Amendment 1 19 December 2017 To AIS-038 (Rev.1) Electric Power Train Vehicles-Construction and Functional Safety Requirements 1 Page 5/19
Amendment 1 19 December 2017 To AIS-038 (Rev.1) Electric Power Train Vehicles-Construction and Functional Safety Requirements 1 Page 5/19
Amendment 1 19 December 2017 To AIS-038 (Rev.1) Electric Power Train Vehicles-Construction and Functional Safety Requirements 1 Page 5/19
to
AIS-038(Rev.1)
Electric Power Train Vehicles-Construction and Functional Safety
Requirements
1 Page 5/19
3.3.5 There shall also be an optical / visual indication to the driver when state of
charge of the REESS reaches a level where re-charging is recommended, this
indication shall remain ON, even if the vehicle is restarted, till the vehicle is
charged above the charge level where re-charging is recommended. In case
vehicle has an indicator or display which shows continuously the state-of-
charge (SOC) level of REESS to the driver, the provision of indication
mentioned in this clause is optional.
PRINTED BY
THE AUTOMOTIVE RESEARCH ASSOCIATION OF INDIA
P. B. NO. 832, PUNE 411 004
ON BEHALF OF
AUTOMOTIVE INDUSTRY STANDARDS COMMITTEE
UNDER
CENTRAL MOTOR VEHICLES RULES - TECHNICAL STANDING COMMITTEE
SET-UP BY
MINISTRY OF ROAD TRANSPORT & HIGHWAYS
(DEPARTMENT OF ROAD TRANSPORT & HIGHWAYS)
GOVERNMENT OF INDIA
Page 1 of 1
AIS-038(Rev.1):2015
PRINTED BY
THE AUTOMOTIVE RESEARCH ASSOCIATION OF INDIA
P.B. NO. 832, PUNE 411 004
ON BEHALF OF
AUTOMOTIVE INDUSTRY STANDARDS COMMITTEE
UNDER
CENTRAL MOTOR VEHICLE RULES – TECHNICAL STANDING COMMITTEE
SET-UP BY
MINISTRY OF ROAD TRANSPORT & HIGHWAYS
(DEPARTMENT OF ROAD TRANSPORT & HIGHWAYS)
GOVERNMENT OF INDIA
February 2015
I
AIS-038(Rev.1):2015
General Remarks:
II
AIS-038(Rev.1):2015
INTRODUCTION
The Government of India felt the need for a permanent agency to expedite the
publication of Standards and development of test facilities in parallel when the
work of preparation of Standards is going on, as the development of improved
safety critical parts can be undertaken only after the publication of the Standard
and commissioning of test facilities. To this end, the erstwhile Ministry of Surface
Transport (MOST) has constituted a permanent Automotive Industry Standard
Committee (AISC) vide order no. RT-11028/11/97-MVL dated September 15,
1997. The Standards prepared by AISC will be approved by the permanent
CMVR Technical Standing Committee (CTSC) after approval, The Automotive
Research Association of India, (ARAI), Pune, being the secretariat of the AIS
Committee, has published this Standard. For better dissemination of this
information, ARAI may publish this standard on their website.
This standard prescribes the requirements for the construction and functional safety
of Electric Power Train Vehicles.
Considerable assistance has been taken from UN ECE R 100 (Supplement 1 to the
02 series of amendments, Date of entry into force: 10.06.14 Excluding Part II
Applicable for safety requirements for Rechargeable Energy Storage System
(REESS),): Uniform Provisions Concerning the Approval of Vehicles with regard
to Specific Requirements for the Electric Power Train
The AISC panel and the Automotive Industry Standards Committee (AISC)
responsible for preparation of this standard are given in Annex E and Annex F
respectively.
III
AIS-038(Rev.1):2015
Contents
2 Definitions 1/19
List of Annexes
Annex A Protection against direct contacts of parts under voltage 9/19
IV
AIS-038(Rev.1):2015
2 DEFINITIONS
Refer AIS-049:2003, as amended and revised from time to time, for the
definitions.
