Amphenol HVSL 1000 2P User manual

CONFIDENTIAL
PRELIMINARY
Doc. No.: APCD-TD-073
Rev.: A
Amphenol
PCD Shenzhen HVSL 1000 2 芯/3 芯连接器组装说
明书 Page: 1of 13
Subject: Assembly Instruction for HVSL 1000 2P&3P Connector Eff. Date: 2013-08-20
F-0011-A
修订履历 Revision History
修订日期
Date
版本
Rev.
修订内容
Updated Content
作者
Originator
备注
Remark
2013-08-20 A First release Eric
制作 Prepared By: Eric 审核 Checked By: 批准 Approved By:
日期 Date: 2013-08-20 日期 Date: 日期 Date:

CONFIDENTIAL
PRELIMINARY
Doc. No.: APCD-TD-073
Rev.: A
Amphenol
PCD Shenzhen HVSL 1000 2 芯/3 芯连接器组装说
明书 Page: 2of 13
Subject: Assembly Instruction for HVSL 1000 2P&3P Connector Eff. Date: 2013-08-20
F-0011-A
CONTENTS
1. SCOPE ................................................................................................................................... 3
2. DOCUMENTS......................................................................................................................... 3
2.1. Customer drawings........................................................................................................ 3
2.2. Cable specifications....................................................................................................... 3
3. COMPONENTS ......................................................................................................................3
4. ASSEMBLY INSTRUCTIONS................................................................................................ 4
4.1. HVSL 1000 02 2P&3P Assembly instructions................................................................ 4
4.1.1. Overview of exploded all parts.................................................................................... 4
4.1.2. Cable prepare for crimp contact ................................................................................. 4
4.1.3. Crimp the contact ....................................................................................................... 5
4.1.4. Crimp IL contact ......................................................................................................... 5
4.1.5. Assemble the contacts into receptacle....................................................................... 5
4.2. HVSL 1000 06 2P&3P Assembly instructions................................................................ 6
4.2.1. Overview of exploded all parts.................................................................................... 6
4.2.2. Cable prepare for crimp contact ................................................................................. 6
4.2.3. Crimp the contact ....................................................................................................... 7
4.2.4. Crimp the shielding..................................................................................................... 8
4.2.5. Assemble the cable into the plug.............................................................................. 10
4.3. Mating Instruction ........................................................................................................ 11
4.3.1. Unlock CPA and Rotate the lever............................................................................. 11
4.3.2. Insert plug and Lock CPA......................................................................................... 11
4.4. Separating Instruction.................................................................................................. 12
4.4.1. Separating the primary lock...................................................................................... 12
4.4.2. Separating the secondary lock ................................................................................. 12

CONFIDENTIAL
PRELIMINARY
Doc. No.: APCD-TD-073
Rev.: A
Amphenol
PCD Shenzhen HVSL 1000 2 芯/3 芯连接器组装说
明书 Page: 3of 13
Subject: Assembly Instruction for HVSL 1000 2P&3P Connector Eff. Date: 2013-08-20
1.
F-0011-A
SCOPE
本规范适用范围为 HVSL 1000 2 芯和 3芯连接器。具体包括产品为：HVSL 1000 02 2 X /
HVSL 1000 06 2 X / HVSL 1000 02 3 X / HVSL 1000 06 3X。
This specification describes the assembly instruction for HVSL 1000 2P&3P connector. It
covers box mounting receptacle (HVSL 1000 02 2 X / HVSL 02 3 X), straight plug (HVSL
1000 06 2 X / HVSL 1000 06 3 X) .
2. DOCUMENTS
2.1. Customer drawings
C-HVSL1000022X············ 2P Box mounting receptacle
C-HVSL1000062X············ 2P Straight plug
C-HVSL1000023X············ 3P Box mounting receptacle
C-HVSL1000063X············ 3P Straight plug
2.2. Cable specifications
C210005105·····················50 mm^2 Cable Specification
C210005101·····················35 mm^2 Cable Specification
C210005103·····················25 mm^2 Cable Specification
C210005104·····················16 mm^2 Cable Specification
3. COMPONENTS
P/N Description Figure
HVSL 1000 02 2 X Box mounting receptacle –2P
HVSL 1000 06 2 X Straight plug –2P
HVSL 1000 02 3 X Box mounting receptacle –3P
HVSL 1000 06 3 X Straight plug –3P
C200003609 Size 20 Pin contact

