Amphenol HVSL60061 Series User guide

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 2 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
Contents
1. Scope.....................................................................................................................................3
2. Components...........................................................................................................................3
3. Assembly instructions for HVSL600061 .................................................................................9
4. Assembly instructions for HVSL630062 ...............................................................................15
5. Assembly instructions for HVSL280063 ...............................................................................21
6. Testing instruction ................................................................................................................28
7. Equipments and tool lists......................................................................................................29

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 3 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
1. Scope
This specification covers the requirements for application of the
HVSL600061/HVSL630062/HVSL280063 connectors.
2. Components
2.1 HVSL600061 series connector components
HVSL630062 series
HVSL600061 series
HVSL600061 series
HVSL280063 series
1
12
11
8
10
9
7
2
5
4
3
6

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 4 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
Index
APCD P/N
Description
Qty
1
HVSL60006X
Body
1
2
C422003654
Insertion
1
3
C422003657
Side chock
1
4
C310003609
Shielding shell
2
5
C310003614S
Signal contact. If HVSL600061X0XXXX, then no need.
2
6
C420003620
Power contact
1
7
P03BM00388
Inner shielding ferrule
8
-
Signal wire, select 0.5mm²wire.
If HVSL600061X0XXXX, then no need.
0.070m
9
P03BM00117
Outer shielding ferrule
1
10
C220003622
Spacers
1
11
C270003607X
Cable seal
For HVSL600061XXXX10 cable seal P/N is C2700036072
For HVSL600061XXXX11 cable seal P/N is C2700036071
For HVSL600061XXXX12 cable seal P/N is C270003607
For HVSL600061XXXX13 cable seal P/N is C270003607
1
12
C220003620
End cap
1
Interlock option：0 without/1 with
Key option：A/B/C/D/E
HVSL600061 series material lists
Cable spec 25mm²
Cable OD10（10±0.5mm）/11（11±0.5mm）/12（12±0.5mm）/13（13+0/-0.5mm）
HVSL600061 X X XX XX

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 5 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
2.1 HVSL630062 series connector components
HVSL630062 series
6
7
8
5
4
3
2
1
13
10
11
12
9
Interlock option：0 without/1 with
Key option：A/B/C/D/E
Cable spec 4-6mm²。
Cable OD：10（10±0.5mm）/ 11（11±0.5mm）/ 12（12±0.5mm）/ 13（13+0/-0.5mm）。
HVSL630062 X X XX XX

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 6 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
Index
APCD P/N
Description
Qty
1
HVSL63006X
Body
1
2
C220003653
Insertion
1
3
C220003656
Plastic chock
1
4
C220003656
Plastic chock
1
5
C310003609
Shielding shell
2
6
C310003623S
Power contact
2
7
C310003614S
Signal contact
If HVSL630062X0XXXX then no need
2
8
-
Signal wire, select 0.5mm²
If HVSL630062X0XXXX then no need
0.070m
9
P03BM00388
Inner shielding ferrule
1
10
P03BM00117
Outer shielding ferrule
1
11
C220003622
Spacer
1
12
C270003607X
Cable seal
For HVSL630062XXXX10 cable seal P/N is C2700036072
For HVSL630062XXXX11 cable seal P/N is C2700036071
For HVSL630062XXXX12 cable seal P/N is C270003607
For HVSL630062XXXX13 cable seal P/N is C270003607
1
13
C220003620
End cap
1
HVSL630062 series material lists

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 7 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
2.2 HVSL280063 series connector components
6
5
9
2
4
10
8
13
1
3
11
12
7
HVSL280063 / HVSL28A063 series
Interlock option：0 without/1 with
Key option：A/B/C/D/E
Cable spec 2.5-4mm²
Cable OD：10（10±0.5mm）/ 11（11±0.5mm）/ 12（12±0.5mm）/ 13（13+0/-0.5mm）。
HVSL280063 X X XX XX
Key option：A/B/C/D/E。
Cable OD：10（10±0.5mm）/ 11（11±0.5mm）/ 12（12±0.5mm）/ 13（13+0/-0.5mm）。
HVSL28A063 X XX

