TE Connectivity COMBO2 Charge Inlet PSA 1-PH Manual
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TE Connectivity COMBO2 Charge Inlet PSA 1-PH Manual

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Single-Phase Version
1-PH
© 2021 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
Class 1
COMBO2 Charge Inlet PSA
114-15139 Rev.B
12 AUGUST 2021
Three-Phase Version
3-PH
1 of 49

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Summary of Contents for TE Connectivity COMBO2 Charge Inlet PSA 1-PH

  • Page 1 © 2021 TE Connectivity family of companies 1 of 49 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.

  • Page 2: Table Of Contents

    Content ............................3 Processing Note ........................3 Shelf life of the components ...................... 3 APPLICABLE DOCUMENTS ....................3 TE Connectivity Documents ...................... 3 CABLE SPECIFICATIONS....................... 4 Specifications of Prescribed Cables ..................4 Cable selection .......................... 4 Cable preparation ........................5 APPLICATION TOOLS ......................

  • Page 3: Scope

    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. 2.1. TE Connectivity Documents a) Customer drawings for Inlet Combo 2 INLET HSG, COMBO2, ASSY 2322811...

  • Page 4: Cable Specifications

    12 AUGUST 2021 CABLE SPECIFICATIONS 3.1. Specifications of Prescribed Cables PRELIMINARY CABLE DEFINITION: This cable list will be updated after product validation – only cables used during product validation will be specified – non-validated cables will be removed from this list. 2x AC-cable (L1 and N): cross-section 6,0mm²...

  • Page 5: Cable Preparation

    12 AUGUST 2021 3.3. Cable preparation ATTENTION: Cable ends must be cut accurately: the cut must not damage family seal during pass through. The cable insulation must be stripped before crimping (this step must always come after insertion through family seal). The stripping length of the outer insulation and shield is defined in the following Assembly Steps. The insulation must be cut accurately and pulled off from the conductor.

  • Page 6: Requirements On The Crimped Contact

    12 AUGUST 2021 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. REQUIREMENTS ON THE CRIMPED CONTACT 5.1.

  • Page 7: Crimp Geometry

    12 AUGUST 2021 5.3. 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.

  • Page 8: Crimp Position

    12 AUGUST 2021 5.6. Crimp Position The TE applicator positions the contacts in the crimping tool at middle position as shown, figure 5 and 6. Correct position and condition of applicator has to be checked for every production lot. Figure 5 (pic exemplarily) Figure 6 (pic exemplarily) 8 of 49...
  • Page 9 12 AUGUST 2021 Contacts for wire diameter 16 mm² and 50mm² have to be crimped with crimping tool position at end of crimp area as shown figure 7. Figure 7 9 of 49...

  • Page 10: Contact Area

    12 AUGUST 2021 5.7. Contact area During all processing operations the contact area must not be damaged or bended. 5.8. Sealing area During all processing operations the sealing area must not be damaged or bended. 10 of 49...

  • Page 11: Shape And Position Tolerances

    12 AUGUST 2021 5.9. 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 required at least a 10-time better measuring precision compared with the requirement tolerances, see figure 8 and 9.

  • Page 12: Assembly Instructions

    12 AUGUST 2021 ASSEMBLY INSTRUCTIONS 6.1. Assembly overview Charge Inlet COMBO 2 Figure 11.1 (1-PH) Figure 11.2 (3-PH) NOTE: All other Parts are identical to Single-phase Version 12 of 49...

  • Page 13: Parts To Order

    12 AUGUST 2021 6.2. Parts to order Charge inlet COMBO 2 1-phase AC 6mm² 3-phase AC 4x6mm² Variant Ground 16mm² Ground 16mm² DC 50mm² DC 50mm Part Pos. Name COMBO 2, CHARGE INLET ASSY 2322811-1 2322811-2 PIN DIA 6, PE, 16mm² 2293270-4 Same as 1-PH PIN DIA 6, POWER AC, ASSY, 6mm²...