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Doc. No.: APCD-TD-073
Rev.: A
Amphenol
PCD Shenzhen HVSL 1000 2 芯/3 芯连接器组装说
明书 Page: 4of 13
Subject: Assembly Instruction for HVSL 1000 2P&3P Connector Eff. Date: 2013-08-20
F-0011-A
C4200036152 10 mm Pin contact
C420003616 10 mm Socket contact
C422003601/2/3 Kit of socket insert assembly
C4200036151 10 mm Pin contact
4. ASSEMBLY INSTRUCTIONS
4.1. HVSL 1000 02 2P&3P Assembly instructions
4.1.1. Overview of exploded all parts
Crimp
Type
Bus-Bar
Type
Figure 1 HVSL 1000 02 Box Mounting Receptacle Exploded View
4.1.2. Cable preparation for crimp contact
将非屏蔽线缆去除外被如下图示。
Strip the un-shielding cable jacket as blow figure and dimensions.
A
Figure 2: cable design and dimension

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Amphenol
PCD Shenzhen HVSL 1000 2 芯/3 芯连接器组装说
明书 Page: 5of 13
Subject: Assembly Instruction for HVSL 1000 2P&3P Connector Eff. Date: 2013-08-20
F-0011-A
Cable Type 70 mm^2 50 mm^2 35 mm^2 25 mm^2 16 mm^2
Dimension
A(mm) 19+0.5 19+0.5 17+0.5 15+0.5 --
4.1.3. Crimp the contact
将线缆装入端子压接孔中，用专用压接工具压接，并检查压接高度及压接力如下表
要求。
Crimp the contact according to IPC-A-620 standard, then check the dimension of
crimp height and pull-out force.
CH
Figure 3: Crimp height
Cable Type 70 50 35 25 16
CH （mm）12.7+0.2 10.5+0.2 9.0+0.2 7.2+0.1 6.2+0.1
Pull-out Force (N) 3400 2800 2300 1900 1400
Contact resistance (mOhms) 0.36 0.36 0.39 0.40 0.43
4.1.4. Crimp IL contact
将20AWG (0.5 mm^2)线缆去除外被 7-9mm，然后用 M22520/1-02 压接钳压接。
Remove the 20AWG (0.5 mm^2) wire jacket 7-9mm, then crimp the contacts with
M22520/1-02 tools. The final assembly as blow.
4.1.5. Assemble the contacts into receptacle
将压接后的端子依下图所示，组装到插座中。
Put the contacts into the receptacle.

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Doc. No.: APCD-TD-073
Rev.: A
Amphenol
PCD Shenzhen HVSL 1000 2 芯/3 芯连接器组装说
明书 Page: 6of 13
Subject: Assembly Instruction for HVSL 1000 2P&3P Connector Eff. Date: 2013-08-20
F-0011-A
IL contact
assembly
Figure 4: HVSL 1000 02 Box mounting receptacle final assembly
4.2. HVSL 1000 06 2P&3P Assembly instructions
4.2.1. Overview of exploded all parts
Crimp contact
assembly Bus-bar contact
assembly
Figure 5: HVSL 1000 3P Straight Plug Exploded View
4.2.2. Cable preparation for crimp contact
将屏蔽线缆去除外被如下图示。
Strip the shielding cable jacket as blow figure and dimensions.

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Rev.: A
Amphenol
PCD Shenzhen HVSL 1000 2 芯/3 芯连接器组装说
明书 Page: 7of 13
Subject: Assembly Instruction for HVSL 1000 2P&3P Connector Eff. Date: 2013-08-20
F-0011-A
Figure 6: Cable design and dimension
4.2.3. Crimp the contact
将线缆装入端子压接孔中，用专用压接工具压接，并检查压接高度及压接力如下表
要求。
Crimp the contact according to IPC-A-620 standard, then check the dimension of
crimp height and pull-out force.
Cable Type 70 mm^2 50 mm^2 35 mm^2 25 mm^2 16 mm^2
Dimension
A(mm) 35+1 35+1 -- -- --
Dimension
B(mm) 19+0.5 19+0.5 17+0.5 15+0.5 --
Dimension
C(mm) 12 Ref. 14 Ref. -- -- --
CB
A
Figure 7: Crimp contact

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Rev.: A
Amphenol
PCD Shenzhen HVSL 1000 2 芯/3 芯连接器组装说
明书 Page: 8of 13
Subject: Assembly Instruction for HVSL 1000 2P&3P Connector Eff. Date: 2013-08-20
F-0011-A
CH
Figure 8: Crimp height
Cable Type 70 mm^2 50 mm^2 35 mm^2 25 mm^2 16 mm^2
CH （mm）12.7+0.2 10.5+0.2 9.0+0.2 7.2+0.1 6.2+0.1
Pull-out Force (N) 3400 2800 2300 1900 1400
Contact resistance
(mOhms) 0.36 0.36 0.39 0.40 0.43
4.2.4. Crimp the shielding
将压接后端子按下图所示的装配顺序，装入插芯组件。
Assemble the insert as below sequence..
Figure 9: Assembly sequence
端子插入插芯后的尺寸及编织处理如下。

