Amphenol H4 Cable Series User manual

H4 CABLE SERIES INSTRUCTION MANUAL 文件编号(File Name) :WI-S037-ENG REV.L
Amphenol
太阳能连接器H4线端系列安装手册
PV Connector H4 Cable Series Instrucon Manual
H4 太阳能线端连接器
H4 PV CABLE CONNECTOR
H4-H 太阳能线端连接器
H4-H PV CABLE CONNECTOR

4. 组装流程 7
Assembly process
4.1 线端连接器组装 7
Cable connectors assembly
4.2连接器对插及解锁 10
Connectors mang and un-mang
5. 电缆状态 12
Cable roung
6. 连接器对插前防尘保护 12
connector dust protecon to the former
7. 存储注意事项： 13
Note on storage
8. 附件：禁止接触化学品清单： 14
Forbidden to exposure of chemicals list
目 录
Table of Contents
1. 警告 2
Cauon
2. 技术参数 3
Technical data
3. 工具及应用 4
Tools & applicaon
3.1 工具 4
Tools
3.2 剥线流程 5
Cable preparaon and stripping process
3.3 机加端子压接流程 5
Cold Formed contacts crimping process
3.4 冲压端子压接流程 6
Stamping and Formed contacts crimping process
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1.警告
Cauon
1) 连接器在安装或拆卸过程中必须断开电源
The connector must be isolated and disconnected from the power supply during the assembling or disassembling process.
2) 不可带电插拔。
Do not connect or disconnect under load.
3) 推荐使用光伏电缆线。
The use of PV cable is recommended.
4) 推荐使用镀锡线芯线材。
The use of n plated cable is recommended.
5) 安费诺连接器配合状态符合IP68（水下1米一小时）密封性能。
The Amphenol connectors being mated are IP68 compliant in the funcon of sealing, and can be posioned for underwater 1 meter an hour
6) 该产品应由有相应资质或经过专家培训的、具备相关安全应用规范的专业人员安装。
The product may be assembled and installed only by suitably qualified and trained specialists with due observance of applicable safety regulaons
7) 该连接器只适用于B类和C类的铜导线(参考NFPA NEC 70第9章,表格10)。如果与其他等级的铜导线使用，连接器应做标记。参考电缆导体标准：
UL 486A-486B。
This connector is suitable for use only with Class B and C stranded copper conductors (See NFPA NEC 70 chapter 9, Table 10)” If the connector is
found to be in use with other stranding classes, the connector shall be marked with the specific class conductors. See the Standard for Wire Connectors,
UL 486A-486B
8)H4，H4-H连接器沿其轴向可承受最小44Lb拉力，但是不能长时间施加外力在连接器上.如图1.1所示。但不可使用如图1.2所示非连接器轴向力来拉连接器。
The H4，H4-H and Enlarge H4 can withstand the pull force 44Lb MINS. But can't apply external force on the connector for a long me. along the
direcon of picture 11.1 shows at the coupling interface. The force as shown in picture 1.2 shows is forbidden.
图1.1 图1.2
picture 1.1 picture 1.2
9) 安费诺不承担对于未依照此安装手册要求安装而产生的任何责任。
Amphenol declines any liability in the event of failure to comply with this assembly instrucons.
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10）那些可与Amphenol零件相匹配的，非Amphenol原产的连接器以及被有时称为可与“Amphenol兼容”的连接器，它们不符合安全的，
长期稳定的电气要求，并且出于安全方面的考虑，不允许它们与Amphenol零件连接.如果这些连接器（未经Amphenol认证）与Amphenol零件
连接并产生损害，对此我们不承担任何责任。
Connectors not made by Amphenol which can be mated with Amphenol elements and in some cases are also described as “Amphenol-compable”do not
conform to the requirements for safe electrical connecon with long-term stability, and for safety reasons must not be plugged together with Amphenol
elements .Amphenol can therefore accept no liability for damage which occurs as a result of mang these connectors which lack Amphenol approval
with Amphenol elements.
