Amphenol PL18 50 Series User manual

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PowerLok 14mm单芯2代直头组装式连接器安装说明
The Assembly Manual for
14mm 1POS PowerLok Gen2 180D Plug Connector
键位
X 键
Y 键
U 键
V 键
W 键
T 键
Key
X
Y
U
V
W
T
高压互锁
0：无
1：有
HVIL
0：NO
1：WITH
线缆大小
Cable Size
mm2
70
95
120
线缆类型
5：HS cable
G2 Connector
PL18(X)-50(X)-XX-2-5
Document No: 8P1097
Rev.05

①屏蔽壳组件 Shield shell assembly ×1
②带高压互锁端子的绝缘筒 Insulation sleeve with HVIL contact ×1
（非HVIL版本无高压互锁端子 No HVIL contact for non-HVIL version）
③带止转切面的R4端子 R4 holder with anti-rotation chamfer ×1
④锁块 （两个） Lock housing （2PCS）×1
⑤塑料卡簧 Plastic Clamp spring ×1
⑥螺旋弹簧 Coil spring ×1
⑦外铜环 Outer Copper ring ×1
⑧内铜环 Inside Copper ring ×1
⑨金属垫圈 Metal gasket ×1
⑩密封圈 Sealing ×1
⑪尾盖 End cap ×1
第一部分：包装清单
Part 1：Package contents
单芯2代14mm直头组装式连接器安装说明 The Assembly Manual for 1POS 14mm PowerLok G2 180D Plug Connector
01-07Rev.05 20211124 Document No: 8P1097
⑪
③
④⑤
⑥⑦⑧⑨⑩
①②
备注 Note：
安装过程请保留HVIL防护盖在此位置，等线束组装完毕再取出。
HVIL cap should be left in place during assembly, removed after final assembly is complete before use.

1-2 取各1pcs的⑪尾盖, ⑩密封圈，⑨金属垫圈和⑧内铜环, 从右边依次穿过线缆
1-2 Take each 1pcs of ⑪end cap, ⑩Sealing, ⑨Metal gasket and ⑧Inside Copper ring, and make them pass
through the cable from right in sequence
第二部分：插头组装
Part 2: Plug Assembly
注意 : 剥皮完成之后，裁剪屏蔽保留C mm(看上方表2)，并将屏蔽线向后翻180°
Note : After wire stripping, cutting shielded leave over Cmm(see table 2) and fold back the shielding braid
表1：线材规格
Table 1：Cable size
表2：剥线长度
Table 2：Strip length
步骤2：剥线皮，按表2尺寸剥离线缆绝缘皮和外被
Step2：Stripping, Strip off cable insulation and jacket as following size from the table 2
步骤1：穿配件
Step1：Assemble the accessories
1-1 线缆准备：按生产需求从表1选择合适尺寸的线缆，并裁剪
1-1 Cable preparation : take right-sized cable and cut the cable according to production plan from the table 1
⑪End Cap
尾盖
⑩Sealing
密封圈
⑨Metal Gasket
金属垫圈
⑧Inside Copper Ring
内铜环
02-07
连接器
Connector
线缆尺寸
Cable size
线缆外径
Accepted cable OD (mm)
屏蔽线缆
Shield Cable
500/501 系列
500/501 Series
95mm² 19.9±0.4 HS 84100299
120mm² 22.6±0.4 HS 84103410
70mm² 17.0±0.3 HS 84100298
连接器
Connector
线缆尺寸
Cable size
外套剥线长度 A
Stripping jacket (mm)
绝缘皮剥线长 B
Stripping insulation (mm)
保留屏蔽长度 C
Leave over shielding(mm)
500/501系列
500/501 Series
95mm² 44±1 22 +1/-0.5 6±1
120mm² 44±1 22 +1/-0.5 6±1
70mm² 44±1 22 +1/-0.5 6±1
单芯2代14mm直头组装式连接器安装说明 The Assembly Manual for 1POS 14mm PowerLok Gen2 180D Plug Connector
Rev.05 20211124 Document No: 8P1097