The protection against direct contact with live parts shall comply with
paragraphs 3.1.1.1. and 3.1.1.2. These protections (solid insulator, barrier,
enclosure, etc.) shall not be able to be opened, disassembled or removed
without the use of tools.
3.1.1.1 For protection of live parts inside the passenger compartment or luggage
compartment, the protection degree IPXXD as given in Annex A shall be
provided.
3.1.1.2 For protection of live parts in areas other than the passenger compartment
or luggage compartment, the protection degree IPXXB as given in
Annex A shall be satisfied.
3.1.1.3 Connectors
(a) They comply with 3.1.1.1. and 3.1.1.2. when separated without the
use of tools, or
(b) They are located underneath the floor and are provided with a
locking mechanism, or
(c) They are provided with a locking mechanism and other
components shall be removed with the use of tools in order to
separate the connector, or
(d) The voltage of the live parts becomes equal or below DC 60V or
equal or below AC 30V (rms) within one second after the
connector is separated.
3.1.1.5 Marking
3.1.1.5.1 In the case of a REESS having high voltage capability the symbol shown
in Figure 1 shall appear on or near the REESS. The symbol background
shall be yellow, the bordering and the arrow shall be black.
Figure 1
Marking of High Voltage Equipment
3.1.1.5.2 The symbol shall also be visible on enclosures and barriers, which,
when removed expose live parts of high voltage circuits. This
provision is optional to any connector for high voltage buses.
This provision shall not apply to any of the following cases:
3.1.1.5.3 Cables for high voltage buses which are not located within enclosures
shall be identified by having an outer covering with the colour orange.
3.1.2.1 For protection against electrical shock which could arise from indirect
contact, the exposed conductive parts, such as the conductive barrier
and enclosure, shall be galvanically connected securely to the electrical
chassis by connection with electrical wire or ground cable, or by
welding, or by connection using bolts, etc. so that no dangerous
potentials are produced.
3.1.2.2 The resistance between all exposed conductive parts and the electrical
chassis shall be lower than 0.1 ohm when there is current flow of at
least 0.2 amperes. This requirement is satisfied if the galvanic
connection has been established by welding.
3.1.2.3 In the case of motor vehicles which are intended to be connected to the
grounded external electric power supply through the conductive
connection, a device to enable the galvanical connection of the
electrical chassis to the earth ground shall be provided. The device
should enable connection to the earth ground before exterior voltage is
applied to the vehicle and retain the connection until after the exterior
voltage is removed from the vehicle. Compliance to this requirement
may be demonstrated either by using the connector specified by the car
manufacturer, or by analysis.
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AIS-038(Rev.1):2015
The isolation resistance between the high voltage bus and the electrical
chassis may be demonstrated by calculation, measurement or a
combination of both.
3.1.3.4 Isolation resistance requirement for the coupling system for charging the
REESS
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AIS-038(Rev.1):2015
3.3.1 At least a momentary indication shall be given to the driver when the
vehicle is in "active driving possible mode''.
3.3.2 When leaving the vehicle, the driver shall be informed by a signal (e.g.
optical or audible signal) if the vehicle is still in the active driving
possible mode. The condition shall be deemed to be satisfied if the
indication specified in 3.3.1 above is not momentary and continues to be
displayed.
3.3.3 If the on-board REESS can be externally charged by the user, vehicle
movement by its own propulsion system shall be impossible as long as
the connector of the external electric power supply is physically
connected to the vehicle inlet. This requirement shall be demonstrated by
using the connector specified by the car manufacturer.
3.3.4 The state of the drive direction control unit shall be identified to the
driver.
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The test as per 3.5.1, 3.5.2 and 3.5.3 shall be performed. After each
exposure (vehicles still wet), the vehicle shall then comply with the
isolation resistance test with at least 100 /V of nominal voltage, but
keeping the power equipment connected to the REESS (main switch
closed), and before water test isolation resistance with at least 500 /V of
nominal voltage.
These tests shall not apply to vehicles having chassis connected electrical
circuits where the maximum voltage between any live part and the electrical
chassis or any exposed conductive part does not exceed 30V AC (rms) or 60
V DC.
