DC Charging Connector CHV-03 (PDF format : 2.52MB)

YPES-15-1197E
Instruction Manual for
DC Vehicle Connector
Information in this instruction manual is
subject to change without prior notice.
Yazaki Corporation
Yazaki Parts Co., Ltd.
Established: 2010.November 10
5 Revision: 2012.June 15
△
DC Vehicle Connector
* The connector is designed exclusively for the CHAdeMO system.
Do NOT use the connector for other purposes.
 Conforms to JEVS G105.
 Conforms to IEC 62196-1.
 Conforms to UL 2251.
 Conforms to CSA C22.1 No.182.2.
4
△
Refer to Product Standard on YPES-11-04-213
Contents
Thank you very much for purchasing
YAZAKI DC Vehicle Connector.
o Safety Precautions
P2～P4
Please read this manual carefully to
fully understand the contents for safe
and correct use of the connector.
o Part Names and Functions P5～P8
o How to Use
P9～P12
Your Connector
o Periodic checks
P13
It is recommended to always keep this
manual readily available.
o Specifications and
Circuit Diagram
Description of each sign
Indicates a situation in which
improper handling may cause
Warning death or major property damage.
(in particular, blindness, burns,
electric shock, broken bones)
Indicates a situation in which
improper handling may cause
injury or property damage.
Caution (minor injuries/burns that need
no hospitalization; or damage to
property including residential
buildings, household goods,
livestock, and pets)
P14～P20
(2/20)
1.Safety Precautions
Before putting the connector to use, please read the
following precautions carefully and ensure to observe them.
Warning: Improper use may cause death or major
property damage.
 Do NOT disassemble/repair/modify the connector.
This may result in fire, electric shock, or injury.
NEVER disassemble
the product.
 Do NOT use the connector at voltage higher than its voltage rating.
This may result in fire or electric shock.
 Do NOT use damaged cable, or do NOT damage cables.
(The cable assembly must not be modified or forcibly bent. It should not be put close to
high temperature parts. No heavy objects should be placed on top. Furthermore, it should
not become caught between two objects.)
This may result in fire or electric shock.
 Do NOT use the connector if there is smoke, strange noises or odor
coming from the connector.
This may result in fire or electric shock.
Stop charging immediately. Ensure that it has stopped emitting smoke. Then, consult the
dealer from whom you purchased the connector.
 Ensure to turn off the power before maintenance.
This may result in electric shock or injury.
 NEVER pull the connector out forcibly during charging.
This may result in malfunction.
The connector cannot be removed when locked with the vehicle side Inlet.
To remove it, press the unlock button.
When removing the connector, do NOT pull the cable; ensure to hold the grip.
(3/20)
Warning
2
△
 The connector must not be submerged in water or
any other fluid.
The connector has a waterproof rating of IP44 when completely
engaged and latched.
 Do NOT touch any of the terminals.
This may result in electric shock.
 Do NOT put the connector near fire.
DO NOT
TOUCH
Do not
touch
This may result in fire.
 Do not subject the main unit to shock during charging.
This may result in electric shock or fire.
If the main unit becomes damaged, stop charging
immediately. Then, consult the dealer from whom you 5
purchased the connector.
△
 Do NOT step on the connector. Do NOT let vehicles run over
the connector.
If it becomes damaged, injury, electric shock, or fire may occur.
 Be careful NOT to drop the connector.
Electrical shock, fire, or injury may occur due to failure/breakage.
If you drop the connector, into a puddle, etc., please consult the dealer
from whom you purchased the connector.
 During charging, do NOT step on or lean against the connector.
In addition, do NOT place any object on it.
Injury, electrical shock, or fire may occur due to deformation/breakage.
 Ensure that no foreign objects enter
the engagement interface.
This may result in breakage, electric shock, or fire.
Before using the connector, ensure that there are no foreign objects.
(4/20)
Warning
 Keep the connector away from children.
This may result in electric shock, injury, or burns.
 The connector is heavy; care must be taken when handling it.
This may result in injury.
 Do NOT use extension cables.
Current leakage may occur from the connection. It must be used within the reach of the
cable.
 Do NOT drive the car when the connector is connected to the vehicle Inlet.
