREMENT DECISIONThis Certification Requirement Decision is prepared by UL LLC. It is normative for the applicable ULProduct Certification Program(

2、s); however, it is currently not part of the UL Standard(s) referencedbelow.Product Category (CCN): FFTGStandard Number: UL 2202Standard Title: Standard for Electric Vehicle (EV) Charging System EquipmentEdition Date: October 2, 2009Edition Number: 2Section / Paragraph Reference: Supplement SB (New)

3、Subject: Liquid cooled high power charging system equipmentDECISION:(NEW)SUPPLEMENT SBLIQUID COOLED CHARGER SYSTEMSINTRODUCTION1 Scope1.1 This supplement covers charging equipment systems that utilize liquid cooling to cool the output cableto the electric vehicle and the vehicle connector in order t

4、o deliver higher power to an electric vehicle. Theliquid cooling system encompasses the entire charging system from charger to vehicle connector in onecontinuous closed loop. The charging equipment is intended to comply with the requirements in thisSupplement.1.2 The requirements in this supplement

5、do not cover gaseous cooling systems or simple de-rating ofcurrent to control temperature.2 Glossary2.1 INTERMEDIATE CURRENT LEVELS Output current levels that the system may choose to utilize asallowable output currents based on input from various systems monitoring and sensing devices. Thesecurrent

6、 level values are numerically between the Normal Rated Current and the Maximum Rated Current.2.2 NORMAL RATED CURRENT - Current rating for which the output cable to the electric vehicle is sizedto handle without any cooling means.2.2 MAXIMUM RATED CURRENT Current rating for which the charging system

7、 equipment is designedto provide to the EV when liquid cooling is provided and in use.CONSTRUCTION3 GeneralUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL3.1 The requirements in this supplement are intended to add to the requirements in UL 22

8、02. As such,the two documents are intended to be used in conjunction when evaluating the charging systemequipment with liquid cooling.3.2 The liquid cooling system is intended to cool the output cable to the electric vehicle and the contactswithin the vehicle connector when the maximum rated current

9、 is being conducted. At any time duringnormal operation, the temperature of the contacts in the vehicle connector shall not exceed 90 C. As aminimum during operation, the contact temperatures are to be monitored.3.3 With reference to 3.2, all liquid cooled charging systems shall be rated with a maxi

10、mum rated currentthat indicates the current rating when liquid cooling is used.3.4 The charging system may operate in one of three distinct operational modes. All operational modesinvolve monitoring the temperature of the contacts as indicated in 3.2 and when the temperaturemonitoring indicates the

11、temperatures are approaching 90 C, the system is to perform a specific functionas indicated below.a) For operational mode 1, the unit shall shut down and all output is reduced to zero.b) For operational mode 2, the output shall be reduced to the normal rated current level withoutshut down in order t

12、o reduce the temperature at the contacts. Temperature monitoring is tocontinue. No intermediate levels are allowed. If temperatures continue to approach 90 C afterthe initial current reduction, the unit shall shut down and all output is reduced to zero.c) For operational mode 3, the charging system

13、shall reduce current to either the normal ratedcurrent level or, as an option, to an intermediate current level. Monitoring is to continue in eithercase. If temperatures or other monitored parameters indicate a further reduction in current isnecessary, then the system can reduce current to the norma

14、l rated current level or lowerintermediate limit can be chosen. Once the unit reduces to the normal rated current, regardlessof how many intermediate levels are used, any temperature indication approaching 90 Crequires the unit to shut down and all output is reduced to zero.3.5 With reference to 3.4

15、, charging systems that use operational mode 2 shall have a normal rated currentfor the non-liquid cooled operating condition. Systems for operational mode 3 shall have a normal ratedcurrent level and all intermediate current levels indicated. Testing of the unit will incorporate and verify allof th

16、ese current level limits.3.6 The charging equipment system may be contained within one enclosure or may be in multipleenclosures that are interconnected by cable or conduit. In the case where the multiple enclosures areinterconnected, the wiring or cabling used to interconnect the systems shall be e

