YPES-15-1197Ever3 - Yazakicharge.yazaki-group.com/english/pdf/YPES-15-1197E.pdf · 125 A max. 3 A...

Yazaki Corporation

Yazaki Parts Co., Ltd.

Established: 2010.November 10Revision: 2012.June 15

YPES-15-1197E

Instruction Manual forDC Vehicle Connector

Information in this instruction manual issubject to change without prior notice.

5

Conforms to JEVS G105.

Conforms to CSA C22.1 No.182.2.

Refer to Product Standard on YPES-11-04-213

　　o Safety Precautions 　P2～P4

　　o Part Names and Functions 　P5～P8

　P9～P12

　　o Periodic checks 　P13

　P14～P20

DC Vehicle Connector

Contents

Thank you very much for purchasingYAZAKI DC Vehicle Connector.

Please read this manual carefully tofully understand the contents for safeand correct use of the connector.

It is recommended to always keep thismanual readily available.

Description of each sign

Conforms to IEC 62196-1.

　　o Specifications and Circuit Diagram

　o How to Use Your Connector

* The connector is designed exclusively for the CHAdeMO system. Do NOT use the connector for other purposes.

Conforms to UL 2251.

Indicates a situation in whichimproper handling may causeinjury or property damage.(minor injuries/burns that needno hospitalization; or damage toproperty including residentialbuildings, household goods,livestock, and pets)

Indicates a situation in whichimproper handling may causedeath or major property damage.(in particular, blindness, burns,electric shock, broken bones)

Warning

Caution

4

(2/20)

　This may result in fire, electric shock, or injury.

　This may result in fire or electric shock.



　This may result in electric shock or injury.

　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.

Stop charging immediately. Ensure that it has stopped emitting smoke. Then, consult thedealer from whom you purchased the connector.

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.

(The cable assembly must not be modified or forcibly bent. It should not be put close tohigh temperature parts. No heavy objects should be placed on top. Furthermore, it shouldnot become caught between two objects.)

Do NOT use the connector at voltage higher than its voltage rating.

Do NOT use damaged cable, or do NOT damage cables.

Do NOT use the connector if there is smoke, strange noises or odorcoming from the connector.

Do NOT disassemble/repair/modify the connector.

Ensure to turn off the power before maintenance.

1.Safety Precautions

NEVER disassemblethe product.

NEVER pull the connector out forcibly during charging.

(3/20)

　This may result in electric shock or fire.

　If it becomes damaged, injury, electric shock, or fire may occur.

　Electrical shock, fire, or injury may occur due to failure/breakage.

　Injury, electrical shock, or fire may occur due to deformation/breakage.

　This may result in breakage, electric shock, or fire.

　Before using the connector, ensure that there are no foreign objects.

If you drop the connector, into a puddle, etc., please consult the dealer from whom you purchased the connector.

Warning

If the main unit becomes damaged, stop charging immediately. Then, consult the dealer from whom you purchased the connector.

The connector has a waterproof rating of IP44 when completely engaged and latched.

　This may result in electric shock.

　This may result in fire.

Do NOT put the connector near fire.

Do not subject the main unit to shock during charging.

Do NOT touch any of the terminals.

Do NOT step on the connector. Do NOT let vehicles run over the connector.

The connector must not be submerged in water or any other fluid.

DO NOT TOUCH

Be careful NOT to drop the connector.

During charging, do NOT step on or lean against the connector. In addition, do NOT place any object on it.

Ensure that no foreign objects enter the engagement interface.

2

Do not touch

5

(4/20)

This may result in electric shock, injury, or burns.

This may result in injury.

　This may result in a serious accident.

　The charging functional parts may become damaged.

　This may result in injury or low temperature burns.

　This may result in injury or burns.

　

　This may result in injury.

　This may result in burns or low temperature burns.

Warning

　　　 Caution: Improper handling may cause injury or property damage.

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.

Current leakage may occur from the connection. It must be used within the reach of the cable.

The connector is heavy; care must be taken when handling it.

Do NOT use extension cables.

Do NOT use the connector outside the ambient temperature range of -40C to +60C.

Do NOT store the connector at ambient temperature of -40C or less.

Keep the connector away from children.

Do NOT store the connector at ambient temperature of 80C or more.

Return the connector to its holder on the charge station after charging.

Do NOT touch the connector with bare hands regardless of whether or not it is hot or cold.

Be careful not to catch your fingers when operating the lever.

Do NOT drive the car when the connector is connected to the vehicle Inlet.

