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TE Connectivity CCS1 Manual

Application specification vehicle charge inlet 120 mm2
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Application Specification Vehicle Charge Inlet Type
CCS1 120 mm
© 2024 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
.
owner
Application
Specification
Class 1
2
114-94758
20 NOVEMBER 2024 REV A 2
1
1 of 45

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Summary of Contents for TE Connectivity CCS1

  • Page 1 1 of 45 © 2024 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 owner...

  • Page 2: Table Of Contents

    Content SCOPE .................................. 3 Content .................................. 3 Processing Note..............................3 APPLICABLE DOCUMENTS ..........................4 2.1. TE Connectivity Documents ..........................4 2.2. General Documentation ............................6 APPLICATION TOOLS ............................7 WIRES ................................... 7 Assessment of the wires ............................7 Wire selection ................................ 7 Wire preparation ..............................

  • Page 3: Scope

    114-94758 SCOPE Content This specification describes the assembly and handling of the vehicle charge inlets Combo 1 acc. IEC62196-3 for conductive charging of electric vehicles with AC current and DC current for fast charging. This specification applies to manual assembly of the components in series production configuration.

  • Page 4: Applicable Documents

    TE Connectivity Documents a) Customer drawings for inlet type Combo 1 CHARGE INLET ASSY WITH /WITHOUT AC AND WITH /WITHOUT LED CCS1 INLET HSG, COMBO1, ASSY 2402048 PIN CONTACT SERIES 3.6, 6 mm² 6µm Ag...
  • Page 5 114-94758 b) Specifications 108-94867 Product Spec. Vehicle Charge Inlets Combo 1 114-13000 Application Specification Micro Mate-N-Lock Connectors 108-94519 Product Specification Vehicle Charge Inlet Actuator GEN 2 114-94842 Dia 8 mm, Pin Terminal, Welding Application of Ultrasonic Weld Connection 114-18061 Application Specification MQS Connectors sealed 5 of 46...

  • Page 6: General Documentation

    114-94758 General Documentation Cable Specifications of Prescribed Cables AC-cable: cross-section 2 x 6,0 mm² Supplier Coroplast Outer Diameter 12.5±0.3 mm Min. bending radius 3xD (static) Cable description FHLR2GCB2G 2x6.0mm² similar LV216-2 class F (T200) TPJLR.18.007, Issue 3 Supplier Part No.: 9-2641 (2x6mm²) DC-HV-Cable : Cross-section 120 mm²...

  • Page 7: Application Tools

    114-94758 APPLICATION TOOLS To produce a correct wire crimp, as validated by TE with the wires listed in this specification, following application tools are required. Stripping Crimp TE Crimp Length /WELD Wire Validation is based single wire Size height Cable Specification Supplier Contact P/N Applicator...

  • Page 8: Requirements On The Crimped Contact With W-Crimp Shape (Closed Barrel)

    114-94758 REQUIREMENTS ON THE CRIMPED CONTACT WITH W-CRIMP SHAPE (CLOSED BARREL) The following terms shown below are used in this specification, see Figure 1. Figure 1 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 stand must remain outside the crimp.

  • Page 9: Cross Sections

    114-94758 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 has to be measured over both extensions in middle of the crimp, Figure 3: Figure 3 (picture exemplarily) Cross Sections When creating cross-sections, the correct grinding layer must be selected.

  • Page 10: Crimp Position

    114-94758 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 (picture exemplarily) Figure 6 (picture exemplarily) Contact area During processing and following processing, the contact area may not be damaged or bended.

  • Page 11: Shape And Position Tolerances

    114-94758 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 7 and 8. Meeting the specific shape and position tolerances must be ensured before the contact is inserted into the housing.

  • Page 12: Requrements On The Weld Contact With Welding Flag

    114-94758 REQUREMENTS ON THE WELD CONTACT WITH WELDING FLAG The welding of the 120 mm² cables on 180 DEG DC power contacts with weld flag geometry has to be processed according to Application Specification 114-94842. 12 of 46...

  • Page 13: Assembly Instructions

    114-94758 ASSEMBLY INSTRUCTIONS Assembly overview Charge Inlet Combo1 Charge Inlet Combo 1 without AC & with LED Kit Figure 10a 13 of 46...
  • Page 14 114-94758 Charge Inlet Combo 1 with AC & with LED Figure 10b 14 of 46...
  • Page 15 114-94758 Charge Inlet Combo 1 with AC & without LED Figure10c 15 of 46...
  • Page 16 114-94758 Charge Inlet Combo 1 without AC & without LED Figure10d 16 of 46...

  • Page 17: Parts To Order

    114-94758 7.2.1 Parts to order for 12V Actuator Variants 17 of 46...