11) 安费诺已知接触或使用化学品可能引起产品被污染，腐蚀，导致产品性能的衰减、或出现产品开裂的情形，禁止这些化学品与产品接触
见附件文件：WI -S047-ENG Rev.B。
A warning to our customers and users of product to prevent exposure of the chemicals to our product. These chemicals may cause corrosion, degradaon
of performance, or cracking of product and might lead to potenal safety issues in applicaons. See file：WI -S047-ENG Rev.B。
2.技术参数:
Technical data
额定电压 :
Electrical rang
额定电流:
Current rang
保护等级:
1000V DC (TÜV IEC 62852) ①
1500V DC (UL 6703)
TÜV(IEC 62852) 25A @85℃; (2.5mm²/ 14 AWG) / 35A @85℃; (4mm²/ 12 AWG) / 45A @85℃; (6mm²/ 10
AWG) UL (UL 6703) 15A (14 AWG) / 20A (12 AWG) / 30A (10 AWG)
连接器互配状态IP68 ,连接器分离状态 IP2X
Protecon degree: IP68 mated and IP2X unmated
安全等级: II
Safety class
可使用温度范围: -40℃to +85℃
Operaon Temperature Range
持证方： Amphenol Industrial Operaons
License holder
地址： 40-60 Delaware Avenue, Sidney, New York State 13838-1395, USA
Full Address
制造商 Amphenol Technology （Shenzhen）Co.,Ltd
Producer
电话 [phone]
Telephone
① H4-H just get TÜV cerficaon
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3.工具及应用
Tools & applicaon
3.1)工具:
Required tools
机加工端子压接钳:
Crimp tool for cold forming contact
（2.5/4.0/6.0/10mm²端子）
(for 2.5/4/6/10mm² contact)
冲压端子压接钳:
Crimp tool for stamping forming contact:
（2.5/4.0/6.0mm²端子）
(for 2.5/4/6mm² contact)
剥线钳（2.5/4.0/6.0mm²光伏线）:
Strip tool for 2.5/4/6mm² PV cable
端子深度探测工具
Contact depth inspecon tool
母端防尘帽：
Female protect caps
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机加工端子钳口:
Crimping die for cold forming contact:
（2.5/4.0/6.0/10mm²端子）
(for 2.5/4/6/10mm² contact)
UTXTC0004
UTXTC0005
UTXTD0004
UTXTD0005
H4TC0003 UTXTD0003
冲压端子钳口:
Crimping die for stamping forming contact:
（2.5/4.0/6.0mm²端子）
(for 2.5/4/6mm² contact)
H4TS0000 H4TW0001
H4&H4-H连接器蓝色扳手:
Wrench tool for H4&H4-H Cable connector
H4&H4-H连接器套筒:
Open-end back cap spanner for H4&H4-H
H4TTW100
工具箱:
Complete tool kit for installers
H4TK0000
H4TT0001
公端防尘帽：
Male protect caps
UTXPF
UTXPM
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3.2) 剥线流程:
Cable preparaon and stripping process
使用安费诺剥线工具(H4TS0000)剥线时，首先调整卡位将线材放置合适位置，剥去线皮长度7.0±0.5 mm。注意不要伤及铜丝, 见下图3.2.1到图3.2.3。
Amphenol specified strip tool (H4TS0000) can be used in this step. First adjust the striper stopper ,then put the cable in corresponding notch to strip the
length of 7±0.5mm. Strip cable are carefully not to nick conductors. See below pictures3.2.1 to 3.2.3.
3.3) 机加工端子压接流程:
Cold Formed contacts crimping process:
使用安费诺压线钳(UTXTC0004/ UTXTC0005)压线时，首先将已剥好的线材线芯放入端子孔内并确保所有线芯都在端子孔内（可从检查孔确认线芯是否到位）
然后将带线材的端子放入对应的压线钳钳口，并对应正确的定位器孔位，如图3.3.1至图3.3.5。压接后端子电缆拔出力要求需要满足表3.3.1
Amphenol specified crimp tool (UTXTC0004/ UTXTC0005) can be used in this step. Insert striped cable into contact barrel and insure all conductor strands are
captured in the contact barrel and the conductors are visible in the inspecon hole. Crimp contact barrel by using the 4-ident crimping die, by pung the contact
barrel with striped cable in the corresponding crimping locator. See below pictures 3.3.1 to 3. 3.5 . The pull-out forces have to meet below table 3.3.1 requirement.