3.5.1 Washing
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AIS-038(Rev.1):2015
The test uses a hose nozzle according to IPX5 as specified in IEC 60529
(Refer Annex-D for details). Using fresh water with a flow rate of
12.5 l/min, all borderlines shall be exposed and followed in all directions
with the water stream at a speed rate of 0.1 m/s, keeping a distance of 3 m
between the nozzle aperture and the borderline.
3.5.2 Flooding
This test is intended to simulate the driving of an Electric Power Train
vehicles on flooded streets or in water puddles.
If the wade pool used is less than 500 m in length, so that it has to be
driven through several times, the total time including the periods outside
the wade pool shall be less than 10 min.
The critical areas of the vehicle regarding this test are those accessible with
opened opening parts.
This test uses a spray nozzle according to IPX3 as specified in IEC 60529.
Using fresh water with a flow rate of 10 l/min, all surfaces with normally
open opening parts shall be exposed for 5 min, possibly through a regular
movement of the spray nozzle.
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5.1 General guidelines for transitional provisions for this standard shall be as
per AIS-000, as amended from time to time, as applicable, with the
following additional requirements.
5.2.1 Requirement set out in 3.1.1.3 with respect to protection against Electric
Shock (Connectors)
5.2.2 The Cables for high voltage buses which are located underneath the
vehicle floor shall be identified by having an outer covering with the
colour orange. (Requirements set out in 3.1.1.5.3)
5.2.4 The clause 3.1.2.3 for motor vehicles intended to be connected to the
grounded external electric power is met.
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AIS-038(Rev.1):2015
ANNEX-A
(See 3.1.3.1)
1 ACCESS PROBES
Access probes to verify the protection of persons against access to
hazardous parts are given in Table 1.
2 TEST CONDITIONS
The access probe is pushed against any openings of the enclosure with
the force specified in Table 1. If it partly or fully penetrates, it is placed in
every possible position, but in no case shall the stop face fully penetrate
through the opening.
A low-voltage supply (of not less than 40 V and not more than 50 V) in
series with a suitable lamp should be connected, if necessary, between the
probe and live parts inside the barrier or enclosure.
The signal-circuit method should also be applied to the moving live parts
of high voltage equipment.
3 ACCEPTANCE CONDITIONS
The access probe shall not touch live parts.
In the case of the test for IPXXB, the jointed test finger may penetrate to
its 80 mm length, but the stop face (diameter 50 mm x 20 mm) shall not
pass through the opening. Starting from the straight position, both joints
of the test finger shall be successively bent through an angle of up to 90
degree with respect to the axis of the adjoining section of the finger and
shall be placed in every possible position.
In case of the tests for IPXXD, the access probe may penetrate to its full
length, but the stop face shall not fully penetrate through the opening.
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TABLE – 1
ACCESS PROBES FOR THE TESTS FOR PROTECTION OF PERSONS
AGAINST ACCESS TO HAZARDOUS PARTS
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Figure 1
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ANNEX- B
(See 3.1.3.1)
ISOLATION RESISTANCE MEASUREMENT METHOD
FOR VEHICLE BASED TESTS
1 GENERAL
The isolation resistance for each high voltage bus of the vehicle shall be
measured or shall be determined by calculation using measurement values
from each part or component unit of a high voltage bus (hereinafter
referred to as the "divided measurement").
2 MEASUREMENT METHOD
In cases where the measured values are not stable due to the operation of
the on-board isolation resistance monitoring system, etc., necessary
modification for conducting the measurement may be carried out, such as
stopping of the operation of the device concerned or removing it.
Furthermore, when the device is removed, it shall be proven, using
drawings, etc., that it will not change the isolation resistance between the
live parts and the electrical chassis.
Utmost care shall be exercised as to short circuit, electric shock, etc., for
this confirmation might require direct operations of the high-voltage
circuit.
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AIS-038(Rev.1):2015
The voltmeter used in this test shall measure DC values and shall have an
internal resistance of at least 10 MΩ.
Figure 1
Measurement of Vb, V1, V2
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Measure and record the voltage (V1) between the negative side of the high
voltage bus and the electrical chassis (see Figure 1).
Measure and record the voltage (V2) between the positive side of the high
voltage bus and the electrical chassis (see Figure 1).