  • Page 18: Wire Cover

    114-94758 LV WIRE COVER 2369838-1 2369838-1 2369838-1 2369838-1 CABLE COVER, AC 2401256-1 2401256-1 CABLE COVER, PE 2369840-3 2369840-3 2369840-3 2369840-3 SINGLE WIRE SEAL DC, 2399667-3 2399667-3 2399667-3 2399667-3 120 mm² STRAIN RELIEF DC, 2399668-3 2399668-3 2399668-3 2399668-3 120 mm² SINGLE SEAL COVER DC, 2399669-3 2399669-3 2399669-3...
  • Page 19 114-94758 PIN CONTACT SERIES 3.6, 2-2293266-3 2-2293266-3 6 mm² 6µm Ag COMBO 1, CHARGE INLET 2389290-1 2389290-1 HSG, CAVITY PLUG PIN CONTACT, DIA 2.8, 2293267-5 2293267-5 2293267-5 2293267-5 PE (25 mm²) PROTECTION CAP, TE, 2292534-1 2292534-1 2292534-1 2292534-1 WATER DRAIN SEALING DC TERMINALS 2338077-1 2338077-1...

  • Page 20: Assembly Configurations Cable Exit

    114-94758 4POS MQS CONNECTOR HSG, SEALS AND p/n acc. Prod. p/n acc. Prod. p/n acc. Prod. p/n acc. Prod. CONTACTS Spec. Spec. Spec. Spec. (ADDITIONAL PART FOR 108-94519 108-94519 108-94519 108-94519 CHARGE INLET CABLING) Optional: FLAP CARRIER, INLET 2358664-5 COMBO, ASSY Optional: FLAP CARRIER, INLET 2358664-1...

  • Page 21: Security Advice

    114-94758 7.5 Security Advice ATTENTION! - HIGH VOLTAGE APPLICATION - CABLE INSULATION MUST NOT BE DAMAGED! The assembly has only be performed by trained personnel. Avoid prolonged or repeated skin contact with silver plated contacts (wear protective gloves)! 21 of 46...

