Amphenol ePower-lite C10-738986-2XS1 User manual

CABLE ASSEMBLY WORK INSTRUCTION
ePower-lite 5.7mm 2 port Connector
Part Numbers:
C10-738986-2XS1
C10-738986-2XS2
Part Numbers:
C10-738985-2XP1
C10-738985-2XP2
Revision Description Issue Date
Alnitial release 2016/03/10
BChange the assembly method of shielding 2019/05/06
CUpdate picture detail 2020/05/13
AI-2

2
1. Package Contents
1: Housing shell assembly (1PCS)
2: Contact assembly (2PCS)
3: Collar (2PCS)
4: Heat shrink tubing (2PCS)
5: Rear shield shell (2PCS)
6: Rear shield ring (2PCS)
7: Rear grommet (1PCS)
8: Rear cover (1PCS)
2. Recommended shielded wire specicaon
Part 1: Plug Package Contents
1 7 82 3 5 64
Wire Size Insulation
Diameter (mm)
Shield Wire
Diameter (mm)
Cable Jacket
Diameter (mm)
Recommended Min.
Cable Pullout Force (N)
16 mm28.1±0.2 0.12 11.2±0.3 1500
25 mm210.2±0.2 0.12 13.9±0.3 1900

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Part 2: Plug Assembly
Step 1: Shielded wire stripping the jacket.
Step 2: Assembly the rear shield ring (Part 6).
Step 3: Cutting shield wire.
Part 6
L1
Item Cung Length
L1 21±0.5mm
Item Cung Length
L2 9±0.5mm
L2

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Step 5: Install the Rear Cover (Part 8) and the Rear Grommet (Part 7) in sequence.
Step 7: Pull one of the wires to make a misplacement with another wire, then assemble contact assembly (part 3).
Step 4: Fold back shielding wires onto the rear shield ring.
Step 6: Remove film layer, stripping insulation.
Item Cung Length
L3 10.5±0.5mm
Mylar Part 7 Part 7
L3
Part 3

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Step 8: Crimp plug contact assembly (Part 3).
Notes: The recommended crimp sizes are only for reference. The customer should adjust them according to cable
specification and crimp tool and test results including temperature rise and metallographic analysis and pullout force.
Recommended crimping tool: Manual hydraulic crimping
Die: 25mm2die for 25mm2cable
Die: 16mm2die for 16mm2cable
Notes: Don't let the shrink tubing cover the braid wire
Tooling: Heat gun as shown in picture
Recommended heat shrink tubing spec: Without hot melt adhesive
Excellent sealing and insulation properties
Shrink ratio: 2:1
Operating temperature: -55~125°C
Cable Size Recommended crimp
length of Side S
Recommended crimp
dist across Flats F
Recommended Min. Cable
Pullout Force (N)
16 mm26.0 7.0±0.1mm 1500
25 mm26.0 7.5±0.1mm 1900
Step 9: Install heat shrink tubing to the area where crimping contact and wire.
Recommended crimp length is 10±0.5mm
0.5mm Gap
Amphenol P/N: CH53X-005-09A ( Part 4)

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Step 10: Repeat steps 7 and 8 and 9 to assemble another contact assembly.
Step 11: Pull one of the wires out and load. Crimp the Rear Shield (Part 5).
Step 12: Repeat step 11 to assemble another Rear Shield.
Notes: The recommended crimp sizes are only for reference. The customer should adjust them according to cable
specification and crimp tool and test results including contact resistance and pullout force.
Crimping tool: Hydraulic press
Cable Size Recommended crimp
length of Side S
Recommended crimp
dist across Flats F
Recommended Min. Cable
Pullout Force (N)
16 mm26.0 11.5±0.1mm 150
25 mm26.0 11.5±0.1mm 150
Recommended crimp
length is 3.5±0.5mm
length: 24.2 - 25.5mm

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Step 14: Insert the crimped terminal into the Plug shell assembly ( Part 1) one by one. Note that the plane A of the
shield and the plane B of the shell are parallel.
Step 13: Assembling Collar (part 2) , and Straighten two cable.
Step 15: lnstall the Rear Grommet (Part 7).
Note the orientation of the Rear Cover,
which is aligned with the Plug shell
Part 2
Part 1
Flat B Flat A
The Rear Grommet beyond the housing 3mm REF.

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Step 16: lnstall the Rear Cover (Part 8). The rear cover buckle should snap-fit with the main housing shell.
Step 17: Requirements for electrical performance testing.
Notes: Need to do lnsulation Resistance and DWV test after cable assembly
lnsulation Resistance test: 850V DC, 100MΩ Min, 60s
DWV test: 2500V AC, leakage current ≤ 5mA, 60s

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Part 3: Receptacle Package Contents
1. Package Contents
1: Receptacle shell assembly (1PCS)
2: Collar (2PCS)
3: Pin contact assembly (2PCS)
4: HVIL socket contact (2PCS)
2. Recommended unshielded wire specicaon
Wire Size Insulation
Diameter (mm)
Recommended Min.
Cable Pullout Force (N)
16 mm28.1±0.2 1400
25 mm210.2±0.2 1900
Part 4: Receptacle Assembly
Step 1: Wire cutting and stripping jacket.
Item Cung Length
L1 11.5±0.5mm
1 2 3 4
L1

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Step 2: Crimp pin contact assembly (Part 3).
Notes: The recommended crimp sizes are only for reference. The customer should adjust them according to cable
specification and crimp tool and test results including temperature rise and metallographic analysis and pullout force.
Recommended crimping tool: Manual hydraulic crimping
Die: 25mm2die for 25mm2cable
Die: 16mm2die for 16mm2cable
Cable Size Recommended crimp
length of Side S
Recommended crimp
dist across Flats F
Recommended Min. Cable
Pullout Force (N)
16 mm26.0 7.0±0.1mm 1500
25 mm26.0 7.8±0.1mm 1900
Step 3: lnstall heat shrink tubing to the area where crimping contact and wire, Then assemble the Collar.
Amphenol P/N: CH53X-O05-09A
Tooling: Heat gun as shown in picture
Recommended heat shrink tubing spec: With hot melt adhesive
Excellent sealing and insulation properties
Shrink ratio: 2:1
Operating temperature: -55~150°C
Recommended crimp length is 10±0.5mm
Gap is 0.5mm reference

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Step 5: HVIL wire cutting and stripping the jacket(Recommended use the 20AWG cable).
Step 6: lnsert conductor into hole of socket and crimping use right crimping tool.
Recommended Crimping tool as below:
Step 4: lnsert the contact with cable assembled into the plug shell, the collar snapped into the shoulder of the hole.
Repeat step 1-4 for another port.
Item Cung Length
L2 3.5±0.5mm
L2

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Step 7: lnsert the HVIL contact and cable assembly into the plug shell assembly.
Step 8: Repeat step 6-8 for another port.