Figure-2
Measurement of V1’
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AIS-038(Rev.1):2015
Figure-3
Measurement of V2 ’
Note: The standard known resistance Ro (in Ω) should be the value of the
minimum required isolation resistance (in Ω/V) multiplied by the
working voltage of the vehicle plus/minus 20 per cent (in volts).
Ro is not required to be precisely this value since the equations are
valid for any Ro; however, a Ro value in this range should provide
good resolution for the voltage measurements.
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AIS-038(Rev.1):2015
ANNEX C
(See 3.1.3.3)
Insert a resistor that does not cause the isolation resistance between the
terminal being monitored and the electrical chassis to drop below the
minimum required isolation resistance value. The warning shall be
activated.
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ANNEX – D
(See 3.5.1)
This Annex specifies dimensionally the hose nozzle to be used for IPX5 test
procedure as specified in IEC 60529 (All dimensions are in mm).
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ANNEX E
(See Introduction)
COMPOSITION OF AISC PANEL ON
ELECTRIC POWER TRAIN VEHICLES- CONSTRUCTION
AND FUNCTIONAL SAFETY REQUIREMENTS*
Convener
Mr. A.A. Deshpande The Automotive Research Association of India
(ARAI)
Members Representing
Mr. M. M. Desai The Automotive Research Association of India
(ARAI)
Mr. D. P. Saste/ Mr. Central Institute of Road Transport (CIRT)
Karthikeyan K (Alternate)
Representative from International Centre for Automotive Technology
(ICAT)
Mr. Vinod Kumar Vehicle Research & Dev. Estt. (VRDE)
Dr. N. Karuppaiah National Automotive Testing and R&D
Infrastructure Project (NATRIP)
Mr. K. K. Gandhi Society of Indian Automobile Manufacturers (SIAM)
Mr. T. M. Balaraman Society of Indian Automobile Manufacturers (SIAM)
(Hero Moto Corp Ltd.)
Mr. Adish Agrawal Society of Indian Automobile Manufacturers (SIAM)
(Hero Moto Corp Ltd.)
Mr. Rajendra Khile Society of Indian Automobile Manufacturers (SIAM)
(General Motors)
Mr. Kiran Mulki Society of Indian Automobile Manufacturers (SIAM)
(Mahindra and Mahindra)
Mr. K. Kiran Kumar Society of Indian Automobile Manufacturers (SIAM)
(Mahindra Reva)
Mr. Vijeth R Gatty Society of Indian Automobile Manufacturers (SIAM)
(Toyota Kirloskar Motors Ltd.)
Mr. Firoz Khan Society of Indian Automobile Manufacturers (SIAM)
(Tata Motors Ltd.)
Mr. Vivekraj S Society of Indian Automobile Manufacturers (SIAM)
(Renault Nissan)
Mr. P. C. Joshi Bureau of Indian Standards (BIS)
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ANNEX F
(See Introduction)
COMMITTEE COMPOSITION *
Automotive Industry Standards Committee
Chairperson
Mrs. Rashmi Urdhwareshe Director
The Automotive Research Association of India, Pune
Members Representing
Representative from Ministry of Road Transport and Highways
(Dept. of Road Transport and Highways), New Delhi
Representative from Ministry of Heavy Industries and Public
Enterprises
(Department of Heavy Industry), New Delhi
Shri S. M. Ahuja Office of the Development Commissioner, MSME,
Ministry of Micro, Small and Medium
Enterprises, New Delhi
Shri Shrikant R. Marathe Former Chairman, AISC
Shri N. K. Sharma Bureau of Indian Standards, New Delhi
Director/ Shri D. P. Saste Central Institute of Road Transport, Pune
(Alternate)
Director Indian Institute of Petroleum, Dehra Dun
Director Vehicles Research and Development
Establishment, Ahmednagar
Representatives from Society of Indian Automobile Manufacturers
Shri T. C. Gopalan Tractor Manufacturers Association, Chennai
Shri Uday Harite Automotive Components Manufacturers Association
of India, New Delhi
Member Secretary
Mr. A. S. Bhale
General Manager
The Automotive Research Association of India, Pune
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