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 8 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
Index
APCD P/N
Description
Qty
1
HVSL28006X
Body
1
2
C220003625
Insertion
1
3
C220003626
Plastic chock
1
4
C220003627
Plastic chock
1
5
C310003609
Shielding shell
2
6
C310003614S
Signal contact
If HVSL280063X0XXXX then no need
2
7
-
Signal wire, select 0.5mm², if HVSL280063X0XXXX then
no need
0.070m
8
C310003612S
Power contact
3
9
P03BM00388
Inner shielding ferrule
1
10
P03BM00117
Outer shielding ferrule
1
11
C220003622
Spacer
1
12
C270003607X
Cable seal
For HVSL280063XXXX10 cable seal P/N is C2700036072
For HVSL280063XXXX11 cable seal P/N is C2700036071
For HVSL280063XXXX12 cable seal P/N is C270003607
For HVSL280063XXXX13 cable seal P/N is C270003607
1
13
C220003620
End cap
1
HVSL280063 series material lists

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 9 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
3. Assembly instructions for HVSL600061
3.1 Select the wire spec according to the connector model.
3.2 Cut and strip the wire insulation, the size is referred as below.
3.3 Crimp the signal terminals as shown in the figure below.
3.4 Select the cable according to the connectors P/N.
Wire spec
OD(mm)
0.5mm²
1.6±0.1
Retention force : The
tensile force meets the
requirements of VW80302
（9.1.4 table 12）
P/N
OD (mm)
HVSL600061XXXX10
10.0 ±0.5mm
HVSL600061XXXX11
11.0 ±0.5mm
HVSL600061XXXX12
12.0 ±0.5mm
HVSL600061XXXX13
13.0 +0/ -0.5mm
4.0±0.5mm
4.0±0.5mm
Crimping orientation
should be the same
65.0mm ref
H

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 10 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
3.5 Slide the end cap, cable seal, spacer, inner shielding ferrule and outer
shielding ferrule on the cable in sequence shown as below.
3.6 Strip the power cable jacket shown as below.
3.7 Slide the inner ferrule to the cut position of the jacket. Then, flip the
shielding braid backwards to cover the surface of the ferrule. Finally, wrap
2-3 layers copper foil shown as below.
Cable
spec
L1(mm)
L2(mm)
L3(mm)
25mm²
24.5±0.5
12.0±0.5
10.0ref
End cap
Spacer
Wrap copper
foil.
Inner
shielding
ferrule
Outer shielding ferrule
Flip over the shielding to
cover the ferrule.
Move the inner ferrule
until it is aligned with the
cutting surface.
Cable seal
Slide direction
Φ13.2-13.5mm ref
When the cable OD is
small, add padding to
the cable jacket.

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 11 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
3.8 Crimp the terminals as shown in the figure below.
3.9 Insert signal contacts into the housing and mount the plastic chock.
If no special requirements:
The cross-sectional acceptance criteria are in accordance with item
USCAR 21-4-2020. 85% to 80% compression ratio of the section is a
good place to start until there is no gap.
Orientate the contacts
end towards their slots.
Fold the wire in half while
keeping the contacts end
at the same level.
Insert signal contacts.
Section
Conductor visible
The housing
locks the
contacts spring
latches.
Insert plastic
chock.
Align the chock
with the
surface of the
insertion.
Orientate the
contacts end towards
their slots.
H

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 12 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
3.10 Insert power contact.
3.11 Assemble shielding shell shown as below.
Claws of the shielding shell
are snapped into the
grooves on both sides.
Insert power contact.
The spring latches
lock the contact.
The shielding shell is
aligned with the edge of
the core connector.
Do the same the
other shielding shell.
Fasten the
shielding shell on
the surface.

