REVISION HISTORY REVISION NUMBER. DATE PAGE CONTENTS New 28-May-2015

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1 Title 1 11

2 REVISION HISTORY REVISION NUMBER DATE PAGE CONTENTS New 28-May

3 Scope This standard specifies EVFC whose rated voltage is 500V DC and breaking capacity is 10000A (hereinafter referred to as "fuse-link" ) that is used in the electric vehicle, the hybrid electric vehicle and so on. 2.Classification The fuse-links shall be classified as shown in Table 1. Table 1 Classification Rated current Part number 60A *0 The mark* of the Part number is to confirm the latest number on the drawing. Dimension Value a 41.5 b 60.0 c 73.0 d 6.5 e 14.0 f 20.0 g 0.6 See drawing in detail Figure 2 Fuse shape

4 3. Construction 4 11 The construction of the fuse-link and the name of each component are shown in Figure 2. Figure 2 Structural drawing of the fuse-link 4.Attention in the use (1)Use the nut or bolt, flat washer and spring washer which are shown by Figure 3 or corresponding. Give the fusebox guide for prevention of the terminal s twist when the terminals are fastened. (2)The tightening torque shall be performed slowly as much as possible within the specified torque range after temporary fastening by bolts on both sides. (3)At the tightening as above-mentioned, the difference of elevation between both tightening faces shall be below 0.5 in case that the tightening face in the counter portion does not match with fuse-link. (4) Confirm the way of tightening and strength of terminal in actual fusebox has no problem. (5) Do not use the fuse which was dropped Arc extinguishing 5.Evaluation items and test items 5.1 Evaluation items (1) Appearance (6) Temperature rise (2) Terminal tightening strength (7) Pre-arcing time (3) Identification/Ampere marking (8) Breaking capacity (4) Temperature characteristics (9) Withstand voltage (5) Voltage drop 5.2 Test items (1) Current cycling test (4) High temperature/high humidity (2) Transient current cycling durability test (5) Temperature/Vibration (3) Resistance against thermal shock The evaluation and test items may be changed after discussion among the related sections.

5 Test conditions The tests of the fuse-link shall be conducted under the following conditions unless otherwise specified. (1) Carry out all electrical tests at a temperature of (23 3), a relative humidity (RH) of 45% to 85 %, an atmospheric pressure of 860 hpa to 1,060 hpa with still air. (2) Mount the fuse-links so that the terminal surface is horizontal using the test module as specified in Figure 3. Nuts tighten at the torque as shown in Table 2. (3) In case the test is conducted while supplying current to the fuse-links, connections shall be made to the fuse-links as shown in Figure 3using not less than 600 mm of copper cable as specified in Table 3. (4) Carry out the tests at a test voltage of (14.0±0.3) V DC. Temperature rise measuring points Voltage drop measuring points Cable Thermosetting resin Figure 3 Test module Table 2 Tightening torque Table 3 Connecting cable size Nut size Tightening torque Rated current Cable size M6 9 1 N m 60A 5sq.mm

6 Test procedures and sequence Endurance test Test sequence, evaluation items and number of samples before/after each test shall be in accordance with Table 4. Table 4 Test sequence Initial performance Number of samples (I.c. shows the total of each test.) (1) Appearance (2) Terminal tightening strength (3) Identification/Ampere marking (4) Temperature characteristics (5) Voltage drop (6) Temperature rise (7) Pre-arcing time * (8) Breaking capacity *2 3 *2 3 *2 3 *2 3 *2 3 *2 (9) withstand voltage Notes 1. Evaluation and test items, number of samples may be changed after discussion among the related sections. 2. The sequence of Initial characteristics shall be as follows: each test each evaluation items 3.*1: Carry out the pre-arcing time test by n=3 each to the test current (6points). 4.-: Not required 5.*2: Carry out the pre-arcing time test at 7000A by n=1 and 10000A by n=2 each to the test currents.