图 3.3.1
Picture 3.3.1 图 3.3.2
Picture 3.3.2
图3.2.1
Picture 3.2.1
图 3.2.2
Picture 3.2.2
图3.2.3
Picture 3.2.3
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剥线长度
Strip length
L=7±0.5mm
检查孔
Inspecon hole
线
cable
公端子
Male contact
母端子
Female contact
图3.3.3
Picture 3.3.3
位置 1
Position 1
位置 2
Position 2
位置 3
Position 3
图3.4.4
Picture 3.4.4
图3.4.5
Picture 3.4.5
表格3.3.1
Table 3.3.1
位置
Position
1 14AWG/2.5 mm² Min. 223 N
2 12AWG/4.0 mm² Min. 312 N
3 10AWG/6.0 mm² Min. 356 N
3 8AWG/10.0 mm² Min. 401 N
Compression Ratio(压缩比率)：60%≤ X ≤80%
电缆拔出力要求
Cable pull-out force
电缆规格
Cable size
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端子压接好后的效果见图3.3.6及图3.3.7.
See below pictures 3. 3.6 and 3.3.7 for crimping result.
3.4) 冲压端子压接流程:
Stamped and Formed contacts crimping process:
使用安费诺压接工具 (H4TC0003)压线时，首先将已剥好的线材线芯放入端子槽内，并确保所有线芯都在端子槽内，然后将要压接的端子放入压线钳钳口, 并对应
正确的定位器孔位，小心不要伤到定位翅膀，见图 3.4.1至图3.4.5. 压接后端子电缆拔出力要求需要满足表3.4.1要求，
Amphenol specified crimp tool (H4TC0003) can be used in this step. Insert striped cable into contact barrel and Insure all conductor strands are captured in the
contact barrel. Crimp contact barrel by using the crimping die, Be careful for not hurng the locator wings. See below pictures 3. 4.1 to 3.4.5. The pull-out force
should meet below table 3.4.1 requirement.
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图3.3.6
Pictures 3.3.6
图3.3.7
Pictures 3.3.7
图3.4.4
Picture 3.4.4
图 3.4.1
Picture 3.4.1
图3.4.3
Picture 3.4.3 图3.4.5
Picture 3.4.5
表格3.4.1
Table 3.4.1
位置
Position
1 14AWG/2.5 mm² Min. 223 N
2 12AWG/4.0 mm² Min. 312 N
3 10AWG/6.0 mm² Min. 356 N
电缆拔出力要求
Cable pull-out force
电缆规格
Cable size
图 3.4.2
Picture 3.4.2
端子压接好后的效果见图3.4.6及图3.4.7。
See below pictures 3.4.6 and 3.4.7 for crimping result.
图 3.4.6
Picture 3.4.6
定位翅膀(不可被压接)
Locator wings should not be crimped
图 3.4.7
Picture 3.4.7
位置 1
Position 1
位置 2
Position 2
位置 3
Position 3
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4. 组装流程:
Assembly process
4.1) 线端连接器安装
For Cable connector assembling
4.1.1) 压接端子及插线
Crimped contacts with cable
将已压接好的端子从连接器后端插入，当插到位后会听到“滴”的卡位声，端子插入后不可再拔出，(端子的压接方法及剥线请参考工具的应用3.2到3.4)
见下图4.1.1到图4.1.4。
Insert contact cable assembly into back of male and female connector. A “click” should be heard or felt when the contact cable assembly is seated in correct
posion. Contacts cannot be removed once seated (Contacts are crimped per tool applicaon 3.2 to 3.4) See below pictures 4.1.1 to pictures4.1.4.
母端连接器
Female connector
客户使用自动打端子机进行压接时, 建议的压接规范,
The customer wants to use the automac crimping machine, we suggest that the contact crimping spec
14AWG/2.5 mm² 2.10mm REF 3.40mm REF
12AWG/4.0 mm² 2.39mm REF 4.00mm REF
10AWG/6.0 mm² 2.70mm REF 4.25mm REF
H/W Ratio(高度/宽度比率)：50%≤ X ≤75%
Compression Ratio(压缩比率)：70%≤ X ≤90%
铆接高度(A)
Crimping Height(A) 铆接宽度(B)
Crimping Width(B)
电缆规格
Cable Size
表格3.4.2
Table 3.4.2
公端连接器
Male Connector:
图4.1.1
Picture 4.1.1
图4.1.2
Picture 4.1.2
图4.1.3
Picture 4.1.3 图4.1.4
Picture 4.1.4
备注：
Notes:
可通过端子探测工具确认端子是否插到位。连接器边缘要落在端子深度探测工具白色区域内。见下图4.1.5到图4.1.7。
Can use the contact depth inspecon tool confirm whether the contact is right seated or not. The edge of connector should locate within the white area of the
contact depth inspecon tool. See below picture 4.1.5 to 4.1.7.
