TE Connectivity EV Charge Inlet Combo 2 Manual Download Page 2

Page: 2 / 31

114-94467

Rev. C

of 31

Content

SCOPE ........................................................................................................................................... 3

Content

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Processing Note

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APPLICABLE DOCUMENTS ........................................................................................................ 4

Customer drawings for COMBO 2 INLET

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Specifications

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WIRES............................................................................................................................................ 5

Assessment of the wires

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Wire selection

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Wire preparation

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Cable Specifications of prescribed Cables

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APPLICATION TOOLS & CRIMP ................................................................................................. 6

REQUIREMENTS ON THE CRIMPED CONTACTS ..................................................................... 7

Conductor position

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Crimp Geometry

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Cross Section

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Wire Pull-out forces

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Crimp Position

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Contact area

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Sealing Area

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Shape and position tolerances

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Measuring equipment and measuring position

...................................................................................... 12

ASSEMBLY INSTRUCTIONS ..................................................................................................... 13

Assembly overview Charge Inlet COMBO 2

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Parts to order

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Security Advice

......................................................................................................................................... 15

Assembly Steps

........................................................................................................................................ 16

END OF LINE TEST .................................................................................................................... 30

Summary of Contents for EV Charge Inlet Combo 2

Page 1: ...d 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 Specification 114 94467 Rev C 10 OCTOBER 2018 Class 1 EV Charge Inlet Combo 2 ...

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 11 Sealing Area 11 Shape and position tolerances 11 Measuring equipment and measuring position 12 6 ASSEMBLY INSTRUCTIONS 13 Assembly overview Charge Inlet COMBO 2 13 Parts to order 14 Security Advice...

Page 3: ...nts 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 the manufacturing process and the proper function of the system The warranty and liability is excluded if quality deficiency or damages occur due to non compliance to this specification or use of not s...

Page 4: ...T 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 2293270 PIN DIA 6 0 POWER AC ASSY 2293269 PIN DIA 8 0 ASSY TYP2 2292542 SEALING 2120571 PROTECTION CAP 2292534 CONTACT MICRO MATE N LOK 794606 MICRO MATE N LOK HOUSING 794617 Specifications 108 94579 Prod...

Page 5: ...The 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 insulation may not remain on the conductor Single strands may not be damaged fanned out cut or pulled out Furthermore the operator should avoid touching the bare single strands and the strands shall not be tw...

Page 6: ...ize 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 FHLR2GCB2G 5 x 6 0 mm Coroplast 2293269 3 W 3 528041 9 Hanke 971 200 Cycle time 1 7 2 5s Stroke 44mm 16 16 0 1 0 5 10 0 1 FLRYW 16 0 6 8 0 41 Leoni 2293270 4 W 2276149 8 35 23 5 0 5 8 30 0 15 FHLR2GCB2...

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 inserted into the crimp area and must be checked via the inspection hole after crimping Insulation must not be inside of the crimping area see Figure 3 Figure 1 Figure 2 Figure 3 ...

Page 8: ...rocess 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 height must be measured over both extensions in middle of crimp as shown in Figure 4 Cross Section When creating cross sections the correct grinding layer must be selected The grinding layer must be at m...

Page 9: ...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 picture exemplarily ...

Page 10: ...ev 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 exemplarily ...

Page 11: ...tact 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 10 and Figure 11 Meeting the specific shape and position tolerances must be ensured before the contact is inserted into the housing If contacts are bent during the application process exceeding the s...

Page 12: ...ing 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 middle of crimp area across whole crimp see Figure 12 Figure 12 picture exemplarily ...

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

Page 14: ...WER 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 CAP AC 2296057 1 10 1 FAMILY SEAL COMBO DC 2296058 3 11 1 COVER CAP COMBO DC 2296059 3 12 2 PIN DIA8 0 CONTACT ASSY TYP2 2292540 2 13 2 SEALING 2120571 1 14 1 PROTECTION CAP TE WATER DRAIN 2292534 1 15...

Page 15: ...4467 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 Figure 15 ...

Page 16: ...e 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 wire insulation of AC multicore cable acc Figure 18 and Table 3 The given length of the single wires ensures that the outer sheath of the multicore cable seals off to the FAMILY SEAL AC 2296040 7 Alte...

Page 17: ...gth 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 fulfil the requirements from Chapter 5 Step 3 Dismantle the wire and crimp the contact 16 mm PE Cable Remove outer insulation acc Figure 19 and Table 4 Figure 19 Wire Size Removal of insulation dim A 16...

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 the conductors to the CONTACT MICRO MNL 794606 1 acc Spec 114 13000 Step 5 Push crimped CONTACT MICRO MNL 794606 1 into the 12P MICRO MNL HSG 1 794617 2 acc spec 114 13000 Correct pinning acc Figure 21...

Page 19: ...1 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 the 35 mm DC Power wires as shown in Figure 23 Especially ensure the correct position of the flange of the L shaped FAMILY SEAL COMBO DC 2296058 3 towards the COVER CAP COMBO DC 2296059 3 per Figure 2...

Page 20: ...lation 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 requirements from Chapter 5 ATTENTION It must be ensured that no shielding braid is closer than 5 mm to the conductor and or the contact Otherwise the HV requirements regarding clearance and creepage di...

Page 21: ...0571 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 the last step the DC cable sub assembly is finished ...

Page 22: ...Assemble 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 acc Figure 29 Figure 28 Figure 29 ...

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 position see Figure 32 To ensure that the contacts are correctly inserted pull with a low force on the cables max 10N Figure 33 shows the contacts in correct end position Figure 31 ...

Page 24: ...ed 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 without the necessary electrostatic discharge ESD precautions Figure 32 Figure 33 Proposed sequence for contact insertion 1 16mm PE contact 2 6mm AC Power contacts starting with L1 and continuing in cl...

Page 25: ...hooks 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 safety required The printed circuit boards are static sensitive devices which can be damaged if touched without the necessary electrostatic discharge ESD precautions Figure 34 Figure 35 ...

Page 26: ...CB 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 touched without the necessary electrostatic discharge ESD precautions Figure 36 ...

Page 27: ...d 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 the inlet and pushed vertically into the end position to make sure that the sealing lips are sitting correctly all around Figure 37 Figure 38 ...

Page 28: ...lips 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 double audible click and by visual checking Move the FAMILY SEAL COMBO DC 2296058 3 into its position in the CABLE EXIT COVER 2307523 1 and snap the COVER CAP COMBO DC 2296059 3 on the CABLE EXIT COVER...

Page 29: ...wn 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 IEC 62196 x and IEC 61851 Also information acc to customer requirements can be applied here Figure 41 ...

Page 30: ...ltage 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 against L3 f L2 against N g L3 against N h L1 L2 L3 and N against AC multicore shield i DC against DC j DC and DC against HV cable shield Correct pinning of all contacts Check seals for correct seating ...

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 10OCT2018 DR C RINGLSTETTER 17OCT2017 TE CONNECTIVITY GERMANY GMBH AMPÈRESTRASSE 12 14 D 64625 BENSHEIM GERMANY CHK F WITTROCK 17OCT2017 APP F WITTROCK 17OCT2017 NO 114 94467 REV C LOC AI TITLE Application...

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