Step3：Crimping Copper Ring
3-1 将⑧内铜环从右端移动到屏蔽线下方，屏蔽线覆盖在铜环表面
3-1 Move the ⑧inside copper ring from the right side to the side below the shield. The shield line is covered
on the surface of the copper ring
3-2 取1pcs ⑦外铜环，铜环从左端安装到屏蔽线上，铜环从屏蔽线的左端开始完全覆盖,并压接在其上(规格
参照表3)
3-2 Take 1pcs ⑦outer copper ring, load it to the cable end on the left, copper ring cover the shielded fully
from the shielded left end, then crimp(refer to table 3)
步骤3：压接铜环
表3：铜环与线缆屏蔽编织层压接规格&拉拔力要求
Table3：Copper Ring and Cable braids Crimping spec & retention force requirement
⑴建议使用H+S线材（H+S线材型号详见步骤1-1），如果客户选用其它电缆，请联系安费诺业务，协商订制零配件
Recommend to use H+S cable.(See section 1-1 for details of H+S cable part numbers.) If you need to use customized cable, Please
contact local sales for product extentions
⑵压接高度和拉拔力需要配合压接截面的金相分析，客户才能判断压接质量合格
Customers need to reconfirm cross section on crimping area and pull out force test to confirm the quality of crimp process
03-07
连接器
Connector
线缆尺寸
Cable size
线缆外径 (1)
Accepted cable OD (mm)
压接高度(2)
Crimping height (mm)
参考抗拉拔力 (2)
Retention Force
500/501 系列
500/501 Series
95mm² 19.9±0.4 23.2±0.25 150N
120mm² 22.6±0.4 25.7±0.25 150N
70mm² 17.0±0.3 20.3±0.25 150N
压接工具：油压机
Crimping tool : Hydraulic press
70mm²Die: 220220150D70
70mm²压模： 220220150D70
95mm²压模： 245245150D95
95mm²Die： 245245150D95
120mm²Die: 275275150D120
120mm²压模：275275150D120
单芯2代14mm直头组装式连接器安装说明 The Assembly Manual for 1POS 14mm PowerLok G2 180D Plug Connector
⑧Inside Copper Ring
内铜环
确保此处铜环前端和外被前端贴紧，
压紧后间隙最佳为0mm
Be sure to be closely in here, the best
clearance is 0mm after crimping
⑦Outer Copper Ring
外铜环
紧靠外被口 Close to the outer Jacket
5+/-1
压接之前，确保
此处外铜环后端
和内铜环后端平
齐
Make sure the
ends are level
with each other
before crimping
外铜环紧靠外被口
Outer Copper Ring Close to the outer Jacket
Rev.05 20211124 Document No: 8P1097