2

(5/20)

(1) Vehicle Connector

(2) Cap (For certified connectors of CE)

2. Part Names and Functions

Charge Indicator Lamp [Red] (LED)　　It lit while the power is on.

Release Button　　Unlocks the lever to disengage from Vehicle Inlet.

Grip　

Cable

Lever　　Pull the lever to connect to Vehicle Inlet.

Insertion Interface Guide　　Facilitates connection to Vehicle Inlet.

Latch　　Engage with Vehicle Inlet.

When Cap is Attached

Cap　　Prevents entry of foreign objects during storage.

Do NOT use the cap as Vehicle Connector Holder.

Lever Stopper Stops the movement of the lever before insertion.

Back

2

(6/20)

(1) Vehicle Connector

(2) Cap (For certified connectors of CE)

２

Lever Stopper Stops the movement of the lever before insertion.

Back

Charge Indicator Lamp [Red] (LED)　　It lit while the power is on.

Release Button　　Unlocks the lever to disengage from Vehicle Inlet.

Grip

Cable

Lever　　Pull the lever to connect to Vehicle Inlet.Insertion Interface Guide

　　Facilitates connection to Vehicle Inlet.

Latch　　Engage with Vehicle Inlet.

When Cap is Attached

Cap　　Prevents entry of foreign objects during storage.

Do NOT use this cap as Vehicle Connector Holder.2


Lever Holder　　Holds the lever for proper charging.

(7/20)

(3) Vehicle Connector Holder


Recommended mounting angle and dimensionsPart Number: 7225-8888-3W

Install Vehicle Connector Holder to your chargestand with the following mounting dimensions.

・When the connector is stored, pull the lever for securance.

2

2 5

(8/20)

(4) Vehicle Connector Holder

If the holder is not installed with the recommendedmounting angle, the connector may fall off and resultin injury.

If the holder will not installed with the recommendedmounting angle, hold the connector or the cable withsuch a holding tool below.

Part Number：7225-8888-3W

2. Part Names and Functions2

With the holderWithout the holder

HoldingTool

HoldingTool

5 5

(9/20)

　<<Insertion operation>>(1) Open the lid of Vehicle Inlet.

(2)

【CAUTION】

To reduce the risk of equipment damage

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.

【CAUTION】

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.

Hold the grip, then insert into theVehicle Inlet completely using InsertionInterface Guide as a reference.

3. How to Use (Operation procedure)

After charging starts, Charge Indicator Lamp light will glowand the lever will be locked by an electromagnetic solenoid.

Lid

Lever

Grip

InsertionInterfaceGuide

Latch

Vehicle Inlet

ChargeIndicatorLamp

Ensure by pullingthe lever

ReleaseButton

Charge IndicatorLamp

Lever Stopper

Back

(10/20)

　<<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) Press Release Button until

there is an audible click,

to make the lever go back to its

original position.

【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.

How to Use (Operation procedure)

Release Button

Release Button

Grip

Charge IndicatorLamp

2

2

(11/20)

　<<Insertion operation>>　(1) Open the lid of Vehicle Inlet.

(2)

　

　

【CAUTION】

To reduce the risk of equipment damage

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

the lever locks into the holder.

【CAUTION】

If the lever is not locked completely,

the connector may fall out while

charging, and

cause damage to

the connector

or Vehicle Inlet.

Hold the grip, then insert into theVehicle Inlet completely usingInsertion Interface Guide as areference

Charge Indicator Lamp

Grip

Lever

Vehicle Inlet

2

InsertionInterfaceGuide

Latch

Lever Stopper

BackLever Holder

The lever locks

ReleaseButton

After charging starts, Charge Indicator Lamplight will glow and the lever will be lockedby an electromagnetic solenoid.

How to Use (Operation procedure)

(12/20)

　<<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.

【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.

Hold until the lever is released.

Release Button

2

Release Button

Grip

Charge Indicator LampHow to Use (Operation procedure)

(13/20)

2. Maintenance

Clean the connector with a clean, dry cloth.

If the insulation covering of the cable tears and the wires inside becomeexposed, please consult the dealer from whom you purchased the connector.

Warning

Warning

(NEVER use gasoline, benzine, thinner, scouring powder,detergent, etc.; This may cause damage to the connector. )

Ensure to disconnect the charging plug from the outlet before doingperiodic checks or maintenance operations.

Ensure that the connector is not exposed to water. This may result inelectric shock.