This may result in a serious accident.
Caution: Improper handling may cause injury or property damage.
 Do NOT use the connector outside the ambient temperature range of -40C to +60C.
The charging functional parts may become damaged.
 Do NOT store the connector at ambient temperature of -40C or less.
This may result in injury or low temperature burns.
 Do NOT store the connector at ambient temperature of 80C or more.
This may result in injury or burns.
2
△
Return the connector to its holder on the charge station after charging.
This product is suitable for outdoor installation but ensure that the connector holder
is installed in a place where it will not be exposed directly to rain or snow;
This may cause product failure.
 Be careful not to catch your fingers when operating the lever.
This may result in injury.
 Do NOT touch the connector with bare hands regardless of whether or not
it is hot or cold.
This may result in burns or low temperature burns.
(5/20)
2. Part Names and Functions
(1) Vehicle Connector
Charge Indicator Lamp [Red] (LED)
It lit while the power is on.
Release Button
Unlocks the lever to disengage
from Vehicle Inlet.
Latch
Engage with
Vehicle Inlet.
Cable
Grip
Lever
Pull the lever to connect to
Vehicle Inlet.
Insertion Interface Guide
Facilitates connection to
Vehicle Inlet.
Lever Stopper
Stops the movement of
the lever before insertion.
Back
2
△
(2)
Cap (For certified connectors of CE)
When Cap is Attached
 Do NOT use the cap as Vehicle Connector Holder.
Cap
Prevents entry of foreign
objects during storage.
(6/20)
２
(1)
2. Part Names and Functions
Vehicle Connector
Charge Indicator Lamp [Red] (LED)
It lit while the power is on.
Release Button
Unlocks the lever to disengage
from Vehicle Inlet.
Grip
Latch
Engage with
Vehicle Inlet.
Cable
Lever Holder
Holds the lever for
proper charging.
Lever
Pull the lever to connect to
Vehicle Inlet.
Insertion Interface Guide
Facilitates connection to
Vehicle Inlet.
Lever Stopper
Stops the movement of
the lever before insertion.
Back
(2)
Cap (For certified connectors of CE)
When Cap is Attached
2
△
 Do NOT use this cap as Vehicle Connector Holder.
Cap
Prevents entry of foreign
objects during storage.
(7/20)
2. Part Names and Functions
2
△
(3) Vehicle Connector Holder
Install Vehicle Connector Holder to your charge
stand with the following mounting dimensions.
5
2 △
・When the connector is stored, pull the lever △
for securance.
Recommended mounting angle and dimensions
Part Number: 7225-8888-3W
(8/20)
2. Part Names and Functions
2
△
(4) Vehicle Connector Holder
Part Number：7225-8888-3W
If the holder is not installed with the recommended
mounting angle, the connector may fall off and result
in injury.
If the holder will not installed with the recommended
mounting angle, hold the connector or the cable with
such a holding tool below.
5
△
5
△
Holding
Tool
Without the holder
Holding
Tool
With the holder
(9/20)
3. How to Use (Operation procedure)
Lid
<<Insertion operation>>
(1) Open the lid of Vehicle Inlet.
Vehicle Inlet
(2) Hold the grip, then insert into the
Vehicle Inlet completely using Insertion
Interface Guide as a reference.
Insertion
Interface
Guide
Charge
Indicator
Lamp
Release
Button
Latch
Lever Stopper
Lever
Back
【CAUTION】
To reduce the risk of equipment damage
Grip
and failure of engagement:
・ Do not insert the connector
while holding the lever
・ Do not press Release Button
during engagement process
(3) Pull the lever until there is an audible
click and connector does not move.
Charge Indicator
Lamp
【CAUTION】
Ensure by pulling
the lever
If the lever is not pulled completely, the connector
while charging, the connector may fall out and
cause damage to the connector or Vehicle Inlet.
After charging starts, Charge Indicator Lamp light will glow
and the lever will be locked by an electromagnetic solenoid.
(10/20)
How to Use (Operation procedure)
<<Removal operation>>
Charge Indicator
Lamp
(1) Ensure that Charge Indicator
Lamp is off.
