Tc Charger Hk-lf-312-20 6.6kw Board Charger High Voltage Instruction Manual

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

Product Information:

Tiecheng Information Technology Co., Ltd

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

Model: HK-LF-312-20, HK-LF-540-14

Name: 6.6KW On-board Charger

Version: V1.0

Issue Date: 2021.1

Website: www.tccharger.com

Product Usage Instructions:

1. Overview

Subject:

This user manual provides information on the usage of the
HK-LF-312-20 and HK-LF-540-14 models of the 6.6KW On-board
Charger.

Main Features:

• Supports UDS diagnosis with CAN wake-up function.
• Full-sealed process, allowing reliable operation in
  temperatures ranging from -40°C to 60°C.
• Built-in thermal sensor that shuts off the charger when the
  temperature reaches 90°C.
• Protection level with IP67 rating.

2. Charger Technical Specification

Environmental Specification:

Charger regulatory requirements and reference
standards:

Please refer to the complete user manual for detailed
instructions and further information.

Tiecheng Information Technology Co., Ltd
5/F, A, No.108 Xiangyuan Rd, Gongshu District, Hangzhou 310015, China
Technical Specification
ModelHK-LF-312-20, HK-LF-540-14 Name6.6KW On-board Charger VersionV1.0 Issue Date2021.1
Tiecheng Information Technology Co., Ltd
www.tccharger.com

Tiecheng Information Technology Co., Ltd
5/F, A, No.108 Xiangyuan Rd, Gongshu District, Hangzhou 310015, China

Version Update Edit

V1.0

Draft

Tianxiang Pan

Audit Approval
Lizhen Tang Hongbin Zhang

Date
2021.1.1

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Tiecheng Information Technology Co., Ltd
5/F, A, No.108 Xiangyuan Rd, Gongshu District, Hangzhou 310015, China
Content 1 Overview …………………………………………………………………………………………………………………………4
1.1 Subject …………………………………………………………………………………………………………………. 4 1.2 Main features ………………………………………………………………………………………………………… 4 2 Charger technical specification …………………………………………………………………………………………. 4 2.1 Environmental requireme ……………………………………………………………………………………….. 4 2.2 Charger regulatory requirements and reference standards ……………………………………………5 3 Charger safety regulations ………………………………………………………………………………………………… 6 4 Charger electrical performance …………………………………………………………………………………………. 6 4.1 Input Performance …………………………………………………………………………………………………. 6 4.2 Output Performance ………………………………………………………………………………………………..6 4.3 Low voltage output performance …………………………………………………………………………….. 7 4.4 Control Interface …………………………………………………………………………………………………….7 4.5 Other ……………………………………………………………………………………………………………………. 7 5 Protection functions ………………………………………………………………………………………………………….8 6 Function Block Diagram ………………………………………………………………………………………………….. 8 7 Control Interface ………………………………………………………………………………………………………………8 7.1 Low voltage connector and pins definition ………………………………………………………………..9
7.1.1 Connector pins definition ……………………………………………………………………………… 9 7.2 High voltage connector and pins definition …………………………………………………………….. 10
7.2.1 AC input connector ……………………………………………………………………………………..10 7.2.2 DC output connector Input connector …………………………………………………………… 10 8 Software Requirement ……………………………………………………………………………………………………. 11 9 Mechanical Requirements ………………………………………………………………………………………………. 11 9.1 Size and weight …………………………………………………………………………………………………….11 9.2 Appearance …………………………………………………………………………………………………………. 11 9.3 Appearance Requirements …………………………………………………………………………………….. 11 10 Installation Size …………………………………………………………………………………………………………… 12 11 Installation Requirement ………………………………………………………………………………………………..12 12 Nameplate, Package, Transport and Storage …………………………………………………………………….13 12.1 Nameplate……………………………………………………………………………………………………….. 13 12.2 Package…………………………………………………………………………………………………………… 13 12.3 Transportation…………………………………………………………………………………………………..13 12.4 Storage……………………………………………………………………………………………………………. 14 12.5 Safe Guide………………………………………………………………………………………………………… 14
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Tiecheng Information Technology Co., Ltd
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1. Overview
1.1 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 is 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 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

2. Charger Technical Specification

2.1 Environmental Specification

Working environmental temperature

Area

Lowest Temperature

Highest Temperature

Global

-40

60

Storage environmental temperature

Area

Lowest Temperature

Highest Temperature

Global

-40

105

Humidityrelative humidity 5%~95%no condensation Altitude5000m Working noisymax when working 65dBmeet China standard QTC 895-2011

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Tiecheng Information Technology Co., Ltd
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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:

No. Standard Code Standard Name

Remark

1

QC/T 895-2011

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 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

