UL SUBJECT 2849-2016 UL Outline of Investigation for Electric Bicycles Electrically Power Assisted Cycles (EPAC Bicycles) Electric Scooters and Electric Motorcycles (Issue 3).pdf

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1、UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULNOVEMBER 11, 20161UL 2849Outline of Investigation for Electric Bicycles, Electrically Power AssistedCycles (EPAC Bicycles), Electric Scooters, and Electric MotorcyclesIssue Number: 3November 11,

2、2016Summary of TopicsThis third issue of the Outline of Investigation for Electric Bicycles,Electrically Power Assisted Cycles (EPAC Bicycles), Electric Scooters,and Electric Motorcycles, UL 2849, covers the expansion of the scope tocover electric bicycles that are not pedalec type, electric scooter

3、s, andelectric motorcycles. Electric scooters and electric motorcycles referto vehicles that are intended for use over road ways. Further, this newissue of the outline covers requirements for battery packs and chargers,including the correlation of the charger and battery combination.ULs Outlines of

4、Investigation are copyrighted by UL LLC. Neither 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 prope

5、rty of ULLLC.COPYRIGHT 2016 UL LLCUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULNOVEMBER 11, 2016UL 28492No Text on This PageUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULCONTENTSINT

6、RODUCTION1 Scope .52 Components 53 Units of Measurement .64 Undated References 65 Glossary .6CONSTRUCTION6 General 77 Connection to Supply Source .87.1 General .87.2 Off board chargers 87.3 On board chargers 98 Personnel Protection Systems 99 Bonding of the Vehicle .109.1 General 109.2 Bonding conne

7、ctions .1010 Double Insulation .1111 Safety Circuits and Safety Analysis .1212 Enclosures .1413 Materials .1413.1 Nonmetallic materials .1413.2 Metallic materials .1514 Flammability .1615 Spacings and Separation of Circuits 1616 Printed Wiring Boards .1817 Internal Wiring and Terminals 1818 Transfor

8、mers .1918.1 General .1918.2 Coil insulation 2019 Fuses .2220 Capacitors .2221 Strength of Enclosures 2322 Sharp Edges .2323 Battery Packs 2324 Operator Interface 2325 Motors and Motor Controllers 2326 Mounting 24PERFORMANCE27 General 2428 Input Test 2529 Leakage Current 2530 Capacitor Discharge Tes

9、t 2831 Temperature Test .2832 Dielectric Strength Test 3033 Isolation Resistance Test 32NOVEMBER 11, 2016 UL 2849 3UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL34 Humidity Conditioning .3235 Abnormal Operations Tests 3335.1 General .3335.2

10、Transformer burnout test 3435.3 Transformer overload test .3635.4 Flanged bobbin transformer abnormal test .3735.5 Capacitor faults 3935.6 Electrolytic capacitor faults 3935.7 Component fault tests 4035.8 Forced ventilation/blocked ventilation .4036 Vibration Test 4037 Impact Test 4138 Environmental

11、 Tests 4138.1 Water exposure test 4138.2 Thermal cycling 4239 Motor Assistance Control - Pedalec .4340 Startup Assistance Mode Test 4341 Maximum Assistance Speed .4342 Mold Stress 4343 Permanence of Marking .44MARKINGS44 General 4445 Nameplate and Identification .4546 Cautionary Markings 45INSTRUCTI

12、ONS47 General 4648 Instructions Pertaining to Risk of Fire, Electric Shock, or Injury To Persons 4649 Installation Instructions 4850 Operating Instructions .4851 User Maintenance Instructions .4952 Moving and Storage Instructions 49NOVEMBER 11, 2016UL 28494UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR

13、FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULINTRODUCTION1 Scope1.1 This Outline covers the electrical systems of eBikes, electric scooters, and electric motorcycles.EBikes are defined as both Pedalec (pedal assist) and non-Pedalec types. Electric scooters and electricmotorcycles ar

14、e intended for over the road use.1.2 This Outline covers the on board electrical system, vehicle systems (which includes the combinationof chargers and batteries) of eBikes, electric scooters, and electric motorcycles. When the battery ischarged while integrated in the vehicle, the charging function

15、 is included in the scope of this Outline. If thebattery is removed from the vehicle for charging, then the charging function is outside the scope of thisOutline, however, the requirements for the charger still apply.1.3 This Outline does not cover any other electrically powered vehicle other than e

16、Bikes, electricscooters, and electric motorcycles, as defined within this document. Electrically powered scooters that arenot intended for road use and are intended for personal mobility are covered under the Standard forElectrical Systems for Personal E-Mobility Devices, UL 2272.1.4 Requirements co

