Quick charging connector (cable) Inspection details <Yazaki new connector>

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Alannah Holmes
6 years ago
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1 Quick charging connector (cable) Inspection details <Yazaki new connector> Daily check Administrator, person in charge of the facility (e.g. gas station Store manager), subcontractor etc. Periodic check Charger distributor (charger maker), subcontractor etc. Recommended inspection frequency Daily check:once a day Periodic check:once a year Prepared: No. Daily Periodic 1 Connector appearance 2 Connecting surface Criterion for the judgment There is no deformation, crack, break, etc. that are Water droplets and foreign objects are not attached on the connecting surface of connector. - Injury caused by broken parts. Occurrence of arc and electric shock due to insulator breakage. Elevation of resistance at terminal contact due to adherence of foreign material temperature rise Increase mating force / unable to mate due to foreign materials. 3 Sealing surface of housing There is no deformation, crack, break, etc. that can be Short circuit and electric shock due to ingress of water. Base material is not exposed on the terminal surface. Elevation of resistance at terminal contact. temperature rise 4 Power terminal Elevation of resistance due to a bad connection at terminals. There is no deformation, flaw, etc. that are confirmed by temperature rise 2 Increase in mating force of connector/ unable to mate. 5 Resin cap for power contact Resin cap is not taken off. Electric shock due to touch to terminals. 6 Moving plate There is no deformation, break, etc. that are confirmed by The plate moves smoothly when it is pushed. Base material is not exposed on the terminal surface. There is no deformation, flaw, etc. that are confirmed by Cross-shaped walls in signal There is no deformation, flaw, etc. that are confirmed by 8 terminal cavity There is no deformation, break, abrasion, etc. that are 9 Latch When the latch is pushed by hand, it functions normally. 10 Lighting of LED LED is lighted during charging. 11 Electromagnetic lock The connector is locked and can not be removed during charging. 5 Electric shock due to touch to the terminal. Increase in mating force of connector. Elevation of resistance at terminal contact. Unable to charge Elevation of resistance due to a bad connection at terminals. Unable to charge Increase in mating force of connector/unable to charge. Lack of protection of signal terminal. Deformation of signal terminal Incomplete latching to inlet. Damage to connector and inlet (occurrence of arc) due to uncoupling during charging. Incorrect operation due to the loss of "in process (charging)" display. Incompletion of charging Damage of connector and/or inlet (occurrence of arc) due to uncoupling during charging. 12 Loose screw Loose and lack of screws are not found. 5 6 Breakdown of connector due to loss of screw. failure 13 Cleaning Touching portion to be clean. 7 Discomfort feeling given to charger operators Signal terminal Inspection item Insertion and removal of connector 16 Cable Inspection details There is no deformation, crack, break, etc. that are The latch functions normally when the ejector button is pushed. The latch returns to the original position when ejector the button. The connector can be smoothly inserted and removed with a inlet. to be neutral position before mating. to be extended position after mating with inlet. Inner cable materials or insulated layers are not exposed due to abrasion on the surface of sheath. Cable and connector are tightly connected. Reference picture Concerns in the event of a failure Unable to remove connector Occurrence of failure due to connector (inlet) trouble. Short circuit and electric shock due to exposed copper.

Detail for inspection method and content There is a risk of injury to drop

Please place the connector on stable area and inspect. 1 No.

3 Sealing surface of housing Connecting surface:inspect inside of connector

each cavity (red circled portion in above figure) 2 No.4 Power terminal / No.

6 Moving plate Power terminal:2 terminals Inspect a resin cap that fixed on

in above figure) Inspect power terminal surface condition visually during

Do not give any damage to sealing surface (refer to item 1) and power

2 Detail for inspection method and content There is a risk of injury to drop the connector during inspection. Please place the connector on stable area and inspect. 1 No.2 Connecting surface / No.3 Sealing surface of housing Connecting surface:inspect inside of connector (red shaded area in above figure) Sealing surface:inspect inside wall for each cavity (red circled portion in above figure) 2 No.4 Power terminal / No.5 Resin cap for power terminal / No.6 Moving plate Power terminal:2 terminals Inspect a resin cap that fixed on tip of power terminal (red shaded portion in above figure) Inspect the cap loosing or separating. Inspect the moving plate can move smoothly when push it (red shaded portion in above figure) Inspect power terminal surface condition visually during pushing down it. Do not give any damage to sealing surface (refer to item 1) and power terminal when push down the moving plate. Recommend to use wood or resin tool for pushing it. 3 No.7 Signal terminal / No.8 Cross-shaped walls in signal terminal cavity Cross-shaped wall: 2 places Signal terminal:3 terminals Signal terminal:4 terminals Inspect any deformation and breakage for the Cross-shaped wall (red lined portion on above figure).

4 No.9 Latch Push down the latch by finger.

Inspect the latch can move smoothly (without any resistance) when push it

And also confirm the latch can return smoothly when release finger from it.

12 Loose screw Screw:7 places To inspect electromagnetic lock working

If the ejector button does not move, the electromagnetic lock is working.

3 4 No.9 Latch Push down the latch by finger. Latch Release finger from the latch. Inspect the latch can move smoothly (without any resistance) when push it by finger into housing case. And also confirm the latch can return smoothly when release finger from it. 4 No.10 Lighting of LED LED(red) 5 No.11 Electromagnetic lock / No.12 Loose screw Screw:7 places To inspect electromagnetic lock working condition, push the ejector button during charging to EV. If the ejector button does not move, the electromagnetic lock is working. If the ejector button moved (possible to push at set condition), hold the connector to mating position with inlet, then return the ejector button to initial position and stop charging. The EVSE or connector needs to be repaired.

6 No.12 Loose screw Screw:4 places 7 No.

If the product has heavy dirt, use cloth with a neutral detergent. Clean with air duster, air blow etc.

If clean connecting surface with brush and cloth, terminal will have some damage.

4 6 No.12 Loose screw Screw:4 places 7 No.13 Cleaning Clean the connector with brush, dry cloth or damp cloth to avoid any scratches on the product. If the product has heavy dirt, use cloth with a neutral detergent. Clean with air duster, air blow etc. for dirt on connecting surface (red shaded area on left figure). If clean connecting surface with brush and cloth, terminal will have some damage. Do not clean with other method as mentioned above. 8 No.14 Latch Pushed condition of the Free condition of the Inspect the ejector button can move smoothly when push it by finger, and confirm the latch goes into the case at same timing. Inspect the release button and the latch return their initial position when free the release button.

9 No.15 Insertion and removal of connector Middle position Neutral (middle position) The ejector button is usually in the middle position when not connected to the vehicle inlet.

5 9 No.15 Insertion and removal of connector Middle position Neutral (middle position) The ejector button is usually in the middle position when not connected to the vehicle inlet. Furthest extended position Correctly connected (furthest extended position) When correctly connected to the vehicle inlet, the ejector button will automatically extend outward. Charging can be started when the button is in this position. The button is flush with the surface of the connector body Press the button all the way in Disconnecting (pressed all the way in) Press the button all the way in to remove the connector from the vehicle inlet. By pressing the button all the way in, the connector will be released from the vehicle inlet and will be able to disconnect it.

Instruction Manual for Electric Vehicle (EV) Quick Charging Connector

Manual No.2002269108 Dated February 18, 201 Instruction Manual for Electric Vehicle (EV) Quick Charging Connector Information in this instruction manual is subject to change without prior notice. Power