17、valuated in the samemanner as the output cable to the electric vehicle. See 4.2.1 and Section 7. The interconnecting cablingshall be included in the risk assessment in Section 5.3.7 The charging system may monitor many different parameters associated with the liquid cooling. Themanufacturer can choo

18、se which parameters are to be included in the design based on risk mitigationneeds. See Risk Assessment, Section 5.3.8 With reference to 3.7, the contact temperatures in the vehicle connector shall always be one of theparameters monitored. The contact temperature monitoring shall require one monitor

19、ing device or sensoron each of the DC contacts in the vehicle connector. During operation of the charging system at maximumrated current, the monitoring devices or sensors on the DC contacts shall continuously send a signal tothe charging system equipment control system. If at any time during operat

20、ion, one or both of themonitoring devices or sensors fails to send a signal to the charging system equipment, the output currentSTANDARD NUMBER: UL 2202 -2-UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULshall be reduced in accordance with the

21、 applicable operational mode for which the charging system wasdesigned. Additionally, the charging system shall insure that the temperature readings provided by themonitoring device or sensor are provided with a degree of accuracy. This is accomplished by comparingthe two signals and determining tha

22、t the difference between the temperature indications is less than 5 C.3.9 If at any time the monitored temperature goes above 90 C, the system must perform an emergencyshutdown defined as reducing all output to zero. Additionally, the incident shall be logged by the systemto indicate that the event

23、occurred. If the monitored temperature goes above 90 C for two consecutivecharge events, then the system shall go into an out of order state and a service person will need to restorethe system to service once the unit is checked and it is determined that no deterioration or damage hasoccurred due to

24、 the over-temperature conditions.4 UL 22024.1 All the requirements within UL 2202 are applicable as well as the requirements in this supplement.4.2 The requirements in 4.2.1 provide for an alternative approach to the requirements in clause 13.2 ofUL 2202.4.2.1 The output cable to the electric vehicl

25、e shall be of any type, suitably insulated for the output voltageof the charger and the conductors shall be suitably sized for the normal rated current involved.5 Risk Assessment5.1 The following requirements are additions to the UL 2202 standard and shall apply to all liquid cooledcharging systems.

26、5.2 A risk assessment of the charging system shall be performed. This risk assessment shall take intoconsideration all hazards and their root causes, as well as addressing faults within the unit that couldresult in a hazard. Risk mitigation is the primary means for addressing risks associated with t

27、he liquidcooling aspect of the charging system.5.3 To mitigate the occurrence of a risk, monitoring systems may be used that will adjust current,shutdown current flow, or other actions to reduce the possibility of a hazard from occurring. The riskassessment shall take into consideration all monitori

28、ng system failures that could result in a hazardouscondition, over temperature condition, or in a condition that could stress insulation and create a situationin which additional stresses could cause a hazard in subsequent use of the system. The risk assessmentshould also address single fault condit

29、ions within the systems to insure that false readings and the likewill not create the same hazardous situations as a full system failure. See 5.7. Additionally, considerationsshall be given to insure the charging system equipment is capable of adequately monitoring andcontrolling the health of the s

30、ystem without being blinded or impaired by the inaccuracy or failure of othersystems.5.4 Examples of monitoring systems that are considered to be applicable to liquid cooled chargingsystems are shown below. This list shall not be considered all-inclusive and other options are availablebased on desig

31、n. However, as previously noted, the contact temperature monitoring in item a) is required.a) Contact temperature monitoringb) Additional temperature monitoring at locations other than contactsc) Coolant temperature monitoringSTANDARD NUMBER: UL 2202 -3-UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FUR

32、THER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULd) Coolant level monitoringe) Coolant pressure monitoringf) Coolant flow rate monitoringg) Ambient temperature monitoringh) Detection of lost monitoringi) Monitoring of fluid characteristics; andi) Other monitoring systems specified by the m

33、anufacturer.5.5 Compliance is determined through a review of the design and the overall system, including thefunctional safety evaluation of section 6 and the tests in this supplement.5.6 An analysis of potential hazards, due to component/monitoring system faults (including an FMEA) oroperation para

34、meter faults, shall be conducted on the liquid cooled charging systems electrical system,including any monitoring systems as needed, to determine that events that could lead to a hazardouscondition have been identified and addressed through design or other means. Documents that can beused as guidanc