  • Page 22: Assembly Steps

    114-94758 7.6 Assembly Steps Step 1 The AC, PE & SIGNAL COVER, AC & PE STRAIN RELIEF and AC, PE & SIGNAL SEAL 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 13.
  • Page 23 114-94758 Step 3 Dismantle the wires and crimp the contact: 25 mm² PE (ground) single wire Remove outer insulation acc. Figure 15 and table 5. Figure 15 Wire Size Removal of insulation dim. "A" Needed wire length inside inlet 25 mm² 18 +/- 1 mm 78 +/- 5 mm Table 6...
  • Page 24 114-94758 Figure 17 (schematic; crimp geometry not shown) Step 5 Push signal terminals 794606-1 (Micro Mate ’N’ Lock) into the Connector Housing 1-794617-2 acc. application spec 114-13000. Pinning according to Figure 18 and table 6a & 6b for with & W/O LED: Figure 18 Cavity No.
  • Page 25 114-94758 Cavity No. Function T DC+ Proxi GND , Temp T DC- T AC PE S Table 7b After Micro Mate ’N’ Lock connector housing assembly the subassembly of cables with cable exit components is complete, see Figure 19 MATE’N’LOCK Connector Figure 19 (schematic;...
  • Page 26 114-94758 Figure 20 Figure 20a Pass the cables through the DC area in the Cable Exit with AC 2390858-2 (Figure 21) or Cable Exit without AC 2390858-1 (Figure 21a) Figure 21 Figure 21(a) 26 of 46...
  • Page 27 114-94758 Step 7 120 mm² DC Power Cables. Strip the wires (Figure 23, Table 7), apply tape to completely cover the remaining cut shield braids and weld the contacts assemblies 2402050-1 according to the 114-94842 specification. Make sure that the distance between the cut shield braids and the open conductor is MIN. 5 mm to ensure creepage and clearance requirements are maintained.
  • Page 28 114-94758 Table 8 Apply the TESA 51618 tape of 19 mm width onto the cut shielding like shown in Figure 23a. The number of loops of tape will be decided by the harness maker, however, need to ensure that the shield is completely covered with tape and the tape not on the sealing area.
  • Page 29 114-94758 Step 8 Assemble the DC contact seals 2338077-1 on the DC contact assemblies. (Figure 25). Pay attention to not damage the seal during handling. Make sure the seal does not twist or flip around, correct assembly is shown in Figure 25a Figure 25 Figure 25a Step 9...
  • Page 30 114-94758 Figure 26a (exemplary) Step 10 The PERIPHERAL SEAL, CHARGE INLET, 2338079-1 needs to be assembled before you move forward with the terminal assembly into the CHARGE INLET HSG, COMBO 1, ASSY 2402048. Figure 27 30 of 46...
  • Page 31 114-94758 Step 11 Insert the Contacts from the backside into the Inlet housing according to the cavity description (see Figure 28) into their locking position, see Figure 29. To ensure that the contacts are correctly inserted, pull with a low force on the cables (max.
  • Page 32 114-94758 Figure 29 Figure 29a Proposed sequence for contact insertion: 1.) 2x 6 mm² AC Power Cable with contacts into L1 and L2/N cavities 2.) 25 mm² Ground Cable with contact into PE/ground cavity 3.) 2x 120 mm² DC Power Cable with contacts into DC+ and DC- cavities 32 of 46...
  • Page 33 (Figure 30). Ensure that both latches are properly engaged with the inlet housing, which must be controlled by the double audible click and by visible inspection. Secondary Locks CCS1 in end position shown in Figure 31 and 31a:...
  • Page 34 114-94758 Step 13 Connect Micro Mate’N’Lock Connector to PCB-Header. Ensure the hook is properly engaged with the header, see Figure 32. MATE’N’LOCK Connector Figure 32 34 of 46...
  • Page 35 114-94758 Step 14 Mount the CABLE EXIT COVER 2390858-1 w/o AC or 2390858-2 with AC to the CHARGE INLET HSG, COMBO1, ASSY, 2402048. Ensure that all 6 hooks are correctly engaged. The press forces must be applied on the marked locations close to the latches, see Figure 33. ATTENTION: The CABLE EXIT COVER 2390858 needs to be aligned properly over the inlet and pushed vertically into position to make sure the seal slips correctly seated all around (Figure 33).
  • Page 36 114-94758 ATTENTION: The Cable Exit Cover 2390858-1 and 2390858-2 needs to be aligned properly over the inlet and pushed vertically into position to make sure the seal slips correctly into the seating all around (Figure 34) Figure 34 36 of 46...
  • Page 37 114-94758 Step 15 Move the STRAIN RELIEF together with SEAL into their position in the CABLE EXIT WITH OUT AC 2390858-1OR WITH AC 2390858-2, see Figure 35 ATTENTION: Ensure that the AC cable is well positioned in the SEAL, that all seal lips are safely placed on the outer isolation of the cables.
  • Page 38 114-94758 Cable tie End of the outer Position of cable insulation seal lips Figure 36a – PE seal lips Position of seal lips End of the outer cable insulation Figure 36b – DC seal lips 38 of 46...
  • Page 39 114-94758 Step 16 Assemble Protection Cap 2292534-1 at Inlet Housing, see Figure 37. Protection cap Figure 37 39 of 46...
  • Page 40 114-94758 Step 17 As part of the End of Line Test as listed in (Chapter 7.7), perform the tightness check of the fully assembled charge inlet. The pressure port on the rear of CABLE EXIT COVER 2390858-1 or 2390858-2 (shown in Figure 38) is designed to fit an elastic plastic tube (Polyurethane or similar) with an outer diameter of 4 mm.
  • Page 41 114-94758 The tubular geometry of the pressure port has a reduced inner diameter towards the bottom to increase the pressure on the elastic tube when being inserted. The tube needs to be pushed that far into the pressure port that a reliable sufficient air tightness can be achieved, see Figure 39 for exemplarily inserted tube. Figure 39 For the tightness check it is intended to perform an air differential pressure decay leak measurement test.
  • Page 42 114-94758 Step 18 Assembly of 4pos MQS connector Assemble the Connector for the Actuator connection acc. to application spec of MQS-Connector. (Applicator 2151038; Die Set 5-1579001-1). Push connector on actuator housing. To ensure that the connector is correctly inserted, pull and push with a low force on the housing (max.

  • Page 43: End Of Line Test

    114-94758 7.7 End of Line Test ATTENTION: The assembled Charge Inlet must be tested electrically and mechanically to applicable requirements, including High Voltage test. As a minimum, following tests have to be performed: • Isolation Resistance: Test Voltage: 500VDC Inspection Duration: 1s min. Riso: 200MOhm pin-to- pin, excluding CP-to-Proxi and CP/Proxi-to-Ground a) L1 versus N b) L1+N versus Ground c) L1+N versus AC multicore shield...

  • Page 44: Torque Value For M6 Screws

    114-94758 TORQUE VALUE FOR M6 SCREWS Figure 42 In the above Figure 42 shows the necessary torque 6Nm±0.9 NM for M6 screws required to maintain in all 4 mounting hole positions. 44 of 46...

  • Page 45: Minimum Length For Cable Fixation

    114-94758 MINIMUM LENGTH FOR CABLE FIXATION Figure 43 As per mentioned in the Figure 43 preferred free length of cables to be within a distance of 100mm exiting from cable covers. 45 of 46...

  • Page 46: Revision Record

    20 NOVEMBER 2024 ADDED SUPRIYA S TE CONNECTIVITY GERMANY GMBH AMPÈRESTRAßE 12-14 D-64625 BENSHEIM CHK GERMANY AMRUTHA RAO C H APVD KASHYAP P B 114-94758 Applicati on Specification Vehicle Charge I nlet Type CCS1 120 mm TITLE 46 of 46...

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