TE Connectivity CCS1 User manual

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Application
Specification
114-94438 REV C1
18JUN2020
Class 1
VEHICLE CHARGE INLET CCS1
acc. IEC62196-3 / SAE J1772

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Content
1. SCOPE......................................................................................................................................3
1.1. Content.................................................................................................................................................... 3
1.2. Processing Note...................................................................................................................................... 3
2. APPLICABLE DOCUMENTS...................................................................................................4
2.1. TE Connectivity Documents .................................................................................................................... 4
3. WIRES.......................................................................................................................................5
3.1. Assessment of the wires ......................................................................................................................... 5
3.2. Wire selection.......................................................................................................................................... 5
3.3. Wire preparation...................................................................................................................................... 5
3.4. General Specifications of Prescribed Cables .......................................................................................... 5
4. APPLICATION TOOLS ............................................................................................................6
5. Requirements on the crimped contact .................................................................................7
5.1. Terms of pin contact................................................................................................................................ 7
5.2. Conductor position .................................................................................................................................. 7
5.3. Crimp data for the wire crimp .................................................................................................................. 7
5.4. Crimpposition .......................................................................................................................................... 8
5.5. Cross sections....................................................................................................................................... 10
5.6. Contact area.......................................................................................................................................... 10
5.7. Sealing Area.......................................................................................................................................... 10
5.8. Shape and position tolerances .............................................................................................................. 10
5.9. Measuring equipment and measuring position...................................................................................... 11
6. ASSEMBLY INSTRUCTIONS ................................................................................................12
6.1. Assembly overview................................................................................................................................ 12
6.2. Assembly configuration cable exit ......................................................................................................... 12
6.3. Parts to order ........................................................................................................................................ 13
6.4. Security Advice ..................................................................................................................................... 14
6.5. Assembly Steps .................................................................................................................................... 15
6.6. End of Line Test .................................................................................................................................... 34

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1. SCOPE
1.1. Content
This specification describes the handling and assembly of the vehicle charge inlets CCS I 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.
1.2. 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
by failing compliance to this specification or using not specified, 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 then the product specification has priority.
2.1. TE Connectivity Documents
a) Drawings / Bill of material:
See Customer drawing for COMBO 1 INLET
DBAG basic number: A 000 340 78 00
TE number: PRJ-14-0337-1072
b) Specifications
108-94519
Product Spec. TE actuator for charge inlets

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3. WIRES
The following designations are used in this specification. The illustrations are exemplary and schematically.
3.1. Assessment of the wires
To ensure the required electrical crimp contactability the permissible maximum storage period of 8
months for unprocessed cable (referring to cable manufacturer production date) must be respected.
3.2. Wire selection
The contact system is released for the application with wires specified in point 3.4
The released contact-wire-combinations and crimp parameters are given in table 1
Other wires require the approval of the engineering department.
The wires are applied as single wire terminations. Double terminations are not intended.
3.3. Wire preparation
The wire must be stripped before crimping. The stripping length of the outer insulation and shield with
tolerances is defined in the following Assembly Steps.
The insulation must be cut accurately and pulled off 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. Sticking out strands are not permitted.
The single strands of the conductor may not be twisted.
3.4. General Specifications of Prescribed Cables
AC-Cable: Cross-section 3 x 6,0mm²
Supplier:Coroplast
Outer Diameter 14,1 -0,6 mm
Cable description: FHLR2GCB2G 3x6.0mm²
acc. LV216-2 Tab. A5
Coroplast Part No.: 9-2641 (3x6mm²)
PE-Earth-Cable: Cross-section 16mm²
Supplier:Coficab
Outer Diameter 8.3-0.9mm
Cable description: FLY 16/0.21
acc. LV112
Part No.: LLYF1600xxyy (xxyy -> color acc. to datasheet)
Note regarding PE-PVC insolation:
PG23 test is carried out according customer request and in conflict to specified requirements with
PE cable which constricts during thermal aging in the sealing area (PVC insolation). To counteract
this effect, the test samples were modified after the thermal aging in such a way, that the
constricted area of the PE cable is moved out of the sealing area.

