ITT CAS25129E-CU User manual

Tethered Lead Charging Cable ACI3-T2
Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -Page 1of 27
OPERATING INSTRUCTIONS
CAS25129E-CU
Tethered Lead Charging Cable ACI3-T2
AC - Electric Vehicle Charging Solution
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Tethered Lead Charging Cable ACI3-T2
Page 2of 27 Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -
IMPRINT
ITT Cannon VEAM Italia S.r.l.
Corso Europa 41/43
20045 Lainate (MI), Italy
Phone: [phone]
ittcannon.com
2023 © ITT Cannon
INFORMATION!
This publication is an integral part of the Technical
Documentation for the “AC e-mobility Interconnect Solution”
and is protected by copyright.
Any use beyond the limits of copyright law without written
permission is forbidden and subject to penalty.
This also applies to reproductions, translations, microfilms, as
well as storage and processing in electronic media. Violations
will give rise to a right to compensation.
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Tethered Lead Charging Cable ACI3-T2
Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -Page 3of 27
REVISION OVERVIEW
Revision
Date
Description
Author
-
13.04.2023
First release
A. Zimmermann
Table 1: Document Revision Table
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Tethered Lead Charging Cable ACI3-T2
Page 4of 27 Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -
TABLE OF CONTENTS
Imprint...........................................................................................................2
Revision Overview .........................................................................................3
Table of Contents...........................................................................................4
Declaration of Conformity..............................................................................5
Information about the Document ..................................................................6
Intended Use..................................................................................................7
Overview and Description ..............................................................................9
Connector Dimensions ACI3-T2 ........................................................................ 10
General Data Tethered Lead Charging Cable....................................................11
Connector Marking ...........................................................................................12
Transportation and Storage .........................................................................13
Delivery.............................................................................................................13
Transportation..................................................................................................13
Storage..............................................................................................................14
Disposal.............................................................................................................14
Installation / Commissioning........................................................................15
Connector Operation ...................................................................................19
Transportation and Storage.............................................................................. 22
Servicing.......................................................................................................23
Checking the Mechanical Components ............................................................23
Checking the Electrical Components ................................................................23
Cleaning the Components ................................................................................24
Disposal.............................................................................................................25
Register Of Illustrations and Tables..............................................................26
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Tethered Lead Charging Cable ACI3-T2
Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -Page 5of 27
DECLARATION OF CONFORMITY
The Tethered lead Charging Cable is in conformity with the relevant harmonization
legislation.
EU-DECLARATION OF CONFORMITY and UK-DECLARATION OF CONFORMITY are
available on request and could be downloaded from ITT Cannon homepage:
ittcannon.com/evc
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Tethered Lead Charging Cable ACI3-T2
Page 6of 27 Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -
INFORMATION ABOUT THE DOCUMENT
This document contains important information about transportation, assembly
(function), installation, operation, maintenance, and disposal of the Tethered Lead
Charging Cable.
CAUTION!
Non-adherence to the information contained in this document may re-
sult in injury or property damage!
Always observe and comply with the warning and safety no-
tices in this document. They are the basic prerequisites for
safe execution of the tasks described in this document. If han-
dled improperly contrary to the specifications in this docu-
ment, the manufacturer will not accept any liability or offer
any refund or compensation. In this case, the operator alone
shall be responsible.
Modifications (of any kind) to components of the Tethered
Lead Charging Cable are strictly forbidden!
This document is intended for the operator or persons authorized by the operator
to perform tasks, such as transportation, assembly (function), installation, opera-
tion, and maintenance, at the Tethered Lead Charging Cable “ACI3-T2” and other
tasks related to the Tethered Lead Charging Cable.
It additionally contains information and instructions regarding the disposal of pack-
aging and transportation material.
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Tethered Lead Charging Cable ACI3-T2
Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -Page 7of 27
INTENDED USE
The Tethered Lead Charging Cable described herein is a cord set with a Vehicle Con-
nector ACI3-T2 (Type 2 acc. to IEC 62196-2). Other side of cable is straight cut cable,
or prepared with customer defined termination, for easy installation into charging
station or into mode 2 cord set.
When operated at a charging station, or wall box; in charging mode 3 case C, a
charging current of up to 63A (depending on the corresponding tethered lead
charging cable) can be supplied for charging electric and hybrid vehicles.
When operated in conjunction with designated In-cable control and protective de-
vice (IC-CPD) or In-cable control (ICCB) in charging mode 2 case B, a charging cur-
rent of up to 32A (depending on the corresponding tethered lead charging cable)
can be supplied for charging electric and hybrid vehicles.
The Tethered Lead Charging Cable has been designed and manufactured using
state-of-the-art techniques and in accordance with approved safety regulations.
Nevertheless, when not used as intended, risks for the user or third parties may still
arise or the tethered lead charging cable and other material assets may be dam-
aged.
Intended use includes:
•Application within the stated performance limits.
•Application when in efficient working order without any damage.
•Application only in conjunction with designated vehicle inlets according
to IEC 62196.
•Application only in conjunction with designated In-cable control and pro-
tective device (IC-CPD) or designated in-cable control box (ICCB) acc. to
IEC 62752.
