Connecting Power Cables; Battery And Motor Connections - Sevcon Gen4 Applications Reference Manual

Connecting power cables

See also 'EMC guidelines' on page 3-6.

Battery and motor connections

CAUTION: Cables carrying high AC currents are subject to alternating forces and may require
support in the cable harness to avoid long-term fatigue.
Equipment required for size 4 or 6 models:

Cables sized to suit the controller and application (see table below)

M8 crimp ring lugs

Crimp tool

Suitable torque wrench and socket
Torque setting: 11 Nm ± 2 Nm
Equipment required for size 2 models:

Cables sized to suit the controller and application (see table below)

M6 crimp ring lugs

Crimp tool

Suitable torque wrench and socket
Torque setting: 7 Nm ± 1 Nm
Consider cable routing before making connections.

Keep cable runs short

Minimize current loops by keeping positive and negative cables as close together as
possible.

Route cables away from the LED if you intend to make this visible under normal operating
conditions.
Connect your power cables using the bolts supplied. USE THE CORRECT TORQUE. They are
sized to clamp one ring lug thickness. Use a longer bolt if you are fastening more than one ring
lug. You need thread engagement of at least 10 mm and the maximum penetration is 15 mm.
CAUTION: If you use a bolt which is too long, damage to the terminal and overheating of the
connection may occur. If you use a bolt which is too short and there isn't enough thread
engagement you may damage the threads.
CAUTION: 'Bottoming out' a screw in the terminal marked 'B+' will damage the cover leading to
liquid ingress
Doc. # 177/52701
Rev. 3.3
Installation
3-9