Danfoss Editron recommended power cables are Huber+Suhner Radox automotive shielded power cables. When using other types of cable, ensure that the specifications of the cable are suitable for the specific usage scenario.
•Correct assembly of the cable ends and shielding is critical. Improper connections can lead to EMI and cause communication, measurement signal and device failures. Short-circuits in the power cables can lead to arcing, fire, and explosion hazards.
•The cable shielding must be properly installed and connected to device chassis ground. Measure the correct length of cable end and shielding before peeling the cable sheath.
•The cable end lugs need to be attached with a proper crimping tool. Do not use excessive force or incorrect tools when crimping the end lugs.
Cable end assembly
- Measure the correct length of cable end and mark it. See the cable measurement section below for more information.
2. Carefully cut the outer layer of the cable using a cable stripping tool, pay attention not to damage the shield wires. Use of a box cutter knife is not recommended.
3. Cut the cable shield with suitable wire cutters to the correct length.
4. (Optional:) Tape the cable shield tightly with copper tape to prevent fraying. Use tape with conductive glue.
5. Measure the cable end length, then cut and remove the cable inner sheath. Make sure there is a minimum of 10 mm distance between the lug and shield wires.
6. Insert the cable lug and rotate it to the desired direction. Crimp the lug to the cable. Use the specific size and shape crimping jaws suitable for the cable and lug. Attention: If you use a cable lug that is too wide to fit through the cable gland, the gland must be threaded on the cable before crimping the cable lug on the cable.
7. Crimp the cable lug with 2 or 3 crimps spaced sufficiently apart.
8. Cover and secure the cable shield ends with self-fusing silicone rubber tape or shrink wrap with embedded glue.
9. Thread the cable gland on. The cable is ready to be installed.
Cable length measurement
Measuring the cable cutting lengths carefully before installation is very important for a clean, safe, and reliable installation, as the correct length depends on the device, connection box design, used cable type as well as the cable lug type. Each Editron device has slightly different connection box design, which means that the measurements must be done for each installation separately.
In the picture below, the distances are marked as follows:
A: Distance from the surface of the connection box to the cable lug bolt center.
B: Distance from cable lug bolt center to the bottom of the cable lug cavity
C: Depth of the cable lug cavity
The cables outermost sheath layer should be cut according to the formula: cut length = A - B + 10 mm. This will ensure that the cable shield will meet and connect with the cable gland spring reliably, but it also ensures that the cable gland will properly seal the cable and provide the specified IP rating.
The shield of the cable should be cut so that it connects to the spring reliably (approx 30 mm of shield left underneath the cable gland). A minimum distance of 10 mm between the cable lug and the shield is needed to give sufficient air gap and isolation.