  • Page 14: Assembly Configurations Cable Exit

    12 AUGUST 2021 6.3. Assembly Configurations Cable Exit The inlet can be assembled with different Cable Exit directions. The configuration to be used for PSA COMBO 2 is with Cable Exit as shown in figures 12.1 and 12.2. Figure 12.1 (1-PH): Assembly view from backside for information.

  • Page 15: Security Advice

    12 AUGUST 2021 Security Advice – Handling Warning 6.4. ATTENTION! - HIGH VOLTAGE APPLICATION - CABLE INSULATION MUST NOT BE DAMAGED! 1) The assembly has only been performed by trained personnel. 2) Avoid prolonged or repeated skin contact with silver plated contacts (wear protective gloves)! 3) In case of any shock or drop of components during handling, these components must be scrapped.

  • Page 16: Assembly Steps

    12 AUGUST 2021 6.5. Assembly Steps Step 1 for 1-PH The COVER CABLE SEAL AC 2316424-1, STRAIN RELIEF AC 2316423-2 and FAMILY SEAL AC 2316422-2 must be pushed over the signal, earth and AC wires. Pay attention to place all wires at correct positions, figure 13.1.
  • Page 17 12 AUGUST 2021 Step 1 for 3-PH The COVER CABLE SEAL AC 1802438-1, STRAIN RELIEF AC 1802437-1 and FAMILY SEAL AC 1802436-1 must be pushed over the signals, earth wires and AC cable. Pay attention to place all wires at correct positions, figure 13.2. Especially ensure the correct position of the flange of the L-shaped FAMILY SEAL AC towards the STRAIN RELIEF.
  • Page 18 12 AUGUST 2021 Step 2 for 1-PH Dismantle the wires: AC and PE (earth) wires Remove outer insulation acc. Figure 14.1 and table 3. Figure 14.1 Wire Size Removal of insulation dim. "A" 6 mm² (AC) 13 mm +/- 1mm 16 mm²...
  • Page 19 12 AUGUST 2021 Step 3 Signal-Wires 0,5mm² Dismantle single wires acc. spec. 114-13000, see figure 15 and crimp the contacts 0-794606-1 acc. to crimping parameters below. Figure 15 TE crimping recommendations for terminal TE P/N 0794906-1 with wire 0.5mm²: TE Applicator: P/N 2151022-2 Data in mm for COFICAB C3ZH 0.5mm²...
  • Page 20 12 AUGUST 2021 After Crimping the subassembly of cables with Cable Exit components is in the condition shown in figure 16.1 and 16.2: Harness Side Inlet Cable Exit side Figure 16.1 for 1-PH Harness Side Inlet Cable Exit side Figure 16.2 for 3-PH 20 of 49...
  • Page 21 12 AUGUST 2021 Step 4 Push signal terminals 0-794606-1 (Micro Mate’n’Lock) into the Connector Housing 1-794617-0 acc. application spec 114-13000. Pinning according figure 17: For 1-PH For 3-PH PINOUT PINOUT Ways Ways Ways Ways Pin# Pin# Pin# Pin# B_A_CP B_A_CP O_A_NTC1_DC O_A_NTC1_DC O_A_NTC1_AC...
  • Page 22 12 AUGUST 2021 Step 4a At the end of this step, it is suggested to add min/max position marking on the wires to be used at Step 9 in order to ensure Family Seal / Strain Relief and Cover position compare to each wire – see Step 9 for further details.
  • Page 23 12 AUGUST 2021 After Micro Mate’n’Lock connector housing is assembled, the subassembly of cables with Cable Exit components is complete, see figure 18.1 and 18.2: Figure 18.1 for 1-PH 23 of 49...
  • Page 24 12 AUGUST 2021 Figure 18.2 for 3-PH 24 of 49...
  • Page 25 12 AUGUST 2021 Step 5 The COVER CABLE SEAL DC 2296059-4 and FAMILY SEAL DC 2296058-4 must be pushed over the 50mm² DC-Power cables, figure 19. Especially ensure the correct position of the flange of the L-shaped FAMILY SEAL AC towards the COVER CABLE SEAL, figures 19 and 19a. Component insertion direction over the wires Figure 19...
  • Page 26 12 AUGUST 2021 The COVER CABLE SEAL DC and FAMILY SEAL DC must be pushed over the DCHV cables as shown in Figure 21. Step 5b Fold back the shielding braid over the outer insulation of the cable. Push then the OUTER FERRULE 2316553-2 over the shielding braid. Take care of position for OUTER FERRULE 2316553-2, free shielding braid longer than outer ferrule must be cut as shown in Figure 22.
  • Page 27 12 AUGUST 2021 Crimp the Ferrule (2316553-2) with the specified tools. Care shall be taken that all braids are caught in the crimp. Not inserted braids may jeopardize HV requirements! Crimp height H shall be conform to dimension acc. table 6. Hex Crimp Height H Measurement Position Crimped Ferrule retention...