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DC-HV-Cable : Cross-section 1 x 16,0mm²
Supplier:Coroplast
Outer Diameter 10,2 -0,6 mm
Cable description: FHLR2GCB2G 16mm²/0.21 T180 0.6/0.9kV
acc. LV216-2 Tab. A.2
Part No.: 9-2611 / 16mm²
DC-HV-Cable : Cross-section 1 x 50mm²
Supplier:Coroplast
Outer Diameter 15,8 - 0,6 mm
Cable description: FHLR2GCB2G 50mm² / 0.21 T180 0.6/0.9kV
acc. LV216-2 Tab.A.2
Part No.: 9-2611 / 50mm²
4. APPLICATION TOOLS
Required application tools are:
Minimum requirements for the press are 20t.
Wire
Type
Wire
Size
[mm²]
Construction
Stripping
Length
[mm]
Crimp
height
CH1
[mm]
Wire std
Specification
Supplier
Contact P/N
Geometry
Applicator
Crimping press used
by TE for Product
Validation
Pure
copper
6
84 x 0.31mm
13,0 ± 1
3,7 ±0,1
LV216-2
FHLR2GCB2G
3x6.0mm²
Coroplast
2293266-3
2-2293266-3
W
7-528041-0
HV Crimping Machine
528008-4 with adapter
or
HV-20
2348822-1 1
Cycle time: 1.7 - 2.5s
Stroke: 44mm
2293266-4
16
512 x 0.21mm
16,0 ± 0,5
5,10 ±0,1
LV216-2
FHLR2GCB2G
single
Coroplast
2292541-4
2-2292541-4
W
2276149-2
500 x 0.21mm
16,0 ± 0,5
5,10 ±0,1
LV112-1
FLY single
Coficab
2293267-4
2-2293267-4
W
2276149-7
50
1600 x
0.21mm
23,5 ±0,5
9,4±0,15
LV216-2
FHLR2GCB2G,
single
Coroplast
2292541-1
W
2276149-4
Crimp
Ferrule
50
1600 x
0.21mm
See step
5b
15.3 ±0.1
LV216-2
FHLR2GCB2G,
single
Coroplast
2316553-2
-
8-528041-2
or
2234183-1
1recommended for new projects using modular die sets
Table 1

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5. REQUIREMENTS ON THE CRIMPED CONTACT
5.1. Terms of pin contact
5.2. Conductor position
The single strands of the conductor are clamped in the wire barrel (drill hole at crimp area). Sticking out or
on top crimped single strands are not permitted.
The wire end must be visible at the inspection hole before and after crimping. Insulation may not be inside of
the crimping area.
5.3. Crimp data for the wire crimp
The crimp form, 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.
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 (figure 2, also see
point 5.9).
Figure 1

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Crimp Die Sets are subject to wear and their condition and quality have to be monitored. Suspect and/or
worn Die Sets have not to be used for the production of these crimps. Die Sets are available as spare
parts.
5.4. Crimpposition
Contacts of diameter 6mm² have to be crimped with crimping tool position at middle of crimp area as
shown.
H
Figure 2
Figure 3
Measuring plane

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Contacts of wire diameter 16 mm² and 50mm² have to be crimped with crimping tool position at end of
crimp area as shown.
Figure 4

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5.5. Cross sections
When creating cross sections, the correct grinding layer must be selected. The
Grinding layer has to be at middle of crimp area and may not be inside of serration.
5.6. Contact area
During processing and following processing, the contact area may not be damaged or bended.
5.7. Sealing area
During processing and following processing, the sealing area may not be damaged or bended.
5.8. Shape and position tolerances
For 6 mm² and 16 mm² meeting the specific shape and position tolerances shown at figure 6 must be ensured
before the contact is inserted into the housing.
Figure 5
Figure 6

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For 50 mm² meeting the specific shape and position tolerances shown at figure 7 must be ensured before
the contact is inserted into the housing.
Measuring the shape and position deviation is not always necessary.
If the contact is obviously straight by eye a simplified shape and position functional test, at diameter 6mm²,
can be performed by inserting it into a suitable housing cavity (crimp may not scrape the walls of secondary
lock).
If contacts are bent during the application process exceeding the specification limits they may not be bent
back and must be rejected.
5.9. Measuring equipment and measuring position
As measuring equipment for measuring crimp height, a digital caliper with accuracy of measuring
0.01mm is required. Measuring of crimp height, has to be done always in middle of crimp area,
across whole crimp.
H
Figure 9
Figure 8
Figure 7