17、ntained in 16 CFR Part 1512, Requirements for Bicycles, apply to eBikes.Verification of compliance with 16 CFR Part 1512 is outside the scope of this Outline.1.5 Federal Motor Vehicle Safety Standards (FMVSS) outlined under 49 CFR, Chapter V, apply to electricscooters and electric motorcycles. Compl

18、iance with these FMVSS documents is outside the scope of thisOutline.2 Components2.1 A component of a product covered by this Outline shall comply with the requirements for thatcomponent.2.2 A component is not required to comply with a specific requirement that:a) Involves a feature or characteristi

19、c not required in the application of the component in theproduct covered by this Outline; orb) Is superseded by a requirement in this Outline.2.3 A component shall be used in accordance with its rating established for the intended conditions ofuse.2.4 Specific components are incomplete in constructi

20、on features or restricted in performance capabilities.Such components are intended for use only under limited conditions, such as certain temperatures notexceeding specified limits, and shall be used only under those specific conditions.NOVEMBER 11, 2016 UL 2849 5UL COPYRIGHTED MATERIAL NOT AUTHORIZ

21、ED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL3 Units of Measurement3.1 Values stated without parentheses are the requirement. Values in parentheses are explanatory orapproximate information.4 Undated References4.1 Any undated reference to a code or standard appearing in the r

22、equirements of this Outline shall beinterpreted as referring to the latest edition of that code or standard.5 Glossary5.1 For the purpose of this Outline the following definitions apply.5.2 CHARGER An off board or on board device that converts grid power to DC power for charging theon board battery.

23、5.3 eBIKE An electrical/mechanical vehicle provided with pedals that includes an electric motor to eitherassist the rider when pedaling (pedalec versions) or provide motive power to the wheels when the rideris not pedaling.5.4 ELECTRICAL SYSTEM, ONBOARD All electrical components located on the vehic

24、le including, butnot limited to, the motor, motor controller, interface/controls, battery pack and charging circuitry (whichmay include an on board charger).5.5 ENCLOSURE That portion of a unit that reduces the accessibility of a part that involves a risk offire, electric shock or injury to persons,

25、 or reduces the risk of propagation of flame, sparks, and moltenmetal initiated by an electrical disturbance occurring within.5.6 END-OF-DISCHARGE VOLTAGE (EODV) The voltage, under load, of the cell or battery at the endof discharge. The EODV may be specified, as in the case of a voltage terminated

26、discharge, or simplymeasured in the case of a time-controlled discharge.5.7 LIVE PART A conductive part, such as metal, within the unit that during intended use has a potentialdifference with respect to earth ground or any other conductive part.5.8 MOTORCYCLE, ELECTRIC A two or three wheeled electri

27、c vehicle that includes a seat for therider. The rider is intended to straddle the vehicle while riding. No pedals are included and the throttlecontrols the propulsion action. These vehicle types are suitable for over the road use.5.9 PEDALEC A version of an eBike where the motor only operates when

28、the pedals are being usedby the rider. The motor stops when the rider stops pedaling or when the eBike reaches a maximum speedof 20 mph (32.2 kph).5.10 RISK OF ELECTRIC SHOCK A risk of electric shock is considered to exist at any exposed livepart of a product or system if the available open-circuit

29、potential is higher than 42.4 volts peak or 60 V dcand the available current through a 1500-ohm resistance is more than 5 milliamperes.NOVEMBER 11, 2016UL 28496UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL5.11 RISK OF ELECTRICAL ENERGY HIGH

30、 CURRENT The capability for damage to property orinjury to persons, other than by electric shock, from available electrical energy exists when between a livepart and an adjacent dead metal part or between live parts of different polarity, there exists a potential of2 volts or more and either an avai

31、lable continuous power level of 240 volt-amperes or more, or a reactiveenergy level of 20 joules or more. For example, a tool, or other metal short-circuiting a component causesa risk of a burn or a fire when enough energy is available at the component to vaporize, melt, or morethan warm the metal.5

32、.12 SCOOTER, ELECTRIC A two- or three-wheeled electric vehicle that includes a flat section orfootrests for the riders feet, a seat for the rider, and a pass-through type design for the footrest portionwhich is located lower than the seat. No pedals are included and the throttle controls the propuls

33、ionaction. These vehicle types are suitable for over the road use.5.13 VEHICLE SYSTEM The combination of the on board electrical system (without an on boardcharger) and an off board charger.CONSTRUCTION6 General6.1 EBikes consist of both pedalec and non-pedalec types, but in all cases functional ped