Release Button
2 【CAUTION】
△
NEVER pull the connector out
forcibly during charging
This may result in breakage,
electric shock, or injury.
(2) Press Release Button until
there is an audible click,
to make the lever go back to its
Release Button
original position.
Grip
2 【CAUTION】
△
Do not hold the lever while pressing
Release Button.
The lever will not go back to its
original position if you hold it
while pressing the button.
(3) Press and hold Release Button again,
then remove the connector.
(4) Close the lid of Vehicle Inlet until it clicks.
(5) Return the connector to the installation place.
【CAUTION】
Please note that every charging stand has
different installation place.
(11/20)
2
△
How to Use (Operation procedure)
<<Insertion operation>>
(1) Open the lid of Vehicle Inlet.
Vehicle Inlet
Insertion
Interface
Guide
(2) Hold the grip, then insert into the
Vehicle Inlet completely using
Insertion Interface Guide as a
reference
Release
Button
Grip
Latch
Lever Stopper
Lever
【CAUTION】
To reduce the risk of equipment damage
Back
Lever Holder
and failure of engagement:
・ Do not insert the connector
while holding the lever
・ Do not press Release Button
during engagement process
(3) Pull the lever until the edge of the lever is
locked into the holder.
Ensure that there is an audible click as
Charge Indicator Lamp
the lever locks into the holder.
After charging starts, Charge Indicator Lamp
light will glow and the lever will be locked
by an electromagnetic solenoid.
【CAUTION】
If the lever is not locked completely,
the connector may fall out while
charging, and
cause damage to
the connector
or Vehicle Inlet.
The lever locks
(12/20)
2
△
How to Use (Operation procedure)
Charge Indicator Lamp
Release Button
<<Removal operation>>
(1) Ensure that Charge Indicator
Lamp is off.
【CAUTION】
NEVER pull the connector out
forcibly during charging;
This may result in breakage,
electric shock, or injury.
(2) Slide and hold the holder,
then press Release Button,
until there is an audible click,
to make the lever go back to its
original position.
Hold until the lever is released.
【CAUTION】
Do not hold the lever while pressing
Release Button.
The lever will not go back to its
original position
if you hold it while pressing
the button or if the edge of the
lever is placed into the holder.
(3) Press and hold Release Button again,
then remove the connector.
(4) Close the lid of Vehicle Inlet until it clicks.
(5) Return the connector to the installation place.
【CAUTION】
Please note that every charging stand has
different installation place.
Release Button
Grip
(13/20)
4. Periodic Checks and Maintenance
Warning
Ensure to disconnect the charging plug from the outlet before doing
periodic checks or maintenance operations.
1. Periodic Checks
To reduce the risk of equipment damage or current leakage, ensure that
there are no foreign objects inside of the insertion interface before using
the connector.
If the insulation covering of the cable tears and the wires inside become
exposed, please consult the dealer from whom you purchased the connector.
2. Maintenance
Warning
Ensure that the connector is not exposed to water. This may result in
electric shock.
Clean the connector with a clean, dry cloth.
(NEVER use gasoline, benzine, thinner, scouring powder,
detergent, etc.; This may cause damage to the connector. )
(14/20)
2
△
5. Specifications
Specifications (For Japan, with Lever Holder)
Type
For Japan
with Lever Holder
Rated
voltage
Power circuit
500 V DC max.
Signal circuit
12 V max.
Rated
current
Power circuit
125 A max.
Signal circuit
3 A max.
Wires
used
Power circuit
2
40mm ×2
Signal circuit
0.75mm2×7
Outside dimensions (mm)
77 (W) x 352 (D) x 184 (H)
Weight (kg)
1.6 kg(weight of connector excluding cable)
Insulation resistance
5 MΩ or more (500 V DC)
Withstand voltage
2500 V DC applied for 1 min.
Solenoid
Coil resistance value 46Ω±10%,
service voltage 9 to 16 VDC
LED
Voltage 2.5 V, current 20 mA
Certification acquired
－
4
△
Part Number
7325-8932-4R
* A detailed circuit diagram is provided on page 19.
