Fachverband Batterien
Postfach 70 12 61
60591 Frankfurt am Main
Lyoner Straße 9
60528 Frankfurt am Main
Tel.:
(0 69) 63 02-209
Fax: (0 69) 63 02-488
e-mail: batterien@zvei.org
Information Leaflet
Dimensioning, Selection and Designs of
Plug-and-Socket Devices and Connecting Cables
for Traction Batteries and Battery Chargers
A General Information
When selecting plug-and-socket
devices and connecting cable in:
electrical industrial trucks <–>
traction batteries <–>
battery charger systems
it is important to make sure that
– plugs are correctly and uniformly selected
– they have the necessary
cable cross-sections and
– the cables have the correct
lengths.
Please use the check-list
(under Point C 9) for the selection.
B Dimensioning Cable
Cross-Sections and
Lengths
1. Traction Batteries
The cross-sections of the battery
terminal connectors are dimensioned to prevent excessive
heating based on the battery
operating current I2 [A] = 0.8 x
C5 [Ah] / 2h (equals 40 A per
100 Ah C5).
These have to be the largest calculated cross section.
As an alternative, the length of
the terminal connectors can be
given as the proximity dimension
L to the outside edge of the tray
which requires a sketch (refer to
the example below).
This applies to standard lengths
up to 1.5 m. Larger cross-sections are necessary if longer terminal connectors are used.
Cable lengths may differ for positive and negative terminal connectors and they should be
given separately. Only one cable
cross-section has to be used
even with varying cable lengths.
This leaflet was prepared by the Working Group „Industry Technique“ of the Product Division „Industrial
Batteries“ of the German Electrical and Electronic Manufacturer’s Association, ZVEI.
(Revised Edition August 2009).
1
For example:
24 V
Circuit A
2. Battery Chargers
Each manufacturer designs its
own cross-sections for the charging cables depending upon the
rated current for the equipment.
The standard length for the charging cables is approximately 3 m.
The cross-sections should be
adjust-ed correspondingly if longer charging cables are needed
to compensate for the higher voltage drop. Battery chargers with
programmable cable lengths do
not have to increase the crosssection.
Adjusting the cross-section may
change the size of the plug-andsocket device (refer to Table 1).
The cross-section should be
adapted in accordance with the
cable calculated for direct current.
A
=
2.L.I
κ . Ua
A
=
cable cross-section in mm2
L
=
single cable length in m
I
=
current in Ampere (the battery charger rated current)
Ua
=
voltage drop in V
κ
=
specific conductivity in
m
2 (for copper = 56
Ω . mm
For simplification, we recommend an increase in the cable cross-section
corresponding to the ratio of the cable length
(Lnew : Lstandard).
Lnew [m]
Lstandard [m]
Anew [mm2]
= Astandard .
Anew
= minimum cross-section needed with extended charging
cables
Example calculation:
standard charging cables
3m
extended charging cables (new) 5 m
Anew =
25 mm2
. . mm2
5
25 .
= 41,66 m2 selected: 50 mm2
3
Comment: Always round up the calculated value!
If it is not possible to increase the cross-section, clarify if the
characteristic values of the battery charger can be adapted.
2
m
2)
Ω . mm
3. Electrical Industrial Trucks
The cross-sections of the connecting cable of electrical industrial trucks are defined as applying rated motor currents.
C Dimensioning and
Designing Plug-andSocket Devices
1. The Socket Device and
Plug Device in Conformity
with DIN 43 589-1
With these plug-and-socket
devices:
– the socket device with female
contacts is mounted on the
battery
– the plug device with male
contacts is mounted on the
battery charger
3 plug and socket designs are
defined for rated currents 80,
160 and 320 A in conformity with
DIN 43 589-1 (Equipment Plugand-Socket Devices 80, 160,
320 A, 150 V for Electrical Industrial Trucks). Plug-and-socket
devices have to satisfy requirements and pass tests in conformity with DIN EN 1175-1 including
Appendix A.
The plug housing, contacts and
cable terminal points have to be
dimensionally stable and the
plug housing materials have to
be resistant to acid for a permanently safe plug-and-socket connection.
The rated current is the current
in A that the plug-in contacts can
conduct permanently without exceeding the maximum acceptable temperature increase in permanent DC operation of 65 K.
– the plug device with male
contacts is mounted in the
electrical industrial truck
In addition to these standardised
plug-and-socket devices, there
are also designs with flat contacts where there is no differentiation made between the plug
and socket. These designs call
for additional coding to define
the plug and socket component.