/

3. Charger Safety Regulations Specification

Grounding resistance test Input insulation test Output insulation test Input withstand test Output withstand test Input to Output withstand test

Condition @25A/AC @1000V/DC @1000V/DC @2000V/AC 1min @2000V/AC 1min @2000V/AC 1min

Requirement 100m 20M 20M Leak current15ma Leak current10ma Leak current10ma

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4. Charger Electrical Performance

4.1 Input

Input

Input voltage range Frequency
Input Current Power Factor
Efficiency Stand-by power consumption
Starting inrush current

AC 90~265V 47~63Hz 32A
0.98 @ 1650W 93% full loading
5W 48A

4.2 Output

Output

Nominal Voltage Platform Output voltage range Max output current Output power Output way Efficiency CV accuracy CC accuracy
Ripple voltage coefficient Output voltage rising time

Shut off response time

540V

312V

400-680V

200-450V

14A

20A

6600W@220VAC3300W@110VAC

CV/CC

94%

±1%

±2%

±5%

5Sovershoot10%

Current decreased below 10% in 300ms, and decreased to 0A in 500ms

4.3 Low Voltage Output

Output way

Output voltage

Low Nominal current

voltage

Output

CV accuracy

Output Power

Ripple voltage coefficient

CV 12V 5.5A ±2% 66W 1%

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4.4 Control Interface
12V wake-up input 12V wake-up signal output
12V CV CAN Communication
Baud rate Terminal resistance

10mA Max 0.2A Sleep current1mApeak current5A
yes Optional for 125Kbps250Kbps500Kbps
Not available

4.5 Other
EMI EMD Harmonic current Protection level
Vibration resistance
Noisy MTBF

Meet GB/T 18487.3-2001 11.3.1 and GB/T 18655-2018
Meet GB/T 18487.3-2001 11.3.2 and GB/T 18655-2018
Meet GB 17625.1-2003 6.7.1.1
IP67 10~25Hz swing 1.2mm25500Hz 30m/S28hours each
direction 65dB Class A
150000H

5. Charger Protection Functions

Input over-voltage protection

AC270±5V

Input low-voltage protection

AC85±5V

Output over-voltage protection

Stop output when exceed the highest voltage ±5V

Output low-voltage protection

Stop output when below the lowest voltage ±5V

Protectio n

Over-temperature protection

Power start to decrease when internal temperature rise to 85, shut off when rise to 90

unctions

Output short circuit protection

Stop output

Output polarity reverse protection

yes

Grounding protection

100m

CAN Communication protection

Automatically stop output when CAN communication fails

Power-off protection

Yes

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6. Function block diagram

7. Control Interface
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, DC output and HIVL Connectors can be appointed by customer if quantity order is more than 5000pcs.
7.1 Low Voltage Connector and Pins Definition

Brand
Molex
Socket Plug

Pin 10 11 12 13 14 17 Others 348302001 334722006

Definition 12V 5A Output Positive
CAN-H CAN-L HVIL positive HVIL negative GND
NA

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Note

Tiecheng Information Technology Co., Ltd
5/F, A, No.108 Xiangyuan Rd, Gongshu District, Hangzhou 310015, China
7.2 High Voltage Connectors and Pins Definition 7.2.1 AC Input

Brand AMPHENOL
Socket P/N Plug P/N:
7.2.2 OBC Output

Pin 1 2 3 AB HVSL633023A
HVSL633063A106I

Definition N PE L
NC

Brand
TE
Socket P/N: Plug P/N:

Pin
1 2 AB 2103124-5 2103177-5

Definition Positive Negative HVIL

8. Software requirements

8.1 CAN communication

No.

Items

1

Baud rate

CAN bus communication

2

protocol

3

Terminating resistor

Technical indicators
250Kbit/s OR 500 Kbit/s Comply with CAN2.0B
specification No terminating resistor

Notes / / /

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Tiecheng Information Technology Co., Ltd
5/F, A, No.108 Xiangyuan Rd, Gongshu District, Hangzhou 310015, China

9. Mechanical requirements

9.1 Size and weight

Lengthmm

Fan-cooled

302±5

Widthmm 270±2

Heightmm 115.5±3

GWKG 8

9.2 Appearance

Fan-cooled
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.
10. Installation size

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Tiecheng Information Technology Co., Ltd
5/F, A, No.108 Xiangyuan Rd, Gongshu District, Hangzhou 310015, China
11. Installation requirements

Best way to install ( At least 50mm distance off to any obstacle)

Forbidden way to install

Acceptable way to install

12. 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:

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Tiecheng Information Technology Co., Ltd
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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:

No. 1 2

Item On-board Charger
Outboard bill

Qty

Unit

1

pc

1

pc

Remark

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
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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
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References

• 铁城信息科技有限公司