35、e for the safety analysis include:a) The Standard for Analysis Techniques for System Reliability - Procedure for Failure Modeand Effects Analysis (FMEA), IEC 60812;b) The Standard for Fault Tree Analysis (FTA), IEC 61025;c) The Potential Failure Mode and Effects Analysis in Design (Design FMEA), Pot

36、ential FailureMode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA), SAEJ1739; andd) The Procedures for Performing a Failure Mode, Effects, and Criticality Analysis, MIL-STD-1629A.Other risk assessment standards that provide equivalent analysis methods, assessment means, a

37、ndcoordination are also acceptable.5.7 When conducting the analysis of 5.6, active devices shall not be relied upon for critical safety unless:a) They are provided with a redundant passive protection device;b) They are provided with redundant active protection that remains functional and energizedup

38、on loss of power/failure of the first level active protection;c) They are determined to fail safe upon loss of power to the active circuit; ord) They are part of a protective circuit that has been shown to comply with an appropriateFunctional Safety evaluation of section 6, with a safety level defin

39、ed by a corresponding hazardand risk analysis.STANDARD NUMBER: UL 2202 -4-UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL5.8 Redundancy in monitoring systems shall also be considered to insure proper monitoring and controlof the charging syst

40、em equipment liquid cooling means. For example, a unit installed in a cold climate mayexperience reduced liquid flow due to gelling of the coolant. The temperature monitoring may provideacceptable results when monitoring the coolant temperature in the reservoir but there is still an issue dueto the

41、restricted coolant flow. If the coolant flow is not being monitored, the system can be fooled intothinking things are fine when in fact a potentially hazardous condition could be developing. Redundancyof systems measuring the same or different parameters but leading to the same risk mitigation may b

42、erequired if determined by the risk assessment.6 Functional Safety Evaluation6.1 The following requirements are additions to the UL 2202 standard and shall apply to all liquid cooledcharging systems.6.2 For all components or systems that are considered critical to safety by the risk assessment of se

43、ction5, a functional safety evaluation in accordance with this section is required.6.3 Devices relied upon for critical safety as noted in 6.2 shall be tested for functionality in accordancewith appropriate functional safety requirements unless already evaluated through the other tests of thisoutlin

44、e. Functional safety criteria can be found in one of the following standards as appropriate to thedesign of the electronic and software protection scheme:a) The Standard for Tests for Safety-Related Controls Employing Solid-State Devices, UL 991,and the Standard for Software in Programmable Componen

45、ts, UL 1998, and Safety functionsincorporating electronic technology, C22.2 No. 0.8;b) The Standard for Automatic Electrical Controls - Part 1: General Requirements, UL 60730-1and Automatic Electric Controls - Part 1: General Requirements, CSA C22.2 E60730-1;c) The Standard for Functional Safety of

46、Electrical/Electronic/Programmable Electronic Safety-Related Systems - Part 1: General Requirements, IEC 61508-1, and all parts;d) The Standard for Safety of Machinery - Safety Related Parts of Control Systems - Part 1:General Principles for Design, ISO 13849-1, and the Standard for Safety of Machin

47、ery - SafetyRelated Parts of Control Systems - Part 2: Validation, ISO 13849-2; ande) The Standard for Road Vehicles Functional Safety, ISO 26262, and all parts.Other functional safety standards that provide equivalent analysis, assessment, and functional safetycoordination may be used.7 Components7

48、.1 In addition to Electrical or electromechanical components that are relied on for safety functions asdetermined in section 5 shall also comply with the applicable component standard for that component.7.1.1 With reference to 7.1, the vehicle connector shall comply with UL 2251 at the normal rated

49、currentbut shall also be tested as part of the overall charging equipment system in accordance with UL 2202under the maximum rated current conditions.7.2 The output cable to the electric vehicle shall comply with 4.2.1. Additionally, the cable shall complywith the requirements in 7.3 and 7.4.STANDARD NUMBER: UL 2202 -5-UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL7.3 In order to determine the suitability of the cable for the voltage it is subject to in use, the cable shallbe subjected to the Dielectric Voltage Withs