High current plug-and-socket
devices:
These higher currents can cause
higher surface temperatures on
the housings of plug-and-socket
devices.
If these plug-and-socket devices
are used to conduct currents higher than the standard rated currents, please make sure that all
3 system plugs (electrical industrial truck / battery / battery chargers) have identical permissible
current load.
The cable cross sections have to
be adapted accordingly and
cable insulation have to meet
higher temperatures.
The plug device of the electrical
industrial truck or battery charger
defines the current load and
should be coded accordingly.
If the plug device is used for
higher currents, a connection
with a standard socket device
must be prevented.
In contrast, a high current-socket
device can be equipped with a
standard plug device.
Plug manufacturers have approved new plug-and-socket devices for rated currents higher
than 80, 160 or 320 A if other
housing materials and/or special
contact materials and/or solid extruded connecting cables are
used.
For example:
2. Rated Current and Rated
Voltage of the Plug-andSocket Device
plug-and-socket device
(standard size)
higher rated current
2.1 The Rated Current
The system plug-and-socket
device should be selected according to the maximum rated current for the electrical industrial
truck or of the battery charger.
80 A
160 A
320 A
120 A
250 A
400 A
3
Example:
Coding pins for high current plug-and-socket devices for batteries with liquid electrolytes, flooded
Coding pin for plug device
(electrical industrial truck/charger)
Coding pin for socket device
(battery)
These special coding pins which
prevent standard plug devices
and high current plug devices
from being plugged together are
not yet available for all plug products.
If coding is not possible, we urgently recommend just selecting
the standard rated currents.
Always follow the rules of electrical industrial truck manufacturers, especially when replacing a
system plug-and-socket device.
Special plug and socket devices
should be used for higher voltages.
3. Rated Cross-Section of the
Cable Terminals
DIN 43 589-1 states that the
following rated cross-sections
of the cable terminals are available with the 3 plug-and-socket
device sizes (Table 1).
The connecting cables should
be crimped according to the
recommendation of the plug
manufacturer.
Reduced bushings can be used
if it has to be adjusted to the
next smaller cross-section,
although reducing bushes inserted into one another should not
be used for technical reasons.
Reduced bushings are generally
not allowed with high current
plug-and-socket devices.
Reducing of cross-sections in
cables is not permitted.
2.2 The Rated Voltage of the
Plug-and-Socket Device
Do not observe only the rated
currents, but also the maximum
acceptable voltages. Standard
plug-and-socket devices in conformity with DIN 43 589-1 are designed for a maximum direct voltage of 150 V. Since this rated
voltage has to be based on the
maximum charging voltage, this
equals a maximum battery rated
voltage of 96 V.
Table 1
rated cross-section mm2
2,5
10
16
25
35
50
70
95
for the plug-and-socket device / type
safety disconnect and auxiliary
contacts
80 A *
80 A, 160 A *
80 A, 160 A *
160 A
160 A, 320 A *
320 A
320 A
* Continuous current limited by the cable cross-section
4
4. Coding
Each plug-and-socket device
has to have coding equipment
which guarantees that a plug
device can only be inserted into
an socket device of the same
operating voltage.
There are only some coding pins
available with additional current
coding that keeps standard plugand-socket devices and high current plug-and-socket devices
from being plugged together
(refer to Point C 2.1).
Different coding exists for correctly selecting battery chargers
to battery technology with liquid
(flooded) or fixed electrolytes
(VRLA / dry).
Example:
Coding system for a rated operating voltage 24 V
5
Table of potential coding pin combinations
Table 2
coding pin
battery
coding pin
battery charger
coding pin
electrical industrial truck
HS
N
U
T
T
U
N
N
U
HS
HS
U
HS
HS
HS
HS
N
HS
HS
N
T
U
=
=
=
=
high current design
battery, flooded
battery, dry
electrical industrial truck, universal
5. Safety Disconnect and
Auxiliary Contacts
auxiliary contacts
An option is to equip the plugand-socket devices with safety
disconnect and/or auxiliary contacts.
Safety disconnect contacts
are used to switch off the charging current before the main contacts of the plug are completely
disconnected from the battery
charger if the plug-and-socket
device (battery charger) is not
correctly handled.
The prerequisite for this safety
function is that the battery charger has the optional equipment
of a safety disconnect contact
control.
At the battery socket device the
safety disconnect contacts are
short-circuited.
Auxiliary contacts are used for
tapping auxiliary voltages
(partial voltages) from the battery.