•Application only in conjunction with charging stations according to
IEC 61851.
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Tethered Lead Charging Cable ACI3-T2
Page 8of 27 Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -
Figure 1: Description and application of Charging mode 2B
Figure 2: Description and application of Charging mode 3C
INFORMATION!
Store the documentation required for operating, maintaining,
and servicing the Tethered Lead Charging Cable “ACI3-T2” at
the point of use, ensuring it is available whenever needed.
Further applicable documents are, for example: Declaration of
Conformity, drawings, wiring plans, specifications and data
sheets, (if available).
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Tethered Lead Charging Cable ACI3-T2
Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -Page 9of 27
OVERVIEW AND DESCRIPTION
The Tethered Lead Charging Cable consists of the following individual components
which - within the overall scope of functioning - represent the interface between
the charging infrastructure and the vehicle being charged:
•Vehicle Connector - ACI3-T2 Type 2
•Charging cable
Figure 3: Overview of the individual components, mode 3
Figure 4: Overview of the individual components, mode 2
Item
Designation
Item
Designation
1
Charging inlet (vehicle)
6
Charging Cable
2
Tethered Lead Cable
7 In-cable control and protective
device (IC-CPD or ICCB)
3
Charging station
4
Vehicle Connector
8
Standard Plug
5
Electric vehicle
9
Standard Socket Outlet
Table 2: Individual Components Designation
4
1
6
5
3
1
6
5
9
4
7
8
2
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Tethered Lead Charging Cable ACI3-T2
Page 10 of 27 Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -
NOTICE!
Observe the cross sections of the signal, power and the pro-
tective earth conductor for installation/commissioning!
Depending on current rating the cross sections differ.
Cross sections can be found in applicable specifications re-
lated to your type of connector.
CONNECTOR DIMENSIONS ACI3-T2
Figure 5: ACI3-T2 Vehicle Connector dimensions (Illustration similar)
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Tethered Lead Charging Cable ACI3-T2
Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -Page 11 of 27
GENERAL DATA TETHERED LEAD CHARGING CABLE
Description
Value
Applied standard
DIN EN 62196-1:2015
DIN EN 62196-2:2017
Charging mode
Mode 2 & 3 (IEC 61851:2017)
Max. operating temperature
+40 °C
Min. operating temperature
-30 °C
Max. operating voltage, depending on Type
250V-AC, 480 V-AC
Rated current, depending on Type
20 A, 32 A, 63 A
Max. application height above sea level
4000 m
Degree of protection
IP24
IP44 (mated with inlet / outlet)
Table 3: Specifications for tethered lead charging cable ACI3-T2
Figure 6: Mating face and pin allocation Vehicle Connector
Item
Designation
Item
Designation
1
Tethered Lead Cable
5
L1 (Line 1)
2
N (Neutral)
6
L3 (Line 3) for 3Phase only
3
CP (Control Pilot)
7
L2 (Line 2) for 3Phase only
4
PP/CS/CC (Proximity)
Table 4: Contact arrangement for ACI3-T2
6
3
2
5
8
4
7
1
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Tethered Lead Charging Cable ACI3-T2
Page 12 of 27 Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -
CONNECTOR MARKING
The type marking is located on the bottom side of the housing.
Graphical expression for identification of vehicles and infrastructures compatibil-
ity for consumer information on EV power supply is located on top Vehicle Con-
nectors
Figure 7: Connector marking
Item
Designation
Item
Designation
1
Manufacturer
5
Conformity marking (EU, UK)
2
Order code
6
VDE marking
3
Characteristics
7
Production site
4
Date of manufacture
Table 5: Connector marking explanation
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Tethered Lead Charging Cable ACI3-T2
Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -Page 13 of 27
TRANSPORTATION AND STORAGE
DELIVERY
INFORMATION!
Always observe the pictograms on the transport packaging
displaying cargo handling information!
The type of packaging may vary depending on the component,
weight, and selected shipping method.
Only store the components in dry, enclosed rooms while ob-
serving the pictograms on the packaging.
Observe the type of delivery!
The components (charging cable) are usually delivered packed in a cardboard box.
Always observe applicable local safety and accident prevention regulations.
Check the delivery!
Check the scope of delivery for completeness using the supplied delivery notes and
order documents (if possible).
Immediately report any missing parts and/or damage to the delivery as a result of
poor packaging or due to transportation to the manufacturer or distributor.
TRANSPORTATION
General information:
•Always observe applicable local safety and accident prevention regula-
tions.
•Specify transportation routes in advance and remove possible obstruc-
tions.
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Tethered Lead Charging Cable ACI3-T2
Page 14 of 27 Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -
•Keep unauthorized persons away from the transportation route and as-
sembly or installation location. Secure affected areas against access by un-
authorized persons.
STORAGE
INFORMATION!
Ensure that packaging and products are not damaged, when
stacked. A packaging unit (pallet) must not be stacked or oth-
erwise loaded with weight during transportation and storage!
Only store the components (pallets) in dry, enclosed rooms
while observing the pictograms on the packaging.
DISPOSAL
NOTICE!