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Amphenol
PCD Shenzhen HVSL 1000 2 芯/3 芯连接器组装说
明书 Page: 9of 13
Subject: Assembly Instruction for HVSL 1000 2P&3P Connector Eff. Date: 2013-08-20
F-0011-A
The contact assy. as below position, and the braid should be handled according to
the figure.
Figure 10: Insert assy.
将内外环套与线缆编织压接，然后再压接外环套与线缆外被。
Crimp the shielding and jacket.
编织要可见，伸出外套
不超过 1mm。
88 The braid is visible and
not exceed 1 mm for
extension.
Figure 11: Crimp dimension and shape
Cable Type 70 mm^2 50 mm^2 35 mm^2 25 mm^2 16 mm^2
A（mm）26.7+0.3 26.7+0.3 26.7+0.3 26.7+0.3 26.7+0.3
Dia. B (mm) 28 Max. 28 Max. 28 Max. 28 Max. 28 Max.
A
B
View A View B
88

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Amphenol
PCD Shenzhen HVSL 1000 2 芯/3 芯连接器组装说
明书 Page: 10 of 13
Subject: Assembly Instruction for HVSL 1000 2P&3P Connector Eff. Date: 2013-08-20
F-0011-A
C (mm) 19+0.2 17.8+0.2 14+0.2 12.5+0.2 --
Pull-out force: Cable >30 N; Shielding: >150 N.
线缆拉力大于 30N；屏蔽拉力大于 150N。
4.2.5. Assemble the cable into the plug
将线缆组件如下所示，插入插头外壳内。
Put the cable assy. into the plug housing.
对齐键与键槽，再插
入。
Orientate key/keyway,
and plug-in.
Figure 12: Assemble the cable assy.
将插头后塞推入到位。
Assemble the end-stop and check the position.

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PCD Shenzhen HVSL 1000 2 芯/3 芯连接器组装说
明书 Page: 11 of 13
Subject: Assembly Instruction for HVSL 1000 2P&3P Connector Eff. Date: 2013-08-20
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楔台可见。
The latch stops
should be visible.
Figure 13: Final assembly
4.3. Mating Instruction
4.3.1. Unlock CPA and Rotate the lever.
插入前先将 CPA 解锁，然后将拉手旋转到垂直状态，同时伴有“咔嗒”声响。
Unlock CPA before mating, and rotate the lever on working position.
2
3
1
Figure 14: Unlock CPA.
4.3.2. Insert plug and Lock CPA
将插座上两边的耳扣顺着插头拉手的导轨插入，插入到位后，拉手将与插头上的机
构扣住并伴有“咔嗒”声响，确保到位；然后将 CPA 推入并锁住拉手。

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Rev.: A
Amphenol
PCD Shenzhen HVSL 1000 2 芯/3 芯连接器组装说
明书 Page: 12 of 13
Subject: Assembly Instruction for HVSL 1000 2P&3P Connector Eff. Date: 2013-08-20
F-0011-A
Orient Plug and Receptacle and insert slowly, when insert properly, the lever is
latched with “Click”; then push the CPA on locked position in order to warranty
locked finally. The final assembly as below
Figure 15: Final mating.
4.4. Separating Instruction
4.4.1. Separating the primary lock
将CPA 拉出解锁，然后按下卡扣将拉手也解锁；用手将插头拉出分离，同时顺时针
旋转拉手以辅助分离。
Pull the CPA out and unlock, then push the clip in order to unlock lever; Pull
out the plug and at the meanwhile rotate the lever clockwise . Secondary
lock position
2
3
1
3
Figure 16: Unlock primary lock
4.4.2. Separating the secondary lock
当插头到达第二级锁紧机构时，用中指向下按解锁第二级机构，同时继续用手将插
头拉出分离，同时顺时针旋转拉手以辅助分离。

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Rev.: A
Amphenol
PCD Shenzhen HVSL 1000 2 芯/3 芯连接器组装说
明书 Page: 13 of 13
Subject: Assembly Instruction for HVSL 1000 2P&3P Connector Eff. Date: 2013-08-20
F-0011-A
Press the secondary lock using middle finger, at the meanwhile, continuously
pull out the plug and rotate the lever clockwise until the plug separate
completely.
1
1
1
Figure 17 Final separating