  • Page 28 12 AUGUST 2021 Step 5d The two SEALING 2120571 have to be placed on the PIN DIA8.0 CONTACTS. Ensure correct position acc. picture (sealing libs on outside). Figure 27 Figure 28 Step 6 Pass the SIGNAL CONNECTOR, AC POWER PINS and PE PIN through the AC slot and DC PINS through DC slot in Combo Cable Exit 2323264-1 Figure 29.1 for 1-PH Figure 29.2 for 3-PH...
  • Page 29 12 AUGUST 2021 Step 7a Insert the Contacts from the backside into the Inlet Housing according to the cavity description into their locking position. To ensure that the contacts are correctly inserted, pull with a low force on the cables (max.
  • Page 30 12 AUGUST 2021 Cavity AC – L1 Cavity AC – N Cavity PE – EARTH Cavity AC – L3 Cavity AC – L2 Cavity DC - Cavity DC + Figure 30.2 for 3-PH: AC and PE cavities 30 of 49...
  • Page 31 12 AUGUST 2021 ATTENTION: The correct contact cavity position must be ensured BEFORE pushing the contact into the cavity in locking position. In case of wrong positioning of the contacts, the complete assembly must be scrapped. There is no rework allowed (risk of damaging contacts and/or locking geometry in housing)! harness wires must not cross each other’s under Cable Exit cover to allow ATTENTION: For 1-PH,...
  • Page 32 12 AUGUST 2021 ATTENTION: For 3-PH, individual AC wires must not cross each other’s under Cable Exit cover to allow proper closing. This rule is applicable for 6mm² wires with any other wire (0.5mm²; 6mm² wires). The PE 16mm² wire should only cross on top of the AC wires. Signal wires 0.5mm²...
  • Page 33 12 AUGUST 2021 Figure 30.1b for 3-PH 33 of 49...
  • Page 34 12 AUGUST 2021 DC + DC - Terminal insertion direction into cavities Figure 31 Figure 31a 34 of 49...
  • Page 35 12 AUGUST 2021 Step 7b Push upward and Lock in position both Secondary Locks. Ensure that all hooks are properly engaged with the inlet housing. For 3-PH, the Secondary Lock of AC terminals has to be pushed first before the Secondary Lock of DC terminals can be pushed.
  • Page 36 12 AUGUST 2021 Push upward the Secondary Lock of AC terminals Push upward the Secondary Lock of DC terminals Figure 32.2 for 3-PH 36 of 49...
  • Page 37 12 AUGUST 2021 Figure 32.1a for 1-PH Secondary Locks in locked position 37 of 49...
  • Page 38 12 AUGUST 2021 Figure 32.2a for 3-PH Secondary Locks in locked position 38 of 49...
  • Page 39 12 AUGUST 2021 Step 8 Connect Micro Mate’N’Lock Connector to PCB-Header. Ensure the hook is properly engaged with the header, see figure 33. MATE N Lock Connector plugged Figure 33 39 of 49...
  • Page 40 12 AUGUST 2021 Step 9 ATTENTION: Ensure harness wires are not crossing each other before closing the Cable Exit: no harness twist allowed under Cable Exit. Assemble the Cable Exit Cover 2323264-1 to the Inlet Housing Assy 2322811-1 for 1-PH and 2322811-2 for 3-PH.
  • Page 41 12 AUGUST 2021 Step 10 10-1 for 1-PH Place the STRAIN RELIEF AC 2316423-2 together with FAMILY SEAL AC 2316422-2 into their position in the CABLE EXIT 2323264-1 ATTENTION: Ensure that the AC and PE cables are well positioned in the FAMILY SEAL, that all seal lips are safely placed on the outer isolation of the cables.
  • Page 42 12 AUGUST 2021 10-1 for 3-PH Place the STRAIN RELIEF AC 1802437-1 together with FAMILY SEAL AC 1802436-1 into their position in the CABLE EXIT 2323264-1 ATTENTION: Ensure that the AC and PE cables are well positioned in the FAMILY SEAL, that all seal lips are safely placed on the outer isolation of the cables.
  • Page 43 12 AUGUST 2021 10-3 Place the FAMILY SEAL DC 2296058-4 into position in the CABLE EXIT 2323264-1. Figure 37 Figure 37 ATTENTION: Ensure that the DC power cables are well positioned in the FAMILY SEAL, that all seal lips are safely placed on the outer isolation of the cables. 10-4 Push the COVER CABLE SEAL DC 2296059-4 over it and snap it on the CABLE EXIT COVER 2323264-1.
  • Page 44 12 AUGUST 2021 Step 11 Place a cable tie (proposed dimensions 2,5mm wide, material to be heat stabilized and suitable for automotive use) around the single wire signal cables and the bridge at the Cover Cable Seal 2316424- for 1-PH and 1802438-1 for 3-PH and pull tight, see figure 39.1 and 39.2.
  • Page 45 12 AUGUST 2021 Step 13 If needed, there are 3 anchor points on the cover where cable ties can be placed in different positions following cable routing. See figures 41 – 41a. Figure 41 Figure 41a 45 of 49...

