Amphenol HELIOS H4 User manual

Amphenol Industrial Operations Amphenol Industrial Operations Europe Amphenol Middle East Enterprises FZE Amphenol Technology Shenzhen Ltd
40-60 Delaware Avenue Via Barbaiana 5 Office C-37 PO Box 21107 Block 5 Fuan 2nd Industrial Park, Dayang Rd
Sidney, NY 13838-1395 I-20020 Lainate (MI) Ajman Free Zone Fuyong Town, Baoan, 518103 Shenzhen
USA ITALY UAE CHINA
Tel: [phone] Tel: [phone] Tel: [phone] Tel: [phone]
Fax: [phone] Fax:[phone] Fax:[phone] Fax:[phone]
1
H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 –OCTOBER 2014
AMPHENOL HELIOS H4 ASSEMBLY INSTRUCTIONS
If, during self assembly, parts and tools other than those stated by Amphenol are used or if the preparation and assembly
instructions described here are disregarded then neither safety nor compliance with the technical data can be guaranteed.
For protection against electric shock, PV-connectors must be isolated from the power supply while being assembled or
disassembled. The end product must provide protection from electric shock.
Unplugging under load: PV plug connections must not be unplugged while under load. They can be placed in a no load state by
switching off the DC/AC converter or breaking the DC circuit interrupter. Plugging and unplugging while under voltage is
permitted.
It is unadvisable to use non-tinned cables type H07RN-F, since with oxidized copper wires the contact resistances of the crimp
connection may exceed the permitted limits.
Disconnected connectors should be protected from dirt and water with sealing caps.
Touch protection, mated/unmated IP68/IP2X
Rated current 40A (2,5mm²/14AWG)/48A (4mm²/10AWG)/56A (6mm²/10AWG)/60A (10mm²)
Ambient temperature range -40° ...+90°C
Rated voltage 1500V (IEC/CEI) and 1000V (UL)
Upper limiting temperature 120°C (IEC/CEI)
Safety class II
NEC 2008/690.33 YES
Certification UL E339277
Certification TUV R50157783/R72131001
Downloaded from Arrow.com.

Amphenol Industrial Operations Amphenol Industrial Operations Europe Amphenol Middle East Enterprises FZE Amphenol Technology Shenzhen Ltd
40-60 Delaware Avenue Via Barbaiana 5 Office C-37 PO Box 21107 Block 5 Fuan 2nd Industrial Park, Dayang Rd
Sidney, NY 13838-1395 I-20020 Lainate (MI) Ajman Free Zone Fuyong Town, Baoan, 518103 Shenzhen
USA ITALY UAE CHINA
Tel: [phone] Tel: [phone] Tel: [phone] Tel: [phone]
Fax: [phone] Fax:[phone] Fax:[phone] Fax:[phone]
2
H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 –OCTOBER 2014
Tools required
Crimping tool with built-in positioner and crimping insert for stamped and formed contacts H4TC0002
or in alternative
Crimping tool with built-in positioner crimping insert for solid contacts H4TC0001
Stripping pliers H4TS0000
Open end spanner –plastic wrench tool H4TW0001
Tools optional
Crimp-Interchangeable dies for stamped and formed contacts H4TD0002
Crimp-Interchangeable dies for solid contacts H4TD0001
Metal wrench insert for wrench tool H4TE0000
Metal secure tool H4TF0000
Metal M12 nut secure tool H4TG0000
Complete toolbox H4TK0000
Downloaded from Arrow.com.Downloaded from Arrow.com.

Amphenol Industrial Operations Amphenol Industrial Operations Europe Amphenol Middle East Enterprises FZE Amphenol Technology Shenzhen Ltd
40-60 Delaware Avenue Via Barbaiana 5 Office C-37 PO Box 21107 Block 5 Fuan 2nd Industrial Park, Dayang Rd
Sidney, NY 13838-1395 I-20020 Lainate (MI) Ajman Free Zone Fuyong Town, Baoan, 518103 Shenzhen
USA ITALY UAE CHINA
Tel: [phone] Tel: [phone] Tel: [phone] Tel: [phone]
Fax: [phone] Fax:[phone] Fax:[phone] Fax:[phone]
3
H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 –OCTOBER 2014
Connector for cable mounting
Female stamped and formed contacts Male stamped and formed contacts
(1,5-2,5mm²/AWG14) H4CFC2D..S H4CMC2D..S
(4,0-6,0mm²/AWG10-12) H4CFC4D..S H4CMC4D..S
Female solid contacts Male solid contacts
(2,5mm²/AWG14) H4CFC2D.. H4CMC2D..
(4,0mm²/AWG12) H4CFC4D.. H4CMC4D..
(6,0mm²/AWG10) H4CFC6D.. H4CMC6D..
(10,0mm²/AWG8) H4CFC8D.. H4CMC8D..
.. = packaging (I= individual packaging/C=100 PCS packaging / M=500 PCS packaging
Connector for panel mounting
Female stamped and formed contacts Male stamped and formed contacts
(1,5-2,5mm²/AWG14) H4CFC2D..S H4CMC2D..S
(4,0-6,0mm²/AWG10-12) H4CFC4D..S H4CMC4D..S
Female solid contacts Male solid contacts
(2,5mm²/AWG14) H4CFM2D.. H4CMM2D..
(4,0mm²/AWG12) H4CFM4D.. H4CMM4D..
(6,0mm²/AWG10) H4CFM6D.. H4CMM6D..
(10,0mm²/AWG8) H4CFM8D.. H4CMM8D..
.. = packaging (I= individual packaging/C=100 PCS packaging / M=500 PCS packaging
Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.

