ITT CAS25130E-CU User manual

Tethered Lead Charging Cable ACI3-E2
Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -Page 1of 26
OPERATING INSTRUCTIONS
CAS25130E-CU
Tethered Lead Charging Cable ACI3-E2
AC - Electric Vehicle Charging Solution
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Tethered Lead Charging Cable ACI3-E2
Page 2of 26 Operating Instruction – ACI3-E2 – 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
All rights reserved
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-E2
Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -Page 3of 26
REVISION OVERVIEW
Revision
Date
Description
Author
-
13.04.2003
First release
A. Zimmermann
Table 1: Document Revision Table
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Tethered Lead Charging Cable ACI3-E2
Page 4of 26 Operating Instruction – ACI3-E2 – 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 ..............................................................................8
Connector Dimensions ACI3-E2 .......................................................................... 9
General Data of ACI3-E2 Tethered Lead Charging Cable..................................10
Connector Marking ...........................................................................................11
Transportation and Storage .........................................................................12
Delivery.............................................................................................................12
Transportation..................................................................................................12
Storage..............................................................................................................13
Disposal.............................................................................................................13
Installation / Commissioning........................................................................14
Connector Operation ...................................................................................18
Transportation and Storage.............................................................................. 21
Servicing.......................................................................................................22
Checking the Mechanical Components ............................................................22
Checking the Electrical Components ................................................................22
Cleaning the Components ................................................................................23
Disposal.............................................................................................................24
Register Of Illustrations and Tables..............................................................25
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Tethered Lead Charging Cable ACI3-E2
Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -Page 5of 26
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-E2
Page 6of 26 Operating Instruction – ACI3-E2 – 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-E2” 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-E2
Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -Page 7of 26
INTENDED USE
The Tethered Lead Charging Cable described herein is a cord set with an Equipment
Plug ACI3-E2 (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 vehicle.
When operated at a charging station, or wall box, in charging mode 3 case A, a
charging current of up to 63A (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 charging stations according to
IEC 61851.
Figure 1: Description and application of Charging mode 3A
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Tethered Lead Charging Cable ACI3-E2
Page 8of 26 Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -
INFORMATION!
Store the documentation required for operating, maintaining,
and servicing the Tethered Lead Charging Cable “ACI3-E2” 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).
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:
•Equipment Plug - ACI3-E2 Type 2
•Charging cable
Figure 2: Overview of the individual components, mode 3
Item
Designation
Item
Designation
1
Electric Vehicle
4
Charging station
2
Tethered Lead
5
Charging cable
3
Vehicle Connector
Table 2: Individual Components Designation
5
3
1
4
2
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Tethered Lead Charging Cable ACI3-E2
Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -Page 9of 26
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-E2
Figure 3: ACI3-E2 Equipment Plug dimensions (Illustration similar)
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Tethered Lead Charging Cable ACI3-E2
Page 10 of 26 Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -
GENERAL DATA OF ACI3-E2 TETHERED LEAD CHARGING CABLE
Description
Value
Applied standard
DIN EN 62196-1:2015
DIN EN 62196-2:2017
Charging mode
Mode 3 (IEC 61851:2017)
Max. operating temperature
+50 °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-E2
Figure 4: Mating face and pin allocation Equipment Plug
Item
Designation
Item
Designation
4
N (Neutral)
6
PE (Protective Earth)
1
L1 (Line 1)
3
CP (Control Pilot)
5
L2 (Line 2) for 3Phase only
2
PP/CS/CC (Proximity)
7
L3 (Line 3) for 3Phase only
8
Connecting Cable
Table 4: Pin allocation Equipment Plug
2
1
3
4
5
7
6
8
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Tethered Lead Charging Cable ACI3-E2
Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -Page 11 of 26
CONNECTOR MARKING
The type marking is located on the bottom side of the housing.
Figure 5: 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-E2
Page 12 of 26 Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -
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-E2
Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -Page 13 of 26
•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-E2
Page 14 of 26 Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -
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-E2
Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -Page 15 of 26
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 Equipment Plug 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 Equipment Plug, cable, and system after installation
for damage like cuts, broken parts, integrity and dirt or pol-
lution.
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-E2
Page 16 of 26 Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -
NOTICE!
The end of system cable to the connection points at the end
of the single wires (red framed area in Figure 6), must be pro-
tected from dirt and water.
•The single wires of the cable must be installed tension
free inside the vehicle.
•Necessary clearances and creepage distances must be
observed in all installation positions.
•Minimum bending radii of single wires must be observed.
•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 6: Component with required protection
add strain relief
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Tethered Lead Charging Cable ACI3-E2
Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -Page 17 of 26
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-E2
Page 18 of 26 Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -
CONNECTOR OPERATION
The Tethered Lead Charging Cable is used to connect the electric vehicle and the
charging station or the wall box.
1. The Equipment Plug must be plugged into the socket outlet (charging
station).
2. Ensure that Equipment Plug 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 ve-
hicle. Further information can be found in the operating in-
structions of the vehicle.
The vehicle manufacturer 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 Equipment Plug must not
be damaged by sharp metal edges!
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Tethered Lead Charging Cable ACI3-E2
Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -Page 19 of 26
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 Equipment Plug, cable, or charg-
ing station for charging.
•Charging while thunder and lightning is prohibited.
•Unplug the Equipment Plug only when the charging has
been terminated and the Equipment Plug 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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Tethered Lead Charging Cable ACI3-E2
Page 20 of 26 Operating Instruction – ACI3-E2 – Tethered Lead – Rev. -
CAUTION!
Misuse of the Tethered Lead Charging Cable can lead to in-
terruption of charging, disruption of service or even injuries:
•Never use high force to plug and unplug the Equipment
Plug.
•Don’t stress the charging connector with mechanical
load like, pushing or pulling, lean against cable / con-
nector during charging process. Do not pull on Equip-
ment Plug while locked.
•Never run over the cable with any type of vehicle
•Prevent twisting of cable during coil up and reel off
Do not use 3rd party adapters and extension cords.
A falling Equipment Plug could injure the user or any people
and pets around.
•People and pets, (especially babies and children) must
stay in distance while charging process.
•Don’t let the connector drop down.
Protect the Tethered Lead Charging Cable against environ-
mental influences.
•Use dust cap or appropriate parking position to ensure
minimum protection IP24 according to IEC 61851-1.
NOTICE!
Only adult persons with a valid driver’s license for vehicles are
allowed to use the Tethered Lead Charging Cable.
People and pets, (especially babies and children) have to stay
in distance while charging process.
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