  • Page 46: End Of Line (Eol) Tests

    12 AUGUST 2021 6.6. End of Line (EOL) Tests The assembled Charge Inlet has to be tested electrically and mechanically to applicable requirements, including High Voltage test. For all electrical tests: test pins must be used for all terminals of connector interface side (front face). Test pins contact Force must be 1.25N +/-0.25N.
  • Page 47 12 AUGUST 2021 APPENDIX 1: Allowed test pin contact area Contact surface allowed area for test-pins are defined from front surface as shown in red and as specified hereafter for each terminal. Be careful that test points touch metallic surface of the contacts & not the plastic protection cap (AC-L1;...
  • Page 48 12 AUGUST 2021 APPENDIX 2 : Electrical test summary table and Ways overview Table for 1-PH Table for 3-PH *RESISTANCE MEASUREMENT VALUE TO BE WITHIN TOLERANCES AS SPECIFIED HEREAFTER, DEPENDING ON AMBIENT TEMPERATURE: NOMINAL RESISTANCE TOLERANCE ±2KΩ [kΩ] VALUE VS TEMPERATURE AMBIANT TEMPERATURE °C 48 of 49...
  • Page 49 3PH WIRE ASSEMBLY PROCEDURE P32; ADDED CRITERIA LEAKAGE TEST P44 UPDATE 1PH WIRE MARKING LENGTHS P22; ADDED C.VOLANTIN B. DUPONT 12AUG.2021 RESISTANCE CURVE P48 C. VOLANTIN TE CONNECTIVITY FRANCE 02AUG2017 1 RUE AMPERE 95300 PONTOISE FRANCE E. CHATELUS 02AUG2017 B. DUPONT...

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Combo2 charge inlet psa 3-ph

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