Amphenol Industrial Operations Amphenol Industrial Operations Europe Amphenol Middle East Enterprises FZE Amphenol Technology Shenzhen Ltd
40-60 Delaware Avenue Via Barbaiana 5 Office C-37 PO Box 21107 Block 5 Fuan 2nd Industrial Park, Dayang Rd
Sidney, NY 13838-1395 I-20020 Lainate (MI) Ajman Free Zone Fuyong Town, Baoan, 518103 Shenzhen
USA ITALY UAE CHINA
Tel: [phone] Tel: [phone] Tel: [phone] Tel: [phone]
Fax: [phone] Fax:[phone] Fax:[phone] Fax:[phone]
4
H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 –OCTOBER 2014
Cable preparation and stripping process
Strip cable 0.276 inches (7.0 mm) and be careful NOT to nick conductors.
Amphenol specified strip tool (H4TS0000) can be used in this step.
Adjust the striper stopper and put the cable in corresponding notch to strip the length of 7mm.
See below pictures.
Cable against stopper Stripped cable
Crimp process solid contacts
When you insert striped cable into contact barrel, always insure all conductor strands are captured in the contact barrel and the
conductors are visible in the inspection hole. See below pictures.
Pin solid contact Inspection hole Socket solid contact
Insert the contact into the corresponding crimping notch or locator (male or female) taking into account the cable size used.
Press the pliers gently together until the crimp lugs are properly located within the crimping die. Insert the stripped cable end
until the insulation comes up against the crimp insert. Completely close the crimping pliers.
See below pictures.
Amphenol specified crimp tool (H4TC0001) should be used in this step.
Positioner Crimper with die
See below pictures for crimp result solid contacts.
Crimped solid pin Crimped Solid socket
Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.

Amphenol Industrial Operations Amphenol Industrial Operations Europe Amphenol Middle East Enterprises FZE Amphenol Technology Shenzhen Ltd
40-60 Delaware Avenue Via Barbaiana 5 Office C-37 PO Box 21107 Block 5 Fuan 2nd Industrial Park, Dayang Rd
Sidney, NY 13838-1395 I-20020 Lainate (MI) Ajman Free Zone Fuyong Town, Baoan, 518103 Shenzhen
USA ITALY UAE CHINA
Tel: [phone] Tel: [phone] Tel: [phone] Tel: [phone]
Fax: [phone] Fax:[phone] Fax:[phone] Fax:[phone]
5
H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 –OCTOBER 2014
Crimp process stamped and formed contacts:
Insert the contact into the corresponding crimping notch or locator (male or female) taking into account the cable size used.
Open barrel socket S&F contact Open barrel pin S&F contact
Press the pliers gently together until the crimp lugs are properly located within the crimping die. Insert the stripped cable end
until the insulation comes up against the crimp insert. Completely close the crimping pliers.
See below pictures of crimp result
Amphenol specified crimp tool (H4TC0002) should be used in this step
Closed barrel socket S&F contact Closed barrel pin S&F contact
The cable pull-out forces requirement will have to be the following:
Cable size
Cable pull –out force requirement
2.5 mm²
Min. 230 N (~50 Lbs)
4.0 mm²
Min.310 N (~70 Lbs)
6.0 mm²
Min. 360.0 N (~80 Lbs)
Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.

Amphenol Industrial Operations Amphenol Industrial Operations Europe Amphenol Middle East Enterprises FZE Amphenol Technology Shenzhen Ltd
40-60 Delaware Avenue Via Barbaiana 5 Office C-37 PO Box 21107 Block 5 Fuan 2nd Industrial Park, Dayang Rd
Sidney, NY 13838-1395 I-20020 Lainate (MI) Ajman Free Zone Fuyong Town, Baoan, 518103 Shenzhen
USA ITALY UAE CHINA
Tel: [phone] Tel: [phone] Tel: [phone] Tel: [phone]
Fax: [phone] Fax:[phone] Fax:[phone] Fax:[phone]
6
H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 –OCTOBER 2014
Assembly process connector:
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 position. Contacts cannot be removed once seated.
See below pictures.
Connector cable female
Connector cable male
Back cap must be closed using a torque between 2.6 and 2,9NM.
Amphenol specified hand wrench tool (H4TW0001) can be used in this step or electric torque controlled wrench tool with as
well the Amphenol open-end back cap spanner (H4TE0000) or socket wrench (H4TF000). See below picture for hand wrench.
Note: Pneumatic wrench tools are NOT recommended since torque control is very difficult.
Double spanner cap closing operation
Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.

Amphenol Industrial Operations Amphenol Industrial Operations Europe Amphenol Middle East Enterprises FZE Amphenol Technology Shenzhen Ltd
40-60 Delaware Avenue Via Barbaiana 5 Office C-37 PO Box 21107 Block 5 Fuan 2nd Industrial Park, Dayang Rd
Sidney, NY 13838-1395 I-20020 Lainate (MI) Ajman Free Zone Fuyong Town, Baoan, 518103 Shenzhen
USA ITALY UAE CHINA
Tel: [phone] Tel: [phone] Tel: [phone] Tel: [phone]
Fax: [phone] Fax:[phone] Fax:[phone] Fax:[phone]
7
H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 –OCTOBER 2014
Connector mating and un-mating:
For mating align the 2 half connectors and mate them together by hand until a “click” is heard and/or felt.
For un-mating, since the Amphenol H4 connector complies with the NEC 2008 690.33, a tool is required to disconnect the
connector once mated.
Amphenol specified wrench tool (H4TW0001) or Universal tool (H4TU0000) should be used in this step.
See below pictures.
WRENCH TOOL DISCONNECT UNIVERSAL TOOL DISCONNECT
Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.Downloaded from Arrow.com.