1. Periodic ChecksTo reduce the risk of equipment damage or current leakage, ensure thatthere are no foreign objects inside of the insertion interface before usingthe connector.

4. Periodic Checks and Maintenance

(14/20)

Power circuit

Signal circuit

Power circuit

Signal circuit

Power circuit

Signal circuit

* A detailed circuit diagram is provided on page 19.

Wiresused

125 A max.

3 A max.

Voltage 2.5 V, current 20 mA

Coil resistance value 46Ω±10%,service voltage 9 to 16 VDC

2500 V DC applied for 1 min.

5 MΩ or more (500 V DC)

77 (W) x 352 (D) x 184 (H)

1.6 kg(weight of connector excluding cable)

Solenoid

Outside dimensions (mm)

Withstand voltage

Certification acquired

LED

Weight (kg)

Insulation resistance

Type

Ratedvoltage

Ratedcurrent

500 V DC max.

12 V max.

For Japanwith Lever Holder

40mm2×2

0.75mm2×7

7325-8932-4R

－

Part Number

Specifications (For Japan, with Lever Holder)

5. Specifications 2

4

(15/20)

Power circuit

Signal circuit

Power circuit

Signal circuit

Power circuit

Signal circuit


73FD-1200-40　（For CSA）Part Number

2AWG × 2

18AWG × 7

7325-8785-3R　（For UL）

UL 2251

CSA C22.2 No.182.2

Type

Ratedvoltage

Ratedcurrent

500 V DC max.

12 V max.

For UL


Withstand voltage

LED

Weight (kg)



Wiresused

120 A max.

3 A max.

Voltage 2.5 V, Current 20 mA

Coil resistance value 46Ω±10%,service voltage 9 to 16 V DC



77 (W) x 352 (D) x 184 (H)


Solenoid

Specifications (For UL)

1

4

4

(16/20)

Power circuit

Signal circuit

Power circuit

Signal circuit

Power circuit

Signal circuit

* The detailed circuit diagram is provided on page 20.

Wiresused

120 A max.

3 A max.

Voltage 2.5 V, Current 20 mA

Coil resistance value 46Ω±10%,service voltage 9 to 16 V DC



77 (W) x 352 (D) x 184 (H)


Solenoid


Withstand voltage

LED

Weight (kg)



Type

Ratedvoltage

Ratedcurrent

500 V DC max.

12 V max.

For ULwith Lever Holder

2AWG × 2

18AWG × 7

CSA C22.2 No.182.2

UL 2251

73FD-1200-41　(For CSA）

7325-8982-3R　（For UL）Part Number

Specifications (For UL, with Lever Holder)

2

4

4

(17/20)

Power circuit

Signal circuit

Power circuit

Signal circuit

Power circuit

Signal circuit

* The detailed circuit diagram is provided on page 20.

Wiresused

120 A or less

3 A or less



2500 VDC applied for 1 min.

5 MΩ or more (500 VDC)

77 (W) x 352 (D) x 184 (H)


Solenoid


Withstand voltage


LED

Weight (kg)


Type

Ratedvoltage

Ratedcurrent

500 V DC or less

12 V or less

For CE

35 sq × 2

0.75 sq × 7

7325-8786-3R

IEC 62196-1

Part Number

5. Specifications

Specifications (For CE)

1

4

(18/20)

Power circuit

Signal circuit

Power circuit

Signal circuit

Power circuit

Signal circuit


Part Number

35 sq × 2

0.75 sq × 7

7325-8983-3R

IEC 62196-1

Type

Ratedvoltage

Ratedcurrent

500 V DC or less

12 V or less

For CEwith Lever Holder


Withstand voltage


LED

Weight (kg)


Wiresused

120 A or less

3 A or less



2500 VDC applied for 1 min.

5 MΩ or more (500 VDC)

77 (W) x 352 (D) x 184 (H)


Solenoid

Specifications (For CE, with Lever Holder)

1

2

4

4

(19/20)

　 Terminal AssignmentFront view

DC Vehicle Connector (For Japan)(JEVS G105 compliant circuit)

CONNECTOR CIRCUIT（Japan）

2

(20/20)

　 Terminal AssignmentFront view

DC Vehicle Connector (For UL, CSA and CE)(JEVS G105 compliant circuit)

CONNECTOR CIRCUIT（UL, CSA） CONNECTOR CIRCUIT（CE）

YPES-15-1197Ever3 - Yazakicharge.yazaki-group.com/english/pdf/YPES-15-1197E.pdf · 125 A max. 3 A...

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