TE Connectivity EV Charge Inlet Combo 2 User manual

1 of 31
© 2018 TE Connectivity family of companies
All Rights Reserved
| 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

114-94467 Rev. C
2 of 31
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

114-94467 Rev. C
3 of 31
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.

114-94467 Rev. C
4 of 31
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

114-94467 Rev. C
5 of 31
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

114-94467 Rev. C
6 of 31
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.

114-94467 Rev. C
7 of 31
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

114-94467 Rev. C
8 of 31
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)

114-94467 Rev. C
9 of 31
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)

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 Figure 8 and Figure 9.
Figure 8 (picture exemplarily)
Figure 9 (picture exemplarily)

114-94467 Rev. C
11 of 31
Contact area
During processing and following processing the contact area may not be damaged or bended.
Sealing Area
During processing and following processing the sealing area may not be damaged or bended.
Shape and position tolerances
Measuring the shape and position deviation is not always necessary, if the contact 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 specification limits they may not be bent back
or reworked, but must be scrapped.
Figure 11 (picture exemplarily)
Figure 10 (picture exemplarily)

114-94467 Rev. C
12 of 31
Measuring equipment and measuring position
As measuring 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)

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

114-94467 Rev. C
14 of 31
Parts to order
Charge Inlet COMBO 2
3-phase AC 6mm²
PE 16 mm²
DC 35 mm²
Variant
Part
Pos.
Qty.
Description
P/N
1
1
INLET HSG, COMBO2, ASSY
2306836-2
2
1
12POS MICRO MNL HSG
Additional part for charge inlet cabling:
1-794617-2
11
CONTACT MICRO MNL
Additional part for charge inlet cabling:
794606-1
3
1
PIN DIA 6.0, RIGID, POWER 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
1
4POS MQS CONNECTOR HSG,
SEALS AND CONTACTS
Additional part for charge inlet cabling:
Choose P/N acc. Prod. Spec. of Actuator:
108-94519
Table 2

114-94467 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

114-94467 Rev. C
16 of 31
Assembly Steps
Step 1
The COVER CAP AC 2296057-1, STRAIN RELIEF AC 2296056-7 and FAMILY SEAL AC 2296040-7 must be
pushed over the signal wire, the PE cable and the AC-Multicore cable. Pay attention to place all wires at correct
positions, per Figure 16. Especially ensure the correct position of the flange of the L-shaped FAMILY SEAL AC
2296040-7 towards the 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 mm² 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. Alternatively, a marking on the outer sheath in a certain distance to the cut-off position can
be used to ensure the proper position of the outer sheath in the FAMILY SEAL AC 2296040-7.

114-94467 Rev. C
17 of 31
Figure 18
Wire
Size
Removal of insulation
dim. "A"
(valid for 4 single
wires)
Length of single
wires dim. “B”
(valid for 4 single
wires)
Removal of insulation
dim. "C”
(valid for 1 single
wire)
Length of single wire
dim. “D”
(valid for 1 single
wire)
6 mm²
13 ± 1 mm
60 ± 2 mm
acc. LEVC
70 + “x” ± 2 mm
Table 3
The value “x” for length “D” in above table represents the wire length 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 mm² PE Cable
Remove outer insulation acc. Figure 19 and Table 4.
Figure 19
Wire Size
Removal of insulation dim. "A"
16 mm²
16 ± 1 mm
Table 4
Crimp conductor to the PIN DIA6.0 POWER PE 2293270-4 with the specified tools listed in Table 1. The crimp
must fulfil the requirements from Chapter 5.

114-94467 Rev. C
18 of 31
Step 4
Dismantle the wires and crimp the contacts: 0.35 mm² Signal Wires
Remove outer cable sheath, cut one of the 12 single wires right after the cable sheath and remove the single
wire 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 mm²
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.
Figure 21

114-94467 Rev. C
19 of 31
Step 6
Insert the uncrimped single wire from the 5 x 6 mm² AC-Multicore cable into the empty aperture of the FAMILY
SEAL AC 2296040-7, STRAIN RELIEF AC 2296056-7 and COVER CAP AC 2296057-1 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 mm² 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
24.
Figure 23

114-94467 Rev. C
20 of 31
Figure 24
Step 8
Dismantle the wires and crimp the contacts: 35 mm² DC-HV cable
Remove outer insulation, shielding braid and inner insulation acc. Figure 25 and Table 6.
Figure 25
Wire Size
Removal of insulation dim. "A"
Removal of shielding dim “B”
35 mm²
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 distance cannot be fulfilled!