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6. ASSEMBLY INSTRUCTIONS
In this chapter the way of assembly is described. All pictures in this chapter may differ from the
specific product. The pictures illustrate the way of assembly and may not reflect all variants. The
exact appearance of the components can be seen in the drawing documentation.
6.1. Assembly overview
Charge Inlet CCS I
Pos.
Description / Bezeichnung
1
INLET HSG, COMBO1, ASSY
2
12P MICRO MNL ASSY
3
PIN DIA 3.6, AC
4
PIN DIA 2.8, PE
5
PERIPHERAL SEAL
6
CABLE EXIT
7
FAMILY SEAL, AC
8
STRAIN RELIEF, AC
9
COVER, CABLE SEAL, AC
10
COVER, CABLE SEAL, DC
11
FAMILY SEAL, DC
12
PIN, DIA8.0
13
SEALING
14
WATER DRAIN
15
4POS MQS ASSY
16
OUTER FERRULE
Table 2
Figure 10

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6.2. Assembly configuration cable exit
The inlet can be assembled with different cable exit directions.The required configaration can be
chosen according to customer requirement.
Configurations for cable exit AC 90° sidewards:
Configurations for cable exit AC 20° downwards:
6.3. Parts to order
See 2.1.a
Attention of symbol triangle and rectangle
PE cable must be always in lower position
PE cable can be chosen left/right
Figure 11

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6.4. Security Advice
The assembly should only be performed by trained personnel.
Avoid prolonged or repeated skin contact with silver plated contacts (wear protective gloves)!
ATTENTION!
- HIGH VOLTAGE APPLICATION -
CABLE INSULATION MUST NOT BE DAMAGED!
Figure 12
Figure 13
ESD safety euied- The pited iuid oads ae stati sesitie
deies, hih a e daaged if touhed ithout the eessay
eletostati dishage ESD peautios. Duig hadlig of the ope
Ilet assely ESD safety is euied. Cadoad pakagig of the
INLET HSG Pos. 1 ae oly to e opeed i ESD poteted aeas.
ATTENTION!

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6.5. Assembly Steps
Step 1
The COVER CABLE SEAL AC [Pos. 9], STRAIN RELIEF AC [Pos. 8] and FAMILY SEAL AC [Pos. 7]
must be pushed over the signal wires, the ground wire and the AC-Multicore wire. Pay attention to place
all wires at correct positions. (Figure 14).
Step 2
Preparation of AC multicore cable.
THE SINGLE BRAIDS MAY NOT BE CUT OR DAMAGED DURING DISMANTLE PROCESS.
Remove outer isolation, shield and filler of AC-multicore-cable acc. figure 15.
The given length of the single wires shown in table 3, ensures that the outer isolation of the multicore
cable seals off to the FAMILY SEAL AC [Pos. 7. A marking on outer isolation in a distance “C” (or in a
offset to “C”) to the cut off position is recommended to ensure the proper position of the outer isolation
in the FAMILY SEAL AC [POS.7].
Wire Size
Removal of isolation
"A"
Length of single
wires “B”
Position outer end of
COVER [POS.9]
“C”
6 mm²
13 +/-1 mm
68 +/-2 mm
96 +/-4 mm
Table 3
Figure 14
Figure 15

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Alternative to prepar cable according step 2 figure 15, is it also possible to prepare cable similar
figure 16. In this case it is necessary to protect complete overlapping shield braid with tape (e.g.
Certoplast 9mm). A marking on outer isolation in a distance “E” (or in an offset to “E”) to the cut off
position is recommended to ensure the proper position of the outer isolation in the FAMILY SEAL AC
[POS.7].
Wire Size
Removal of
isolation
"A"
Length to filler
“B”
Length to
shield braid
“C”
Length to outer
insulation
“D”
Position outer end
of COVER [POS.9]
“E”
6 mm²
13 +/-1 mm
65 +/-2 mm
73 +/-2 mm
78 +/-2 mm
106 +/-4 mm
Table 4
Crimp the conductors to the PIN DIA3.6 POWER AC [Pos. 3] with the specified tools. Care shall be
taken that all braids are caught in the crimp. Not inserted braids may jeopardize HV requirements! Wires
shall be completely inserted to be visible through the inspection hole (Figure 17). Crimp height H shall
be conform to dimension acc. table 1.
Any damage of the wire isolation must be avoided
Figure 17
Figure 16

