Blue Smart IP22 Charger

The Blue Smart IP22 Charger range features rising clamp screw terminals for connection to DC power cabling, which is not included and needs to be supplied by the installer.

To ensure optimal and reliable operation, it is important to select high quality flexible DC power cabling that is suitable for the specific charger model and the overall installation; DC power cable selection should consider the following aspects:

1. Cable size/gauge

   Conductor cross sectional area is proportional to the resistance of a cable per unit length, which effects the amount of heat generated per unit length and the voltage drop over the total cable length.

   1. Current carrying capacity

      Current carrying capacity is the maximum current a cable size/gauge can carry in a particular installation environment without exceeding the temperature limit of the cable insulation; accordingly current carrying capacity is dependent on cable size/gauge, the installation environment and the insulation temperature limit.

      To prevent overheating of the DC power cable and/or interfacing equipment, the maximum current rating for the selected cable size/gauge (including any de-rating applicable to the installation) must exceed the maximum normal operating current and also the rating of the fuse or circuit breaker installed (in case of an overcurrent fault).

   2. Voltage drop %

      Voltage drop percentage is the maximum voltage lost over the cable length, expressed as a percentage in relation to the nominal operating voltage; accordingly voltage drop % is dependent on cable size/gauge, total cable length and the nominal operating voltage.

      To prevent excessive power loss and operational issues due to high voltage drop, design the system layout to minimise DC power cable length and select a cable size/gauge that provides a voltage drop of 3% or less (at maximum normal operating current).

   

2. Conductor

   The conductor material and specifications effect the resistance of a cable per unit length (effecting current carrying capacity), the resistance and heat generated at terminations, and overall cable flexibility.

   1. Conductor material and configuration

      Use high quality flexible DC power cabling that consists of fine multi-stranded oxygen free copper conductors.

   2. Strand diameter

      Strand diameter effects the contact area and accordingly the resistance at terminations; a high resistance termination will generate substantial heat when operating under load and can result in severe overheating.

      To maximise contact area at terminations and prevent overheating at/near terminations, the diameter of each individual copper strand must not exceed 0.4mm (0.016 inch) or a surface area of 0.125mm² (AWG26).

   3. Flexibility class

      To facilitate installation with practical bend radii and prevent failure of the cable and/or interfacing equipment due to excessive force/stress at terminations and/or cyclic fatigue, use high quality flexible DC power cabling with a flexibility class of 5 - Flexible copper conductors, or 6 - Extra flexible copper conductors.

   

3. Insulation

   The insulation material and specifications effect the maximum temperature capability/rating (effecting current carrying capacity) and the maximum voltage isolation capability/rating of a cable.

   1. Temperature rating

      The insulation temperature rating effects the current carrying capacity of a cable and must not be exceeded when considering the combination of a) maximum ambient temperature, b) the installation environment (which effects the dissipation of heat), and c) temperature rise due the heat generated by the cable when operating at the fuse or circuit breaker current rating.

      To prevent overheating of the cable insulation, use high quality flexible DC power cabling with an insulation temperature rating of at least 90°/194°F (preferably 105°C/221°F), or as required for the installation.

   2. Voltage rating

      To ensure robust electrical isolation and overall safety, use high quality flexible DC power cabling with an insulation voltage rating that exceeds the maximum operating voltage of the system; high quality flexible DC power cabling typically has an insulation voltage rating of 0.6/1kV.