TE Connectivity 9-2380197-1 Manual Download Page 10 | Manualshive

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114-94467

Rev. C

10

of 31

Contacts of cross-section

16 mm² and 35 mm²

must be crimped with crimping tool position at end of crimp area

as shown in

and

Figure 8 (picture exemplarily)

Figure 9 (picture exemplarily)

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Summary of Contents for 9-2380197-1

Page 1: ...Indicates Change Trademark TE Connectivity TE connectivity logo and TE logo are trademarks Other logos product and or company names may be trademarks of their respective owners Application Specificat...

Page 2: ...of prescribed Cables 5 4 APPLICATION TOOLS CRIMP 6 5 REQUIREMENTS ON THE CRIMPED CONTACTS 7 Conductor position 7 Crimp Geometry 8 Cross Section 8 Wire Pull out forces 8 Crimp Position 9 Contact area 1...

Page 3: ...ts from series production tooling for the standard version The usage of single wire sealing in the charge inlet is described Processing Note The processor is responsible for ensuring the quality of th...

Page 4: ...COMBO 2307523 RADIAL SEAL 2320511 FAMILY SEAL AC 2296040 STRAIN RELIEF AC 2296056 COVER CABLE SEAL AC 2296057 FAMILY SEAL COMBO DC 2296058 COVER CABLE SEAL COMBO DC 2296059 PIN DIA 6 0 POWER PE 22932...

Page 5: ...he stripping length of the outer insulation and shield are defined in the assembly instructions in Chapter 6 The insulation must be cut accurately and pulled off from the conductor Offcut of insulatio...

Page 6: ...ze mm Stripping Length Single wire for crimp mm Crimp height CH1 mm Cable Specification Supplier Contact P N Geometry Applicator Crimping press used by TE for Product Validation 6 13 0 1 0 3 95 0 1 FH...

Page 7: ...single strands of the conductor are clamped inside the crimp area All single strands need to be caught in the crimp and not a single strand must remain outside the crimp The wire end must be fully ins...

Page 8: ...ocess the crimp height must be checked This is valid for each batch and after every change or switchover of contact reel or wire bundle or applicator respective it s setup or components The crimp heig...

Page 9: ...of 31 Crimp Position Contacts of wire cross section 6mm must be crimped with crimping tool position at middle of crimp area as shown in Figure 6 and Figure 7 Figure 6 picture exemplarily Figure 7 pic...

Page 10: ...v C 10 of 31 Contacts of cross section 16 mm and 35 mm must be crimped with crimping tool position at end of crimp area as shown in Figure 8 and Figure 9 Figure 8 picture exemplarily Figure 9 picture...

Page 11: ...act is obviously straight by eye In case a measurement is required the measurement equipment requires at least a 10 time better measuring precision compared with the requirement tolerances see Figure...

Page 12: ...ng equipment for measuring crimp height a digital caliper with an accuracy of measuring 0 01 mm is the minimum requirement Measuring of crimp height must be done according as following always in middl...

Page 13: ...114 94467 Rev C 13 of 31 6 ASSEMBLY INSTRUCTIONS Assembly overview Charge Inlet COMBO 2 Figure 13...

Page 14: ...ER PE 2293270 4 4 4 PIN DIA 6 0 RIGID POWER AC ASSY 2293269 3 5 1 PERIPHERAL SEAL 2320511 1 6 1 CABLE EXIT RECT COMBO 2307523 1 7 1 FAMILY SEAL AC 2296040 7 8 1 STRAIN RELIEF AC 2296056 7 9 1 COVER CA...

Page 15: ...467 Rev C 15 of 31 Security Advice The assembly should only be performed by trained personnel Avoid prolonged or repeated skin contact with silver plated contacts wear protective gloves Figure 14 Figu...

Page 16: ...STRAIN RELIEF AC 2296056 7 as shown in Figure 17 Figure 16 Figure 17 Step 2 Dismantle the wires and crimp the contacts 5 x 6 mm AC Multicore Cable Remove outer cable sheath shield filler and single w...

Page 17: ...th outside the inlet and needs to be defined by LEVC Crimp the conductors of the 4 short single wires to the PIN DIA6 0 POWER AC 2293269 3 with the specified tools listed in Table 1 The crimp must ful...

Page 18: ...insulation from the remaining 11 single wires acc Figure 20 and Table 5 Figure 20 Wire Size Removal of insulation dim A Length of single wires dim B 0 35 mm Acc spec 114 13000 50 2 mm Table 5 Crimp th...

Page 19: ...like shown in Figure 22 Figure 22 After completing the last step the AC cable sub assembly is finished Step 7 The COVER CAP COMBO DC 2296059 3 and FAMILY SEAL COMBO DC 2296058 3 must be pushed over t...

Page 20: ...ation dim A Removal of shielding dim B 35 mm 23 5 0 5 mm 31 0 5 mm Table 6 Crimp conductor to the PIN DIA8 0 POWER DC 2292542 2 with the specified tools listed in Table 1 The crimp must fulfil the req...

Page 21: ...571 1 must be placed on the crimped PIN DIA8 0 POWER DC 2292542 2 as shown in Figure 26 Ensure correct orientation of seal acc Figure 27 sealing lips on outside Figure 26 Figure 27 After completing th...

Page 22: ...ssemble the RADIAL SEAL 2320511 1 to the CABLE EXIT COVER 2307523 1 like shown in Figure 28 The seal should be properly seated onto the collar of the cable exit Ensure also correct orientation of seal...

Page 23: ...2307523 1 like shown in Figure 30 Figure 30 Step 12 Insert the contacts from the backside into the INLET HOUSING 2306836 2 according the cavity description shown in Figure 31 into their locking positi...

Page 24: ...d There is no rework allowed risk of damaging contacts and or locking geometry in housing ESD safety required The printed circuit boards are static sensitive devices which can be damaged if touched wi...

Page 25: ...ooks are properly engaged with the inlet housing which should be controlled by the double audible click and by visible inspection Secondary locks in correct end position are shown in Figure 35 ESD saf...

Page 26: ...B Header Ensure that the locking latch is properly engaged with the PCBA header see Figure 36 ESD safety required The printed circuit boards are static sensitive devices which can be damaged if touche...

Page 27: ...be applied on the marked locations close to the latches as shown in Figure 38 Ensure that all 5 hooks are properly engaged ATTENTION The CABLE EXIT COVER 2307523 1 needs to be aligned properly over t...

Page 28: ...ips are safely placed on the outer insulation of the cables Push the COVER CAP AC 2296057 1 over it and snap it on the CABLE EXIT COVER 2307523 1 Ensure that both hooks are correctly engaged by the do...

Page 29: ...n in Figure 40 Figure 40 Step 18 For identification apply a label on this specified polished face on the CABLE EXIT 2307523 1 see Figure 41 The label needs to include information acc requirements of I...

Page 30: ...tage 2000 V AC Inspection Duration 1 s max Leakage current 10 mA pin to pin excluding CP to Proxi and CP Proxi to PE a L1 L2 L3 and N against PE b L1 against L2 c L1 against L3 d L1 against N e L2 aga...

Page 31: ...ASSEMBLY 2306836 1 CHANGED TO 2306836 2 POS 1 IN TABLE 2 DIM B IN TABLE 3 CHANGED FROM 65 MM TO 60 MM PERIPHERAL SEAL 8 2320511 1 CHANGED TO 2320511 1 POS 5 IN TABLE 2 C RINGLSTETTER F WITTROCK 10OCT2...

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