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Inside the dé charging connectors covered by the supplied manufacturing document, the main components include power and signal terminals, sealing rings, heat-shrink tubing, wire-positioning parts, connector fasteners, epoxy potting and a moulded cable-entry section.
Internal structure at a glance
From the connector face towards the cable, the documented structure includes:
- Contact pins or sockets at the connector face.
- Sealing rings fitted around designated terminals.
- Heat-shrink tubing around specified connections.
- Power and control wires arranged inside a wire holder.
- Upper and lower fixing parts secured with screws.
- Epoxy resin potting inside the connector housing.
- An SR moulded section where the cable enters the connector.
Power and signal terminals
The manufacturing document records several terminal types. The terminals used in a specific connector depend on its configuration.
| Terminal group | Types recorded in the document |
|---|---|
| Current-rated terminals | 16 A and 32 A pins and sockets |
| Control terminals | CP and PP terminals, plus a terminal identified as CCCP in the document |
| Other terminal forms | Ring terminals |
Certain 16 A and 32 A socket terminals are recorded as brass with a “silver 5UM” specification. This description applies only to the socket terminals identified in the manufacturing document and should not be extended to every terminal.
Recorded wire arrangement
The document uses the following circuit labels and wire colours:
| Circuit | Recorded wire colour |
|---|---|
| PE | Yellow/green |
| N | Blue |
| L1 | Brown |
| L2 | Black |
| L3 | Grey |
| CP | Red |
| PP | Red resistor silicone wire |
This table shows the wire identifiers recorded across the covered production process. It does not mean that every connector version contains every circuit listed. For product-specific information, check the Portable AC Charger User Manuals – 3–22 kW Series.
Sealing and insulation components
- Terminal sealing rings: Installed at designated terminal positions before the terminal assembly is completed.
- Connector sealing ring: Installed inside the vehicle connector during assembly.
- Heat-shrink tubing: The document records sizes of 5.5 × 15 mm, 4.0 × 15 mm and 3.5 × 15 mm.
- Epoxy resin potting: Applied inside the connector after the internal parts have been assembled.
These components form part of the connector assembly. Their presence alone should not be used to infer a finished connector’s IP rating or permitted exposure to water.
Cable retention and connector closure
The internal wires pass through a black wire holder recorded as 41.5 × 16. Upper and lower fixing parts are then installed around the cable assembly. The document records a diameter of 16.2 for these fixing parts and two 3 × 12 × 5.2 mm screws.
An SR moulded section is formed where the cable enters the connector. The supplied document does not identify the SR moulding material, so no specific material is stated here.
Related connector information
- See the charging connector design overview to identify the visible external parts.
- See charging connector grip and handling for user handling guidance.
- See how the charging connectors are assembled and manufactured for the production sequence.