In order to protect the environment, dispose of packaging ma-
terials, such as film or cardboard, according to the applicable
local environmental protection regulations.
Transfer possibly arising residual materials to a certified waste
disposal company.
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Tethered Lead Charging Cable ACI3-T2
Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -Page 15 of 27
INSTALLATION / COMMISSIONING
INFORMATION!
Observe the general, basic, and special safety and warning no-
tices in this document at all times and follow stipulated rules
of conduct.
All persons assigned with the tasks described herein must
have read this document before starting actual work.
DANGER!
Danger of death due to electric shock!
Modifications (of any kind) to components of the Tethered
Lead Charging Cable are strictly forbidden!
In this case, injuries due to an electric shock and/or burns
are possible and may cause immediate death.
Work on live components may only be carried out by in-
structed specialist personnel who have undergone profes-
sional training in the field of mechatronics or electrical engi-
neering.
During installation/commissioning, ensure that the affected
areas (also areas supplied by external sources) are de-ener-
gized and secured against accidental switch-on.
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Tethered Lead Charging Cable ACI3-T2
Page 16 of 27 Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -
CAUTION!
Injury or property damage possible due to incorrect installation / com-
missioning!
Incorrect installation/commissioning can result in damage to
the components or faults during subsequent operation.
Foresee a safe mounting bracket in system to ensure safe
storage of Vehicle Connector while not used for charging.
Installation/Commissioning may only be carried out by the
operator (or the operator’s specialist personnel) or by spe-
cialist personnel specifically trained by the operator.
Check Vehicle Connector, cable, and system after installa-
tion for damage like cuts, broken parts, integrity and dirt or
pollution.
Conduct electrical safety testing on Vehicle Connector, ca-
ble, and system after installation.
Use appropriate tools and equipment to ensure correct in-
stallation and prevent accidents.
For safety of Personnel:
•Always wear personal protective equipment when
working on the system,
•Comply with relevant accident prevention regulations,
•Comply with the occupational health regulations,
•Comply with the generally recognized safety rules.
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Tethered Lead Charging Cable ACI3-T2
Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -Page 17 of 27
NOTICE!
The end of system cable to the connection points at the end
of the single wires (red framed area in Figure 8), must be pro-
tected from dirt and water.
•The single wires of the cable must be installed tension
free inside the charging station, ICCB or IC- CPD.
•Necessary clearances and creepage distances must be
observed in all installation positions.
•Incorrect use caused by torsional stress together with
simultaneous expansion of cable should be avoided.
•Observe the cross sections of the signal conductors,
power conductors, and the protective earth conductor
for installation/commissioning! (see connector specifica-
tion)
•Minimum bending radii of single wires must be observed.
Static application--------------------------------- 5 x D
Dynamic application--------------------------- 15 x D
Important: Cable sheath, and single wires must not be
damaged by sharp metal edges!
Figure 8: Component with required protection
add strain relief
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Tethered Lead Charging Cable ACI3-T2
Page 18 of 27 Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -
INFORMATION!
The protective earth conductor, power lines, signal lines are
connected using a cable lug, clamped connection or through
crimping.
Also see connector specification for cable cross section, wir-
ing, and color coding.
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Tethered Lead Charging Cable ACI3-T2
Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -Page 19 of 27
CONNECTOR OPERATION
The Tethered Lead Charging Cable is used to connect the electric vehicle and the
charging station or the Standard Socket Outlet.
1. The Vehicle Connector must be plugged into the charging inlet (vehicle).
2. For Mode 2B the Standard Plug (IC-CPD cord set) must be plugged into the
standard socket outlet (AC supply network).
3. Ensure that Vehicle Connector is completely engaged. The charging cable
must not be stretched.
INFORMATION!
The operating concept of the AC charging system can only be
described in conjunction with the operating concept of the
charging station or IC-CPD cord set. Further information can
be found in the operating instructions of the charging station.
The charge post operating company has to ensure the use of
the system in accordance with local regulations and law.
NOTICE!
Observe the minimum bending radii of the cables when the
Tethered Lead Charging Cable is in use.
Static application--------------------------------- 5 x D
Dynamic application--------------------------- 15 x D
Incorrect use caused by torsional stress together with simul-
taneous expansion of cable should be avoided.
Important: Cable sheath and Vehicle Connector must
not be damaged by sharp metal edges!
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Tethered Lead Charging Cable ACI3-T2
Page 20 of 27 Operating Instruction – ACI3-T2 – Tethered Lead – Rev. -
DANGER!
Danger of death due to electric shock!
Injuries due to an electric shock and/or burns are possible
and may cause immediate death.
•Always check the Tethered Lead Charging Cable and
contacts for damage and contamination before use.
•Never use a damaged Vehicle Connector, Standard Plug,
cable, IC-CPD or ICCB cord set, vehicle inlet or charging
station for charging.
•Charging while thunder and lightning is prohibited.
•Unplug the Standard Plug and Vehicle Connector only
when the charging has been terminated and the Vehicle
Connector is unlocked.
•Take safety measures to protect users if using Tethered
Lead Charging Cable within laboratory, test setups and
not qualified systems
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