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Step 3
Preparation of PE single wire.
Dismantle PE-single wire cable acc. Figure 18.
THE SINGLE BRAIDS MAY NOT BE CUT OR DAMAGED DURING DISMANTLE PROCESS.
Wire Size
Variant of CABLE
EXIT [POS. 6]
Removal of
insulation "A"
Position outer end of
COVER [POS.9]
“B”
16 mm²
AC 90° (rect. right / left)
16.0 +/-1 mm
95 mm REF
AC 20° down (straight)
95 mm REF
Table 5
Crimp conductor on PIN DIA 2,8 POWER PE [Pos. 4] with the specified tools. Care shall be taken that
all braids are caught in the crimp. Not inserted braids may jeopardize HV requirements! Wires shall be
completely inserted to be visible through the inspection hole (Figure 19). Crimp height H shall be conform
to dimension
Any damage of the wire isolation must be avoided
Figure 18
Figure 19

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Step 4
Dismantle LV single wires (dim. A) acc. spec. 114-13000. Crimp Contacts acc. Spec. 114-13000 on LV
signal wires.
THE SINGLE BRAIDS MAY NOT BE CUT OR DAMAGED DURING DISMANTLE PROCESS.
Wire Size
Variant of CABLE EXIT
[POS. 6]
Removal of
isolation
"A"
Position outer end of
COVER [POS.9]
“B”
0,35mm²
AC 90° (rect. right / left)
Acc. 114-13000
80 mm REF
AC 20° down (straight)
75 mm REF
Table 6
Push signal terminals into the Connector Housing 12P MICRO MNL [Pos. 2] (not part of Charging Inlet)
acc. application spec 114-13000. Take care of correct pinning as shown in figure 22
Micro Mate-N-Lock
Connecor
Figure 20
Figure 21
Figure 22

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Step 5
There are 3 different ways of preparation of DC-HV-Cables necessary:
For DC-HV-Cables of 16mm² in combination with CABLE EXIT AC 90° SIDEWARDS please see Step 5a.
For DV-HV-Cables of 50mm² in combination with CABLE EXIT AC 90° SIDEWARDS please see Step 5b.
For DV-HV-Cables of 50mm² in combination with CABLE EXIT AC 20° DOWN please see Step 5c.
Step 5a
DC-HV-Cables of 16mm² in combination with CABLE EXIT AC 90° SIDEWARDS.
THE SINGLE BRAIDS MAY NOT BE CUT OR DAMAGED DURING DISMANTLE PROCESS.
Remove outer isolation and shielding braid of DC-HV-Cable acc. dimension B, remove inner isolation
acc. dimension A (figure 23).
Wire Size
Removal of isolation
"A"
Removal of shielding dim
“B”
Position outer end
of COVER [POS.10]
“C”
16mm²
16 +/-1 mm
25 +/-1 mm
53 mm REF
Table 7
Alternative to prepar cable according step 5a figure 24, is it also possible to prepare cable similar figure
24. In this case it is necessary to protect complete backward folded shield braid (folded over outer
isolation) with tape (e.g. Certoplast 9mm).
Wire Size
Removal of
isolation
"A"
Length of shield
braid (before
folding backward)
“B”
Length of outer
isolation
“C”
Pos.Tape
“D”
Position outer end
of COVER [POS.10]
“E”
16 mm²
16 +/-1 mm
21 +/-2 mm
26 +/-2 mm
max. 38mm
53 mm REF
Figure 23
Figure 24

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Table 8
Take care, to protect single conductors and braid against contamination, bending and other damages
until crimping process.
The COVER CABLE SEAL DC (Pos. 10) and FAMILY SEAL DC [Pos. 11] must be pushed over the
DC-HV-wires (figure25)
Crimp the conductors to the PIN DIA8.0 CONTACT [Pos. 12] with the specified tools. Care shall be
taken that all braids are caught in the crimp. Not inserted braids may jeopardize HV requirements! Wires
shall be completely inserted to be visible through the inspection hole (Figure 26). Crimp height H shall
be conform to dimension acc. table 1.
ATTENTION:
Any damage of the wire isolation must to be avoided!
Figure 26
Figure 25