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 13 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
3.12 Move the outer shielding ferrule on the shell, then crimp it into shape
with a holding force > 150N.
3.13 Insert the cable into the housing shown as below.
3.14 Insert spacer, cable seal and end cap shown .
Move the outer shielding
ferrule until the ferrule’s end
is aligned to the rear of the
shielding shell.
Crimp shielding
ferrule.
Orientate the insertion boss to the housing
position without rib.
Insert insertion to the housing
The two sides’latches
are completely visible.
15.6±0.1mm ref

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 14 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
Insert spacer
Insert spacer until it is
aligned with the edge
Insert cable seal
0.5mm ref
After the end cap is
mounted, the latches should
be visible
Mount the end cap

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 15 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
4. Assembly instructions for HVSL630062
4.1 Select the wire according to the connectors P/N.
4.2 Cut and strip the wire insulation, the size is referred as below.
4.3 Crimp the signal terminals as shown in the figure below.
4.4 Select the cable according to the connectors P/N.
Wire space
OD(mm)
0.5mm²
1.6±0.1
Retention force : The
tensile force meets the
requirements of VW80302
（9.1.4 table 12）
P/N
OD (mm)
HVSL630062XXXX10
10.0 ±0.5mm
HVSL630062XXXX11
11.0±0.5mm
HVSL630062XXXX12
12.0 ±0.5mm
HVSL630062XXXX13
13.0 +0/
-0.5mm
4.0±0.5mm
4.0±0.5mm
Crimping orientation
should be the same
65.0mm ref
H

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 16 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
4.5 Slide the end cap, cable seal, spacer, inner shielding ferrule and outer
shielding ferrule on the cable in sequence shown as below.
4.6 Strip the jacket shown as below
4.7 Slide the inner ferrule until it is aligned with the cutting surface of the
jacket, then flip the shielding braid over to cover the ferrule, finally wrap 2-3
layers copper foil and cut all the filler shown as below.
End cap
Spacer
Inner
shielding
ferrule
Outer shielding ferrule
Cable seal
Direction
34.0±0.5mm
10.0±0.5 mm ref
Cut the filler.
Move the inner ferrule to align it
with the cutting surface.
Flip over the shielding and
cover on the ferrule.
Wrap copper foil.
Φ15.6±0.1 mm ref
When the cable OD is
small, add padding to
the cable jacket.

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 17 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
4.8 Strip the insulation shown as below.
4.9 Crimp the terminals as shown in the figure below.
4.10 Insert signal contacts into the housing.
Retention force : 2.5mm²Above (inclusive) The tensile force
meets the requirements of VW80304（6.2.11）.
6.0±0.5 mm
Orientate the
contacts ribs towards
their slots.
Fold the wire in half while
keeping the contacts ends
at the same level.
Insert signal
contacts
Orientate the
contacts ribs towards
their slots.

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 18 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
4.11 Insert power contacts into the rubber core. Then, mount the chock.
The housing locks
the contact spring
latches.
Contacts metal
spring latches lock
the housing.
Insert power contacts.
Insert chock 1 on
the rubber core.
The chock surface is at the
same level than the
rubber core surface.
Insert chock 2 into
the rubber core.
The chock surface is at the
same level than the core
surface.
Orientate with the
rib of the chock.

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 19 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
4.12 Assemble the shielding shell shown as below.
4.1 Move the outer shielding ferrule on the shell, then crimp it into shape
with a holding force > 150N.
Snap the outside claws
into their slots.
Align the shielding
shell edge with the
rubber core.
Do the same with the
other shielding shell.
Put the shielding
shell on the
rubber core.
Move the outer shielding ferrule
until the ferrule end aligns to the
shielding shell end side.
Crimp shielding
ferrule.
15.6±0.1mm ref

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 20 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
4.2 Insert the cable into the housing shown as below.
4.3 Finish assembling spacer, cable seal and end cap.
Orientate the insertion boss to the
housing position without rib.
Insert insertion to
the housing.
The two sides latches
should be completely
visible.
Insert spacer
Insert spacer until it is aligned
with the edge of the housing.

Amphenol PCD
Shenzhen
Application Specification for
HVSL60061/HVSL630062/
HVSL280063
Doc. No.: APCD-TD-282
Rev.: H
Page 21 of 29
Subject:
Application specification for HVSL600061/HVSL630062/HVSL280063
ECN NO.: C5467N
Eff. Date:: 2021-5-20
F-0866-B
5. Assembly instructions for HVSL280063/HVSL28A063
5.1 Select the cable according to the connectors P/N.
Cable spec
OD(mm)
0.5mm²
1.6±0.1
Insert cable seal
0.5mm ref
After the end cap is
mounted, the latches must
be visible
Mount the end cap