(15/20)
Specifications (For UL)
Type
For UL
Rated
voltage
Power circuit
500 V DC max.
Signal circuit
12 V max.
Rated
current
Power circuit
120 A max.
Wires
used
Power circuit
2AWG × 2
Signal circuit
18AWG × 7
1 3 A max.
△
Signal circuit
Outside dimensions (mm)
77 (W) x 352 (D) x 184 (H)
Weight (kg)
1.6 kg(weight of connector excluding cable)
Insulation resistance
5 MΩ or more (500 V DC)
Withstand voltage
2500 V DC applied for 1 min.
Solenoid
Coil resistance value 46Ω±10%,
service voltage 9 to 16 V DC
LED
Voltage 2.5 V, Current 20 mA
UL 2251
Certification acquired
△
4
Part Number
4
△
CSA C22.2 No.182.2
7325-8785-3R　（For UL）
73FD-1200-40　（For CSA）
* A detailed circuit diagram is provided on page 20.
(16/20)
2
△
Specifications (For UL, with Lever Holder)
For UL
with Lever Holder
Type
Rated
voltage
Power circuit
500 V DC max.
Signal circuit
12 V max.
Rated
current
Power circuit
120 A max.
Signal circuit
3 A max.
Wires
used
Power circuit
2AWG × 2
Signal circuit
18AWG × 7
Outside dimensions (mm)
77 (W) x 352 (D) x 184 (H)
Weight (kg)
1.6 kg(weight of connector excluding cable)
Insulation resistance
5 MΩ or more (500 V DC)
Withstand voltage
2500 V DC applied for 1 min.
Solenoid
Coil resistance value 46Ω±10%,
service voltage 9 to 16 V DC
LED
Voltage 2.5 V, Current 20 mA
UL 2251
Certification acquired
△
4
Part Number
4
△
CSA C22.2 No.182.2
7325-8982-3R　（For UL）
73FD-1200-41　(For CSA）
* The detailed circuit diagram is provided on page 20.
(17/20)
5. Specifications
Specifications (For CE)
Type
For CE
Rated
voltage
Power circuit
500 V DC or less
Signal circuit
12 V or less
Rated
current
Power circuit
120 A or less
Wires
used
Power circuit
35 sq × 2
Signal circuit
0.75 sq × 7
Signal circuit
1 3 A or less
△
Outside dimensions (mm)
77 (W) x 352 (D) x 184 (H)
Weight (kg)
1.6 kg(weight of connector excluding cable)
Insulation resistance
5 MΩ or more (500 VDC)
Withstand voltage
2500 VDC applied for 1 min.
Solenoid
Coil resistance value 46Ω±10%,
service voltage 9 to 16 VDC
LED
Voltage 2.5 V, current 20 mA
Certification acquired
IEC 62196-1
4 Part Number
△
7325-8786-3R
* The detailed circuit diagram is provided on page 20.
(18/20)
2
△
Specifications (For CE, with Lever Holder)
For CE
with Lever Holder
Type
Rated
voltage
Power circuit
500 V DC or less
Signal circuit
12 V or less
Rated
current
Power circuit
120 A or less
Wires
used
Power circuit
35 sq × 2
Signal circuit
0.75 sq × 7
1 3 A or less
△
Signal circuit
Outside dimensions (mm)
77 (W) x 352 (D) x 184 (H)
Weight (kg)
1.6 kg(weight of connector excluding cable)
Insulation resistance
5 MΩ or more (500 VDC)
Withstand voltage
2500 VDC applied for 1 min.
Solenoid
Coil resistance value 46Ω±10%,
service voltage 9 to 16 VDC
LED
Voltage 2.5 V, current 20 mA
Certification acquired
4 Part Number
△
4
△
IEC 62196-1
7325-8983-3R
* A detailed circuit diagram is provided on page 20.
(19/20)
2
△
DC Vehicle Connector (For Japan)
(JEVS G105 compliant circuit)
Terminal Assignment
Front view
CONNECTOR CIRCUIT（Japan）
(20/20)
DC Vehicle Connector (For UL, CSA and CE)
(JEVS G105 compliant circuit)
Terminal Assignment
Front view
CONNECTOR CIRCUIT（UL, CSA）
CONNECTOR CIRCUIT（CE）