TE Connectivity EV Charge Inlet Combo 2 User manual

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Application
Specification
114-94467 Rev. C
10 OCTOBER 2018
Class 1
EV Charge Inlet Combo 2

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Content
1. SCOPE........................................................................................................................................... 3
Content......................................................................................................................................................... 3
Processing Note.......................................................................................................................................... 3
2. APPLICABLE DOCUMENTS........................................................................................................ 4
Customer drawings for COMBO 2 INLET.................................................................................................. 4
Specifications.............................................................................................................................................. 4
3. WIRES............................................................................................................................................ 5
Assessment of the wires............................................................................................................................ 5
Wire selection.............................................................................................................................................. 5
Wire preparation.......................................................................................................................................... 5
Cable Specifications 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 ......................................................................................................................................... 15
Assembly Steps........................................................................................................................................ 16
7. END OF LINE TEST .................................................................................................................... 30

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1. SCOPE
Content
This specification describes the handling and assembly of the vehicle charge inlets CCS 2 acc. IEC 62196-3 for
conductive charging of electric vehicles. This specification applies to manual assembly of the components 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 specified, or not released tools, cables and components.

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2. APPLICABLE DOCUMENTS
The following technical documents, if referred to, are part of this specification. In case of a contradiction
between this specification and the product drawing or this specification and the specified documentation,
the product specification has priority.
Customer drawings for COMBO 2 INLET
INLET HSG, COMBO 2, ASSY
2306836
CABLE EXIT, RECT, 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
Product Spec. Vehicle Charge Inlets IEC62196-3 COMBO 2 (in preparation)
108-94519
Product Spec. TE actuator for charge inlets
114-13000
Application Specification Micro Mate-N-Lok Connectors

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3. WIRES
The following designations are used in this specification. The illustrations are exemplary and schematically.
Assessment of the wires
To ensure the required electrical crimp contactability with stable crimp resistance a permissible maximum storage
period of 8 months for unprocessed cable (referring to cable manufacturer production date) must be respected.
Wire selection
The contact system is released for the application with wires specified in Chapter 3.4.
The released contact-wire-combinations and crimp parameters are given in Table 1.
Other wires require the validation approval of the TE engineering department.
The wires are applied as single wire terminations. Double terminations are not intended.
Wire preparation
The cable insulation must be stripped before crimping. 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 twisted. All single strands need to be
caught in the crimp and not a single strand must remain outside the crimp.
Cable Specifications of prescribed Cables
AC-cable: Cross-section 5 x 6,0mm²
Supplier:Coroplast
Outer Diameter: 16,3 -0,6 mm
Cable description: FHLR2GCB2G 5x6.0mm² acc. LV216-2 table A5
Supplier Part No.: 9-2641 (5x6,0mm²)
PE-cable: Cross-section 16mm²
Supplier:Leoni
Outer Diameter 6,9 -0,2 mm
Cable description: FLRYW 16,0 / 6,8 / 0,41 acc. ISO 6722 –Class C
Supplier Part No.: 76B00436# (colour code Green/Yellow)
Signal-cable: Cross-section 12 x 0,35mm²
Supplier: TE
Outer Diameter: 7,1 -0,4 mm
Cable description: ASC120875A

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DC-HV-cable: Cross-section 35,0mm²
Supplier:Coroplast
Outer Diameter 14,4 -0,6 mm
Cable description: FHLR2GCB2G 35mm² acc. LV216-2 table A.2
Supplier Part No.: 9-2611 / 35mm²
4. APPLICATION TOOLS & CRIMP
To produce a correct wire crimp, as validated by TE with the wires listed in this specification, following application
tools are required. The press machine for crimping is required to provide minimum 20 tons press force.
Wire
Size
[mm²]
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 mm²
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
FHLR2GCB2G
35 mm²
Coroplast
2292542-2
W
2276149-3
Table 1
Crimp Die Sets are subject to wear. Their condition and quality must be monitored. Suspect and/or worn Die Sets
have not to be used to produce these crimps. Die Sets are available as spare parts.

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5. REQUIREMENTS ON THE CRIMPED CONTACTS
The following terms shown below are used in this Specification, see Figure 1 and Figure 2.
Conductor position
The 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

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Crimp Geometry
The crimp geometry, crimp heights including their corresponding tolerances as well as wire sizes are given in
Table 1.
The crimp height is the key quality feature of a crimp connection. The measurement allows a non-destroying
examination and a continuous process inspection. It is provided for every wire size and contact. The crimp height
is given in Table 1.
Crimp height and width may also be measured in a cross-section image. The mechanical operated measurement
though is preferred.
During the application process 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 middle
of crimp area and may not be inside of serration, as shown in Figure 5.
Wire Pull-out forces
Measurement of wire pull-out forces from the wire crimp is a supporting manufacturing control.
The pull-out forces must fulfil the requirements according product specification 108-94579.
CH1
Figure 4 (picture exemplarily)
Figure 5 (picture exemplarily)

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Crimp Position
Contacts of wire cross-section 6mm² 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)

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Contacts of cross-section 16 mm² and 35 mm² 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)