UL SUBJECT 2272-2016 UL Outline for Investigation Electrical Systems for Self-Balancing Scooters (Issue 2).pdf

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1、UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULJANUARY 29, 20161UL 2272Outline of Investigation for Electrical Systems for Self-Balancing ScootersIssue Number: 1January 29, 2016Summary of TopicsThis first issue of the Outline of Investigation

2、 for Electrical Systems forSelf-Balancing Scooters, UL 2272, covers the electrical drive train systemincluding the battery and charger system combinations for electric-powered self-balancing scooters as defined in this outline of investigation.ULs Outlines of Investigation are copyrighted by UL. Nei

3、ther a printed norelectronic copy of an Outline of Investigation should be altered in any way. All ofULs Outlines of Investigation and all copyrights, ownerships, and rights regardingthose Outlines of Investigation shall remain the sole and exclusive property of UL.COPYRIGHT 2016 UNDERWRITERS LABORA

4、TORIES INC.UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULJANUARY 29, 2016UL 22722No Text on This PageUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULCONTENTSINTRODUCTION1 Scope .52 Com

5、ponents 53 Units of Measurement .54 Undated References 55 Glossary .5CONSTRUCTION6 Non-Metallic Materials .87 Metallic Parts Resistance to Corrosion .98 Enclosures .99 Wiring and Terminals .1010 Chargers 1211 Fuses .1212 Lighting 1213 Electrical Spacings and Separation of Circuits 1214 Insulation Le

6、vels and Protective Grounding 1415 Protective Circuits and Safety Analysis 1516 Cells 1617 Motors .1718 Manufacturing and Production Line Testing 17PERFORMANCE19 General 1820 Tolerances .1921 Post Test Cycle 2022 Results Criteria .20ELECTRICAL TESTS23 Overcharge Test 2024 Short Circuit Test .2125 Ov

7、erdischarge Test .2226 Temperature Test .2327 Imbalanced Charging Test .2528 Dielectric Voltage Withstand Test .2629 Isolation Resistance Test 28MECHANICAL TESTS30 Vibration Test 2831 Shock Test 3032 Crush Test 3133 Drop Test 3234 Mold Stress Relief Test 3335 Motor Overload Test 3336 Motor Locked Ro

8、tor .34JANUARY 29, 2016 UL 2272 3UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL37 Strain Relief Tests (Cord Anchorages) 3537.1 General .3537.2 Strain relief pull test 3537.3 Push-back test .36ENVIRONMENTAL TESTS38 Water Exposure Tests .3638.

9、1 IPX4 Code rating .3638.2 Partial immersion .3739 Thermal Cycling Test 3840 Label Permanence Test .39MARKINGS41 General 39INSTRUCTIONS42 General 40APPENDIX AStandards for ComponentsA1JANUARY 29, 2016UL 22724UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMI

10、SSION FROM ULINTRODUCTION1 Scope1.1 These requirements cover the electrical drive train system including the battery and charger systemcombinations for electric-powered self-balancing scooters as defined in this outline of investigation.1.2 This outline of investigation is intended for evaluation of

11、 the safety of the electrical drive train systemand battery and charger combination and does not evaluate the performance or reliability of thesedevices. In addition, it does not evaluate the overall safety of the self-balancing scooters.2 Components2.1 A component of a product covered by this outli

12、ne of investigation shall comply with the requirementsfor that component. See Appendix A for a list of standards covering components generally used in theproducts covered by this outline of investigation.3 Units of Measurement3.1 Values stated without parentheses are the requirement. Values in paren

13、theses are explanatory orapproximate information.4 Undated References4.1 Any undated reference to a code or standard appearing in the requirements of this outline ofinvestigation shall be interpreted as referring to the latest edition of that code or standard.5 Glossary5.1 BATTERY A generic term for

14、 one or more cells electrically connected in series and/or parallel withor without monitoring and protection circuitry for charging and discharging.5.2 BATTERY PACK Batteries that are ready for use in a self-balancing scooter, contained in aprotective enclosure, with protective devices, with a batte

15、ry management system, and monitoring circuitryand that may be removable by the user for charging separately from the scooter.5.3 BATTERY SYSTEM Battery system includes the battery, charger and monitoring and protectioncircuit for charging and discharging of the battery.5.4 CAPACITY, RATED The total

16、number of ampere-hours that can be withdrawn from a fully chargedbattery at a specific discharge rate to a specific end-of-discharge voltage (EODV) at a specifiedtemperature as declared by the manufacturer.5.5 CASING The container that directly encloses and confines the electrolyte, and electrodes o