7 8. Evaluating methods and test methods 8.1 Evaluating methods Appearance 7 11 Perform with the visual inspection and the touch under the illumination of 300 Lx or more Terminal tightening strength Tighten the terminals in test module as shown in Figure 3 with the tightening torque as specified in Table 2 10 times Identification/Ampere marking Perform with the visual inspection under the illumination of 300 Lx or more Temperature characteristics Subject the fuse-link to the operating time rating test in environments at ( 20 1), (24 3), and (80 1). Calculate a rate of change in fuse current carrying capacity to ambient temperature on the basis of Voltage drop The Voltage drop are calculated by multiplying the voltage drop which shall be measured between the points as shown in Figure 3 after the temperature is saturated and supplied currents. The supplying currents are equal to rated current Temperature rise The temperature rise shall be measured at the temperature-rise measuring points as shown in Figure 3 after supplying 100 % of rated current Pre-arcing time The pre-arcing times of the fuse-link shall be performed with supplying test currents which specified in Table 5. 1) Check whether the fuse-link operates or not after supplying a current equal to 110 % of the rated current for 4hours. 2) Measure pre-arcing time in the test currents of 135%, 150%, 200%, 300% and 500%, at a test voltage of 500V DC. All current Table 5 Supplying current of pre-arcing time measurement (%) Percentage of the fuse-link's rated current Breaking capacity The interrupting currents of 2,000A, 3,000A, 7,000A and 10,000Aover shall be applied at release voltage of 500 V DC min. to the fuse-link. The test circuit shall be in accordance with Figure 4. After the test, the following shall be confirmed. Check the appearance during and after operation. Measure pre-arcing times. It can be calculated by dividing squared each breaking capacity current by Pre-arcing I 2 t. Confirm if there is a current carrying for 180 seconds or more after operation. Measure the insulation resistance between terminals by 500V insulating resistance meter. The rise time of the test current shall not exceed 2.5 milliseconds. See Figure 5, Pre-arcing and operating current-wave example.

8 Switch Current meter Adjustable resister 8 11 Battery or Power Supply fuse-link Voltage meter Figure 4 Example of breaking capacity test circuit Current-wave example Pre-arcing Operating Arcing time Figure 5 Pre-arcing and operating current-wave example Withstand voltage Wrap around the case with an aluminum foil as shown in Figure 6 and apply a commercial frequency of 2,700V AC between the terminal and aluminum foil (the case) for 1 minute. Wrap all around the case with an aluminum foil as avoiding the caps Figure 6 Test method of withstand voltage 8.2 Test methods Current cycling test Mount the fuse-links on the test module and supply them with a current in the current cycling pattern as shown in Figure 3 20,000 times repeatedly. The test contents may be changed after discussion among the related sections Elapsed time (sec) cycle Figure 7 Current cycling

9 Transient current cycling durability test Mount the fuse-links on the test module and supply them with a current in the current cycling pattern as shown in Figure 8 50,000 times repeatedly. The test contents may be changed after discussion among the related sections cycle Figure 8 Transient current cycling Resistance against thermal shock Mount the fuse-link on the test module and subject them to 1,000 thermal shock cycles as shown in Figure 9. One cycle consists of: (a) 1h at a temperature of 40, (b) 1h at the temperature of h 1h Within 30sec Within 30sec 1 cycle Figure 9 Thermal shock cycle High temperature/high humidity Mount the fuse-links on the test module and subject them at chamber temperature (85 3) for 1,000 hours at 93 % to 97 % relative humidity. After that, remove the fuse-links and leave them until it returns to ordinary temperature.

10 Temperature/Vibration test Mount the fuse-link on the vibration tester as shown in Figure 10 and apply a simple harmonic motion to the fuse-links under the conditions as specified in Table 7 The motion shall be applied for 100 hours in each of the three mutually perpendicular directions, two of which shall be horizontal (total 300 hours). Figure 10 Vibration tester Items Vibration acceleration Vibration frequency Sweep time Table7 Temperature/vibration Conditions 44.1 m/s 2 (4.5G) constant Hz Test temperature 80 3 Current-carrying cycle 3 min. (Log sweep) Current equal to 50% of the rated current One cycle: 45 min. ON/15 min. OFF

11 9.Criteria The criteria shall be in accordance with Table 8 and Table 8 Criteria No. Items Criteria 1 Appearance The fuse-links shall be free from defects harmful to use such as flaws, cracks, burr and rust. Also, there shall be no looseness between the element and the case and no leakage of arc-extinguishing sand. 2 Terminal tightening There shall be no defects such as deformation and breakage that strength would be impaired functionality. 3 Identification/Amper The identification and the ampere marking shall be e marking recognizable clearly. 4 Temperature The ratio of temperature variation in rated current shall characteristics exceed 0.13% per 1degC. In the initial and after each test, the 5 Voltage drop power losses shall not exceed the spec values. Spec value 350mV In the initial and the after each test, the 6 Temperature rise temperature rise ( t) at the terminal case shall not exceed the spec values. Spec value 60degC 7 Pre-arcing time 8 Breaking capacity Before the endurance tests See Table 9,No.8-, and After the endurance tests No.9 The fuse-link shall be free from defects harmful to use such as fire evolution, breakage and deformation during and after operati on. See Table 10. Not to carry any current After the test the fuse-links shall meet the requirements specified in No.1, 3, 9 and 10 of the criteria. Interrupting resistance shall be more than 1M 9 Withstand voltage There shall be no dielectric breakdown. Table 9 Pre-arcing time Test current A Pre-arcing time s Min. Max. 110% of rat ed current 4h - 135% of rated current % of rated current % of rat ed current % of rated current % of rated current Table 10 Pre-arcing time Test current A Pre-arcing time ms Min. Max. 2000A A A A - 1

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