34、als shall beprovided. For pedalec type eBikes, the motor shall disengage its assist function when the eBike achievesa maximum speed of 20 mph (32.2 kph), or if the user stops pedaling, whichever occurs first. Fornon-pedalec versions of eBikes, the motor is not required to disengage when the user sto

35、ps pedaling, butthe maximum speed is limited to 20 mph. The maximum speed shall be controlled in either case. Anon-pedalec type eBike may be provided with a pedalec mode. Additionally, the motor shall not exceed750 W (1 hp).6.2 Electric scooters and electric motorcycles shall not be provided with pe

36、dals and are provided with aseat for the rider to sit on during operation. There is no maximum speed associated with these vehicles.Operation is controlled through the throttle and the user is not required to act in any other manner topropel the vehicle other than manipulation of the throttle contro

37、l.6.3 Charging of the battery may occur with the battery installed on the vehicle, with the battery removedfrom the vehicle, or a combination of the two. If the battery must be removed for charging, the chargingfunction of the electrical system is not considered by these requirements. If the battery

38、 may be optionallyremoved for charging, but on board charging can occur, this Outline covers the on board chargingfunction.6.4 For portions of the electrical system located on the vehicle, all equipment shall be evaluated asoutdoor use equipment. Outdoor use equipment shall comply with all the requi

39、rements in this Outline asapplicable to outdoor use equipment operating at a maximum altitude of 6562 feet (2000 m) and over anambient temperature range of -3C to 40 C (-22F to 104F). For equipment located off board the vehicle,such as chargers, the equipment may be for indoor or outdoor use. Outdoo

40、r use is assumed unless theequipment is marked in accordance with 46.3. Indoor use only equipment shall comply with all therequirements in this Outline as applicable to indoor use equipment operating at a maximum altitude of6562 feet and over an ambient temperature range of 0C to 40C (32F to 104F).N

41、OVEMBER 11, 2016 UL 2849 7UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL6.5 For off board chargers, the equipment may be permanently connected or cord connected to thesupply source. Permanently connected chargers are fixed in place and subje

42、cted to the applicable indooror outdoor use requirements indicated in this Outline. Cord connected chargers are considered movable,but shall be designated as indoor use only, or shall be evaluated to the outdoor use requirements in thisOutline.6.6 The requirements in this Outline are based on the le

43、vel of exposure to risks. For the risk of electricshock or the risk of electrical energy high current (see 5.10 and 5.11 respectively), an enclosure isrequired to protect the user from contact with the components or circuits that are involved. If the voltageor energy is less than the limits specifie

44、d in 5.10 or 5.11, then a hazard is not considered to exist and therequirements that address risk mitigation for those hazards need not apply.7 Connection to Supply Source7.1 General7.1.1 The connection to the supply source is dependent on whether an off board charger is used or anon board charger i

45、s used. For off board chargers where the battery is charged on the vehicle, therequirements in 7.2 apply. For on board chargers where the battery is charged on the vehicle, therequirements in 7.3 apply.7.2 Off board chargers7.2.1 For eBikes and electric scooters intended to be charged by an off boar

46、d charger, the off boardcharger shall comply with one of the following. For electric motorcycles, the off board charger shall complywith item (a) only:a) The Standard for Electric Vehicle (EV) Charging System Equipment, UL 2202.b) The Standard for Power Units Other Than Class 2, UL 1012.c) The Stand

47、ard for Class 2 Power Units, UL 1310.d) The Standard for Information Technology Equipment Safety Part 1: GeneralRequirements, UL 60950-1, along with the relevant Part 2 Standard as applicable.7.2.2 For off board chargers that comply with 7.2.1 (c), no hazard exists at the output of the charger andre

48、quirements to mitigate a shock hazard or an electrical energy-high current hazard may be reduced asdescribed in 6.6. Personnel protection in accordance with Section 8 is not required.7.2.3 Off board chargers that comply with 7.2.1 (a), (b), or (d) are not necessarily limited at the outputand the req

49、uirements for hazard mitigation apply. Personnel protection in accordance with Section 8 shallbe provided.NOVEMBER 11, 2016UL 28498UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL7.3 On board chargers7.3.1 For vehicles intended to be provided with an on board charger, AC supply power shall beconductively connected to the vehicle through an acceptable means as indicated in 7.3.2.7.3.2 AC power shall be delivered to eBikes and electric scooters using any of the following. AC powershall b