高度Height
宽度Width
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4.1.2) 锁紧螺帽
Tightening the back cap
H4及H4-H连接器锁紧螺帽的扭矩：2.6 N·m 到2.9 N·m。
H4 and H4-H connector back cap must be screwed up with a properly torque range 2.6 to 2.9 N·m.
在锁紧螺帽时，不论是使用帽子还是本体进行连接器组装都不会影响连接器的功能,客户可以根据自己的组装工艺选择组装方式。
Whether the connectors were screwed by cap or body, there is no any effect on the funconality. Customer can choose the different screwed method
according to their manufacturing processes.
以下是连接器通过本体和帽子组装时的受力面， 如图4.1.7
See the acng point when connector was screwed by body and cap, as below picture 4.1.7
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白色区域/White area
图4.1.5
Picture 4.1.5
图4.1.6
Picture 4.1.6
图4.1.7
Picture 4.1.7
受力面
Acon surface
连接器边需要在白色区域中间
Edge of connector should be
in the middle of white area.
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客户在现场安装时，可使用安费诺蓝色扳手(H4和H4-H使用H4TW0001 )组装连接器，如图4.1.8及图4.1.9。
客户用扭力扳手组装连接器时，可使用安费诺专用连接器套筒进行组装(H4和H4-H使用H4TTW100)。如图4.1.10及图4.1.11
Amphenol specified wrench tool (H4TW0001 for H4&H4-H and H4TW0004 for Enlarge H4) can be used in this step See below picture 4.1.8 and 4.1.9.
Customer can use open-end back cap spanner (H4 use H4TTW100) if customer use electric torque controlled wrench tool
to ghten the cap，as below picture4 .1.10 and 4.1.11.
图 4.1.8
Picture 4.1.8
图 4.1.9
Picture 4.1.9
图 4.1.10
Picture 4.1.10
图 4.1.11
Picture 4.1.11
4.1.3) 备注：
Notes：
1> H4及H4-H连接器线材外径要求为ø4.5mm 到 ø7.8mm。
The cable range of H4 and H4-H connector is from ø4.5mm to ø7.8mm.
2> 适用H4及H4-H连接器导线的线芯数为7到140根。
The number of conductor strands for H4 and H4-H is from 7 to 140.
3> 扭矩要求只针对太阳能线材。不同的线材组装完成后都需达到IP68及拉力测试要求（无端子状态下吊重20Lb，一分钟）。
These torque force apply to Amphenol PV cable only. The cable assembly should pass IP68 and Pullout test (20Lb, 1Min, without contact).
4> 线材线芯只能用铜线芯。
A statement that the conductor type is limited to copper wire only ( "Copper" or "CU" are acceptable).
5> 从2017年10月起，仅适用于EN50618认证的线缆。
From October 2017 Only valid in connecon with cables cerfied according EN50618.
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10
安费诺提供蓝色扳手(H4TW0001)和解锁工具(H4TU0000)用于安费诺H4系列连接器连接器的解锁, 如图4.2.1及图4.2.2。
Amphenol specified wrench tool (H4TW0001) or Universal tool (H4TU0000) should be used in this step for H4 series. See below picture 4.2.1 and 4.2.2.
H4-H连接器可直接用手打开。
The H4-H can be disconnected by hand.
图 4.2.1
Picture 4.2.1 图 4.2.2
Picture 4.2.2
万能解锁工具解锁
Universal Tool Disconnect
蓝色扳手解锁
Wrench Tool Disconnect
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4.2) 连接器对插及解锁
Connector mang and un-mang
公端和母端连接器对插直到听到“滴“的卡位声说明对插到位。安费诺H4连接器符合NEC 2008 690.33标准, 所以需要工具进行解锁。
For mang, align the 2 half connectors and mate them together by hand unl a “click” is heard and/or felt. For un-mang, since the Amphenol H4 complies with the NEC 2008 690.33,
a tool is required to disconnect the connector once mated.