6
pilot contacts / air adapter
Important comment:
If a 2-channel air adapter is
mounted as optional equipment
for air agitation instead of safety
disconnect contacts (refer to
Point C 6.), the safety disconnect control can be implemented
via the auxiliary contacts.
If the safety disconnect contacts
are used for safety disconnect
control for the battery charger
and the auxiliary contacts are
used to pick off auxiliary voltage,
the air agitation can only be
supplied with separate air coupling.
6. Air Supply System for
Batteries with Air Agitation
Example: air adapter for air agitation
Some plug-and-socket devices
can be equipped with optional
2-channel air adapters at the
position of the safety disconnect
contacts for traction batteries
with air agitation. The air supply
system designs are manufacturer-specific so that the plug-andsocket devices may not be compatible.
7. Optional Combinations
These designs allow the following combinations:
– plug device / socket device
– plug device / socket device
with safety disconnect contacts
– plug device / socket device
with air adapter
– plug device / socket device
with air adapter and auxiliary
contacts
– equipment plug / equipment
socket with safety disconnect
contacts and with auxiliary
contacts
8. References to Standards
DIN EN 1175-1; VDE 0117
Part 1, Safety of industrial trucks
– Electrical requirements
DIN EN 50272-3; VDE 0510
Part 3, Safety requirements for
secondary batteries and battery
installations – Traction batteries
DIN EN 60204-1; VDE 0113
Part 1, Safety of machineryElectrical equipment of machines – General requirements
DIN 43531; 43535; 43536, Bleiakkumulatoren – Antriebsbatterien 48V; 24V; 80V mit Zellen
Maßreihe L für Flurförderzeuge
DIN 43537, Bleiakkumulatoren –
Antriebsbatterien 24V, 36V, 48V,
80V mit Zellen Maßreihe E für
Flurförderzeuge
DIN 43589-1, Geräte – Steckvorrichtungen 80A, 160A, 320A,
150V für Elektro-Flurförderzeuge
7
9. Check-List for defining Plug-and-Socket devices and connecting cables
1.
Electrical Industrial Trucks (plug device with male contacts)
information required for ordering
2.
rated current
cable cross-section
plug model and product
coding Urated **
option
………. A
………. mm²
………. A / ……….
………. V
HS Battery (socket device with female contacts)
information required for ordering ***
battery
capacity
length of
terminal
cable
cable
crosssection
plug model
and product
….. Ah
pos. … m
neg. … m
….. mm²
………. A
/ ……….
3.
coding **
option
flooded
dry
Urated
HS
PK*
HK*
EUW*
G
Z
.... V
Charger (plug device with male contacts)
information required for ordering
rated
current
for
charger
length of
charging
cable
cable
crosssection
plug model
and product
….. A
..… m
….. mm²
………. A
/ ……….
HS =
PK =
HK =
EUW =
G
=
Z
=
coding **
option
flooded
dry
Urated
HS
PK*
HK*
EUW*
G
Z
.... V
high current design
safety disconnect contact assignment
auxiliary contact assignment
air adapter for air agitation
plug-and-socket device with grip
strain relief (standard with DIN plugs)
*
If an optional air adapter is needed for air agitation (mounted at the position of the safety disconnect contact) and safety
disconnect control is needed, the safety disconnect control can be implemented via the auxiliary contacts. Important: This
configuration has to be designed uniformly with the battery socket device and battery charger plug device.
**
Also refer to Table 2 for the coding pin combination
***
More information is needed on the cable type and battery connection design if the complete battery terminal connectors
are ordered separately.
Important comments:
I)
plug type + coding (Urated):
has to be identical with the industrial truck, battery and battery charger.
II) plug type + plug product + coding (Urated):
has to be identical with the EUW option with the industrial truck,
battery and battery charger.
III) plug type + plug product + coding (Urated):
If the industrial truck or battery charger is equipped with an HS plug device,
the battery also has to be equipped with an HS socket device.
IV) plug type and cable cross-section:
They have to be adapted in accordance with the maximum possible rated
current of the industrial truck or battery charger.
V) cable cross-section
battery connecting cable:
If the cable cross-section battery charger and/or industrial truck < battery
connecting cable, it is not necessary to adapt it.
If the cable cross-section battery charger and/or industrial truck > battery
connecting cable, then it is necessary to adapt to the maximum.
VI) cable type:
8
satisfies the requirements of DIN EN 50272-3 / VDE 0510, Part 3.