17、f a cell.5.6 CELL The basic functional electrochemical unit (sometimes referred to as a battery) containing anelectrode assembly, electrolyte, separators, container, and terminals. It is a source of electrical energy bydirect conversion of chemical energy.JANUARY 29, 2016 UL 2272 5UL COPYRIGHTED MAT

18、ERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL5.7 CHARGING The application of electric current to battery terminals, which results in a Faradicreaction that takes place within the battery that leads to stored electro-chemical energy.5.8 CHARGING, CONSTANT CUR

19、RENT (CC) Charging mode where current is held constant whilecharging voltage is allowed to vary.5.9 DUT Device under test.5.10 ELECTRIC SHOCK HAZARD A potential for exposure of persons to hazardous voltage circuitsthrough direct contact from openings in protective enclosures and/or insufficient insu

20、lation betweenhazardous voltage circuits and accessible parts.5.11 ELECTROLYTE LEAKAGE A condition where liquid electrolyte escapes through an opening in adesigned vent as well as through a rupture or crack or other unintended opening in the casing orenclosure of a cell or capacitor and is visible e

21、xternal to the DUT.5.12 ENCLOSURE The outer cover of device that provides protection to its contents.5.13 END-OF-DISCHARGE VOLTAGE (EODV) The voltage, under load, of the cell or battery at theend of discharge. The EODV may be specified, as in the case of a voltage terminated discharge, or simplymeas

22、ured in the case of a time-controlled discharge.5.14 EXPLOSION A violent release of energy that produces projectiles or an energy wave from theDUT and results in the DUTs contents being forcibly expelled through a rupture in the enclosure orcasing.5.15 FIRE The sustained combustion of the DUTs conte

23、nts as evidenced by flame, heat and charringor other damage of materials.5.16 FULLY CHARGED A battery which has been charged per the manufacturers specifications to itsfull state of charge (SOC).5.17 FULLY DISCHARGED A battery, which has been discharged, according to the manufacturersspecifications,

24、 to its specified end of discharge voltage (EODV).5.18 HAZARDOUS VOLTAGE Voltage exceeding 30 Vrms/42.4 Vac peak or 60 Vdc.5.19 INSULATION LEVELS The following are levels of electrical insulation:a) BASIC A single level of insulation that provides protection against electric shock. Basicinsulation a

25、lone may not provide protection from electric shock in the event of a failure of theinsulation.b) DOUBLE INSULATION Insulation comprising both basic insulation and supplementaryinsulation.c) FUNCTIONAL INSULATION Insulation that is necessary only for the correct functioning ofthe equipment. Function

26、al insulation by definition does not protect against electric shock. It may,however, reduce the likelihood of ignition and fire.JANUARY 29, 2016UL 22726UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULd) REINFORCED INSULATION Single insulation

27、system that provides a degree of protectionagainst electric shock equivalent to double insulation under the conditions specified in thisoutline of investigation. The term insulation system does not imply that the insulation has tobe in one homogeneous piece. It may comprise several layers that canno

28、t be tested as basicinsulation and supplementary insulation.e) SUPPLEMENTARY INSULATION Independent insulation applied in addition to basicinsulation in order to reduce the risk of electric shock in the event of a failure of the basicinsulation.5.20 NORMAL OPERATING REGION That region of voltage, cu

29、rrent and temperature within which acell can be safely charged and discharged repetitively throughout its anticipated life. The manufacturerspecifies these values, which are then used in the safety evaluation of the device and may vary as thedevice ages. The normal operating regions will include the

30、 following parameters for charging anddischarging as specified by the manufacturer:a) CHARGING TEMPERATURE LIMITS The upper and lower limits of temperature, specifiedby the manufacturer for charging of the cell. This temperature is measured on the casing.b) DISCHARGE TEMPERATURE LIMITS The upper and

31、 lower limits of temperature,specified by the manufacturer for discharging the cell. This temperature is measured on thecasing.c) END OF DISCHARGE VOLTAGE Refer to 5.13.d) MAXIMUM DISCHARGING CURRENT The maximum discharging current rate, which isspecified by the cell manufacturer.e) MAXIMUM CHARGING

32、 CURRENT The maximum charging current in the normal operatingregion, which is specified by the cell manufacturer. This value may vary with temperature.f) UPPER LIMIT CHARGING VOLTAGE The highest charging voltage limit in the normaloperating region specified by the cell manufacturer. This value may v

33、ary with temperature.5.21 ROOM AMBIENT Considered to be a temperature in the range of 25 5C (77 9F).5.22 RUPTURE A mechanical failure of the DUTs enclosure/casing from either internal or externalcauses, that results in spillage and/or exposure of internal contents of the DUT, but does not result inp