以下特征可以确认连接器是否对插到位：
Below feather can confirm the connector has been good mated or not：
1. 卡扣卡到位如下第一点。/ The latch was hookup as below point one.
2. 密封圈在外部不可看见。/ O-ring pressed inside and invisible.
3. 公头和母头之间仅可有小的间隙(间隙≤0.3mm）。/ There is very small gap between the interface of male and female（gap≤0.3mm）.
2
3 1
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连接器选型：
Connector order number:
How to Order a Connector (please choose one code per posion, below)
Product
Line Product Type Gender Connector
Type Cable Size Cerficaons Packaging Contact Type
H4
(H4 series)
C
(Connector)
F
Female
M
Male
C
Cable gland
tool unlock
0 Without Contact
2 2.5mm²/ 14AWG
4*
6 6.0mm²/ 10AWG
D
Dual
UL/TÜV Cerfied
I 1 pc/bag
100
pcs/bag
400
pcs/bag
S S&F
(Blank) CF
C
M
*When ordering a S&F contact, please use cable size order code “4” for both 4.0mm²/ 12AWG & 6.0mm²/ 10AWG
4.0mm²/12 AWG &
6.0mm²/10AWG(S&F)
4.0mm²/12AWG(CF)
卷装冲压端子选型：
Stamped and Formed contacts order number:
How to Order S&F contacts on Reels (please choose one code per posion, below)
Product
Line Product Type Gender Connector
Type Cable Size Packaging
H4
(H4 series)
F
(S&F contact)
F
Female
M
Male
C
Cable gland
tool unlock
1.5mm²/ 16AWG & 2.5mm²/ 14AWG
4
2 R 2000pcs/reel
Note: if ording contacts in 2000pcs/reel version, need to order contact and plasc housing seperately. Contact’s ordering code refers to this
table, plasc housing should be chosen as H4CF0DM for female housing and H4CMC0DM for male housing.
4.0mm²/12 AWG & 6.0mm²/10AWG
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5. 电缆状态:
Cable roung
电缆根部建议保留20mm未折弯长度，以免因线缆折弯产生的外力引起连接器密封件变形. 如图5.1和图5.2。
In order to avoid the cable bend force lead to a visible deformaon in the sealing poron of the insulaon, the cable need keep at least 20mm straight length.
See picture 5.1 and 5.2.
电缆最小弯曲半径请参考电缆生产厂商详细要求。
Refer to cable manufacturer’s specificaon for minimum bending radius of cable.
图 5.1
Picture 5.1 图 5.2
Picture 5.2
图 6.1
Picture 61
图 6.2
Picture 6.2
6. 连接器对插前防尘保护:
connector dust protecon before mang:
连接器安装过程中，如未能及时对插公母头连接器，需要用防尘帽（母头使用UTXPF，公头使用UTXPM) 组装保护，以防止连接器内部被污染。如图6.1和图6.2。
In the process of connector assembly, the connect need be protected by dust cap (female end use UTXPF and male end use UTXPM) if connector can't be
mated in me, so as to prevent the internal of connector be
contaminated. See picture 6.1 and 6.2.
H4 CABLE SERIES INSTRUCTION MANUAL 文件编号(File Name) :WI-S037-ENG REV.L
12www.amphenol-sustainable.com
20mm 20mm
Final interpreaon is owned by Amphenol

H4 CABLE SERIES INSTRUCTION MANUAL 文件编号(File Name) :WI-S037-ENG REV.L
13 www.amphenol-sustainable.com
7. 存储注意事项：
Note on storage：
我们建议连接器零件的存储温度为-30℃-+60℃，相对湿度低于70%。连接器零件不能暴露在因直接降雨、冷凝等带来的水汽中。确保零件不能与酸、碱、瓦斯、
丙酮或者任何其他会影响材料使用的化学物质接触。如果以上条件得到满足，连接器的零件存储时间长达两年时间。
We recommend that you store connector components at temperature between-30℃to +60℃ and with a relave humidity of less than 70%.The components
must not be exposed to moisture due to direct rainfall ,condensaon .etc ,Ensure that the individual components do not come into contact with acids, alkalis, gases,
acetone or any other chemical substance that could impact the materials use .If these condion are met. The components can be stored for a maximum period of
up to two years from the date of manufacture.
