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4
Electrical Connection
4.1
Preparing Cables
Determine the heat resistance grade of the cable insulation material based on the ambient temperature. It is recommended that the cables
resist heat of at least 105°C.
Cables for the 15 kW Charger
Recommended Cable Specifications (Choose Any of the
Port
Following)
Cross-sectional area 6 mm
cables able to work for a long term at 105°C)
Cross-sectional area 10 AWG (UL1015 material 105°C)
DC output
power
cable
Cross-sectional area 6 mm
105°C, flexible wire)
Cross-sectional area 4 mm
cables able to work for a long term at 105°C)
AC input
Cross-sectional area 12 AWG (UL1015 material 105°C)
power
cable
Cross-sectional area 4 mm
105°C, flexible wire)
Shielded twisted pair: minimum cross-sectional area 0.08 mm
CAN
maximum cross-sectional area 1.5 mm
communicati
sectional area 28 AWG, wire maximum cross-sectional area 16
ons cable
AWG
Cables for the 20 kW Charger
Port
Recommended Cable Specifications (Choose Any of the Following)
Cross-sectional area 6 mm
DC output power
a long term at 105°C)
cable
Cross-sectional area 10 AWG (UL1015 material 105°C)
Cross-sectional area 6 mm
Cross-sectional area 6 mm
a long term at 105°C)
AC input power
cable
Cross-sectional area 10 AWG (UL1015 material 105°C)
Cross-sectional area 6 mm
CAN
Shielded twisted pair: minimum cross-sectional area 0.08 mm
communications
sectional area 1.5 mm
cable
maximum cross-sectional area 16 AWG
4.2
Preparing Terminals for Connecting Input and Output Power Cables
NOTE
• The metal terminals are delivered together with the DC output terminal and AC input terminal.
• The recommended crimping tool is XCXY-02. The locator model is DWQ-18.
• Recommended heat-shrink tubing diameter for output power cables of the 15 kW charger: 6 mm; recommended temperature resistance:
125°C; recommended baking temperature: 110°C. Recommended heat-shrink tubing diameter for input power cables: 4 mm; recommended
temperature resistance: 125°C; recommended baking temperature: 110°C
• Recommended heat-shrink tubing diameter for the 20 kW charger: 6 mm; recommended temperature resistance: 125°C; recommended
baking temperature: 110°C
• The metal terminals must be reliably crimped. Minimum pulling-out force: 250 N for the cross-sectional area 12 AWG or 280 N for the cross-
sectional area 4 mm
; 300 N for the cross-sectional area 10 AWG or 350 N for the cross-sectional area 6 mm
2
Preparing a DC Output Terminal
After preparing the DC output terminal, connect it to the output port of the charger.
Preparing an AC Input Terminal
After preparing the AC input terminal, connect it to the input port of the charger.
Connecting CAN Communications Cables
4.3
NOTE
• A 120-ohm resistor must be connected in parallel between the cables of the first and last chargers. Otherwise, communication may be poor.
• It is recommended that twisted pairs be used as CAN communications cables.
1. Connect CAN communications cables to the address board.
2
(H07Z-K, UL3386, or equivalent
2
(BVR-ZR-105, flame retardant,
2
(H07Z-K, UL3386, or equivalent
2
(BVR-ZR-105, flame retardant,
2
; wire minimum cross-
2
(H07Z-K, UL3386, or equivalent cables able to work for
2
(BVR-ZR-105, flame retardant, 105°C, flexible wire)
2
(H07Z-K, UL3386, or equivalent cables able to work for
2
(BVR-ZR-105, flame retardant, 105°C, flexible wire)
2
; wire minimum cross-sectional area 28 AWG, wire
3
Remarks
•
If a single cable is used as the output power cable, the
specifications depend on the result of temperature rise test
for cables inside the cabinet. If the maximum cable surface
temperature is lower than 90°C, the specifications meet the
requirements. Otherwise, use two cables.
•
If the AF200 high temperature-resisting cable with the same
cross-sectional area is configured (allowed long-term
temperature: 200°C), a single cable meets the requirements.
-
-
-
2
,
-
Remarks
Two cables are required. If the cable
surface temperature is higher than
90°C, use high temperature-resisting
cables.
If the cable surface temperature is
higher than 90°C, use high
temperature-resisting cables.
2
, maximum cross-
-
.
2
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