34、rojectiles and violent energy release such as occurs during an explosion.5.23 SAFETY CRITICAL CIRCUITS/COMPONENTS Those circuits or discrete components that arerelied upon for safety as identified in the safety analysis of 15.2.5.24 SELF-BALANCING SCOOTER A consumer mobility device with a rechargeab

35、le electric drive trainthat the rider balances on while in motion, and which may be provided with a handle for grasping whileriding.JANUARY 29, 2016 UL 2272 7UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL5.25 STATE OF CHARGE (SOC) The availa

36、ble capacity in a pack, module or cell expressed as apercentage of rated capacity.CONSTRUCTION6 Non-Metallic Materials6.1 The materials employed for enclosures shall comply with the applicable enclosure requirementsoutlined in the Standard for Polymeric Materials Use in Electrical Equipment Evaluati

37、ons, UL 746C, PathIII of the Enclosure Requirements in Table 4.1, except as modified by this outline of investigation.6.2 Polymeric materials employed for enclosures shall have a minimum flame rating of V-1 in accordancewith the Standard for Tests for Flammability of Plastic Materials for Parts in D

38、evices and Appliances, UL94.Exception: The enclosure may alternatively be evaluated to the 20 mm end product flame test inaccordance with the Standard for Polymeric Materials Use in Electrical Equipment Evaluations, UL746C.6.3 The following factors in (a) (e) are taken into consideration when an enc

39、losure employingnonmetallic materials is being judged. For a nonmetallic enclosure all of these factors are to be consideredwith respect to thermal aging. Dimensional stability of a polymeric enclosure is addressed by complianceto the mold stress relief test. Suitability to factors (a) (e) below may

40、 be determined by the tests of thisoutline of investigation.a) Resistance to impact;b) Crush resistance;c) Abnormal operations;d) Severe conditions; ande) Mold-Stress Relief Distortion.6.4 The polymeric materials employed for enclosures and insulation shall be suitable for anticipatedtemperatures en

41、countered in the intended application. Enclosures shall have a Relative Thermal Index(RTI) with impact suitable for temperatures encountered in the application but no less than 80C (176F),as determined in accordance with the Standard for Polymeric Materials Long Term PropertyEvaluations, UL 746B.6.5

42、 The enclosure materials intended to be directly exposed to sunlight and rain in the end useapplication shall comply with the UV Resistance and the Water Exposure and Immersion tests inaccordance with the Standard for Polymeric Materials Use in Electrical Equipment Evaluations, UL746C.JANUARY 29, 20

43、16UL 22728UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL6.6 Materials employed as electrical insulation in the assembly shall be resistant to deterioration thatwould result in an electrical shock, fire or other safety hazard. Compliance is d

44、etermined by the tests ofthis outline of investigation. Materials employed for direct support of live parts at hazardous voltage, shalladditionally meet the direct support insulation criteria outlined in the Material Property Considerations,Table 6.1, in the Standard for Polymeric Materials Use in E

45、lectrical Equipment Evaluations, UL 746C,unless employed as part of a component that has been evaluated to a suitable component standard.Insulated wiring is subjected to the requirements outlined in Section 9, Wiring and Terminals.6.7 Gaskets and seals relied upon for safety, shall be determined sui

46、table for the environmentalconditions and chemical substances they are anticipated to be exposed to in their end use.7 Metallic Parts Resistance to Corrosion7.1 Metal enclosures shall be corrosion resistant. A suitable plating or coating process can achievecorrosion resistance. Additional guidance o

47、n methods to achieve corrosion protection can be found in theStandard for Enclosures for Electrical Equipment, Environmental Considerations, UL 50E.7.2 Metal enclosures may be provided with an insulating liner to prevent shorting of live parts to theenclosure. If using an insulating liner for this p

48、urpose, the insulating liner shall consist of non-moistureabsorbent materials that have a temperature rating suitable for temperatures during operation includingcharging.7.3 Conductive parts in contact at terminals and connections shall not be subject to corrosion due toelectrochemical action.8 Encl

49、osures8.1 The enclosure shall have the strength and rigidity required to resist the possible physical abuses thatit will be exposed to during its intended use, in order to reduce the risk of fire or injury to persons.8.2 A tool providing the mechanical advantage of a pliers, screwdriver, hacksaw, or similar tool, shall bethe minimum mechanical capability required to open the enclosure.8.3 Openings in the enclosure shall be designed to prevent inadvertent access to hazardous parts.Com