Final interpreaon is owned by Amphenol
8.注意事项：
Note ：
请注意，有关第三方测试仅作为应用设计的参考，客户有责任自行验证在特殊应用及极端环境条件下的系统功能和连接器的耐久性， 我们建议客户在设计应用系统
时，考虑预留充足安全系数，以避免高电流情况下引起产品过热失效。
Please be aware that this 3rd party laboratory test just as a reference for application design. It’s customer’s responsibility to validate system functions and
connector durability at specific application and extreme environment conditions. We recommend customer to consider margin in application design to avoid
overheat in high current situation.

Halogenated hydrocarbon 族碳化合物 Ketone 酮类 Aromac Hydrocarbon 芳香族碳氢化合物 Other，Organic solvent 其他/有机溶剂 Adhesion sealant 粘合密封材料 Pong Material 填充材料
Freon氟利昂、Carbon tetrachloride四氯化碳、Trichloromethane氯仿/三氯化碳,
Virex 256烷基二甲基氯化铵 Acetone丙酮、Methyl ethyl ketone甲基乙基酮/丁酮 Toluene甲苯、Xylene二甲苯、Cresol甲酚
Ethyl acetate乙酸乙酯、Butyl acetate乙酸丁酯、Tributyl phosphate磷酸三丁酯、
Kerosene煤油、Gasoline汽油、Varnish清漆、Esters酯类、Ethers醚类、 Amines 胺类、Glacial acetic acid冰醋酸、 Print ink添加剂、3M 稀释剂
APF125(Wacker Chemical) KE-200(ShinEtsu)、CX-200(ShinEtsu)
Remarks: Chemicals not listed in the above table (other oils & chemicals in manufacturing process & in solar farm sites), it is the responsibility of user to validation such chemicals not affect our product performance. 备注：对于不在此列表内的其他在生产制造过程和产品安装过程中可能接触或使用的化学品需用户自行确认对产品无影响后 方可使用。
Final interpretation is owned by Amphenol
FORBIDDEN TO EXPOSURE OF CHEMICALS LIST 文件编号(File Name) : WI-S047-ENG Rev.B
安费诺已知接触或使用以下化学品可能引起产品被污染，腐蚀，导致产品性能的衰减、或出现产品开裂的情形，禁止这些化学品 与产品接触。 A warning to our customers and users of product to prevent exposure of the following chemicals to our product. These chemicals may cause corrosion, degradaon of performance, or cracking of product and might lead to potenal safety issues in applicaons.
Classify分类 Commonly used chemicals
常用化学品
Grease 脂类 Oils 油类 Mould Release Agent 脱模剂 Binder 粘合剂 Alcohols 醇类
Fay hydrocarbons 脂肪族化合物 Acid,Alkali,Salt 酸碱类
Chemical Name化学品名称
Grease 黄油、Lubricate oil 润滑油、Rust inhibitors防锈剂 、Stamping oil冲压油、 Engine Oil机油、Banana Oil天那水、WD40、Insecticide杀虫剂、Oily sealing agent
油性封孔剂、Doduconta B25 Kontaktol、Evabrite S、Virex TB强氧化性消毒剂、 Suma Lima L3餐具清洗剂、Suma Rinse、Detergent餐具清洗剂、Plasticizer增塑剂
Spray cleaner8188 喷头清洗剂8188、CM-31S 模具清洗剂
Molykote EM-50L(Dow Corning)、Molykote PG-641(Dow Corning)
Die Cut(OELHELD), Machine Oil KV46(Nippon Oil)、Infeld stamping oil
Pelicoat S-6(Chukyo-Kasei) Chemlok(LORD) Isopropyl alcohol(IPA)乙丙醇
Heptane庚烷、Hexane乙烷、Cyclohexane环已烷、Liquid paraffin液状石蜡 Salt acid盐酸、Sulfuric acid 硫酸、Nitric acid硝酸、Phosphoric acid磷酸、 Acec acid醋酸、Ammonia氨气/氨水、Sodium hydroxide氢氧化钠
Lists of all known chemicals： 已知化学品清单如下表：
WARNING 警告
3M adhesive、Avancis adhesive

Amphenol Technology (Shenzhen) Co., Ltd
Tel: [phone]
Email：in[email protected]om
web: www.amphenol-sustainable.com
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