步骤4：取1pcs的③R4 holder 自左端穿上线缆，并压接在其上(规格参照表4)
Step 4: Take a ③R4 holder, load it to the cable end on the left, then crimp(refer to table 4)
步骤5：取1pcs的⑥螺旋弹簧安装在⑦外铜环上
Step 5: Take 1pcs ⑥Coil spring is installed on ⑦Outer Copper Ring
步骤6：取2pcs的④锁块，将2pcs④锁块前端的台阶放置入端子和内皮之间的间隙
Step 6: Take 2pcs ④lock housing, Place the front step of the 2pcs ④lock housing into the space between
the terminal and the Insulation
表4：端子与线缆压接压接规格&拉拔力要求
Table 4：Contact and Conductor Crimping spec & retention force requirement
120mm²横截面
120mm²Cross section
⑴建议使用H+S线材（H+S线材型号详见步骤1-1），如果客户选用其它电缆，请联系安费诺业务，协商订制零配件
Recommend to use H+S cable. （See section 1-1 for details of H+S cable part numbers.）If you need to use customized cable, Please
contact local sales for product extentions
⑵压接高度和拉拔力需要配合压接截面的金相分析，客户才能判断压接质量合格
Customers need to reconfirm cross section on crimping area and pull out force test to confirm the quality of crimp process
⑶横截面仅供参考（其他举例：等边六变形的横截形状），客户负责采购压接工具或刀模
Cross section only reference tooling geometry (ex. hex and indent dimensions ),customer will take liability for sourcing tools or dies
⑥Coil spring
螺旋弹簧
④Lock Housing
锁块
⑦Outer Copper Ring
外铜环
Crimp cable here
此处压接线束
Be sure the gap here is 2.5±1mm
确保这里的间隙是1.5mm到3.5mm之间
③R4 holder
95mm²横截面
95mm²Cross section
04-07
连接器
Connector
线缆尺寸
Cable size
线缆外径 ⑴
Accepted cable OD (mm)
压接高度⑵
Crimping height (mm)
参考抗拉拔力 ⑵
Retention Force
500/501 系列
500 /501 Series
70mm² 17.0±0.3 13.18 ±0.25 3400N
95mm² 19.9±0.4 13.29±0.25 4200N
120mm² 22.6±0.4 15.44±0.25 5000N
压接工具：油压机
Crimping tool : Hydraulic press
70mm²压模： L132153150D70
70mm²Die: L132153150D70
95mm²压模： L132173140D95
95mm²Die： L132173140D95
120mm²Die: L150195150D120
120mm²压模：L150195150D120 70mm²横截面
70mm²Cross section
单芯2代14mm直头组装式连接器安装说明 The Assembly Manual for 1POS 14mm PowerLok G2 180D Plug Connector
锁块缺口与端子止转面对齐
Gap of lock is in the same line with
the holder anti-rotation chamfer
Rev.05 20211124 Document No: 8P1097

步骤7：取出②绝缘筒，按图示方向插入③ R4 holder中, 并使其触底
Step 7: Take a ②Insulation sleeve ,plug it to ③R4 holder in direction as show in photo , and make it contact the
bottom
步骤9：取出①屏蔽壳组件（样品参照下面的图片）
Step9：Take each 1pcs of ①Shield shell assembly (sample refer to picture below)
Key mark on connector
连接器标示 X Y U V W T
Inner Pin color
防触摸Pin颜色
Orange
橙色
Black
黑色
Yellow
黄色
Green
绿色
Red
红色
Blue
蓝色
有倒角的面朝左侧方向
The chamfer faces left A-A
A A
②Insulation Sleeve
绝缘筒
④Lock Housing
锁块
⑤Plastic Clamp Spring
塑料卡簧
单芯2代直头组装式连接器安装说明 The Assembly Manual for 1POS PowerLok G2 180D Plug Connector
05-07
②Insulation sleeve
绝缘筒
HVIL position
③R4 holder
R4 端子
Make sure R4
end visible &
reach the
insulation cap
edge open.
确保R4尾端可见
& 尾端位置与绝缘
筒前端边缘平齐
同一方向
keep in the same
direction
步骤8：取出⑤塑料卡簧安装到②绝缘筒和④锁块之间的间隙，并确认卡簧活动顺畅
Step 8: Take a ⑤plastic Clamp spring, install into the space between the ②Insulation sleeve and the ④lock
housing ，and make sure clamp spring can be moved freely.
防触摸Pin
Inner Pin
连接器标示
Key Mark On Connector
①Shield Shell Assembly
屏蔽壳组件
Rev.05 20211124 Document No: 8P1097

步骤11:将⑨金属垫圈和⑩密封圈推入屏蔽壳组件内部的底部，接着将⑪尾盖扣住屏蔽壳组件，完成此端线束的组
装
Step 11: Push the ⑨metal gasket and ⑩sealing to the bottom of Shield shell assembly. The ⑪end cap is then
fastened to the Shield shell assembly，one end assembly done
12-2 耐压测试
12-2 Dielectric Withstand Voltage test
Positions
位置
Test voltage（DC）
测试电压（直流）
测试时间（推荐）
Test Time
（
recommended)
Leakage Current
漏电流
Cable(power) to shell
电缆芯线到壳体 5000 V 10S < 5mA
Cable(power) to HVIL
电缆芯线到高压互锁 5000 V 10S < 5mA
HVIL to shell
高压互锁到壳体 500 V 1S < 5mA
步骤12：在线缆组装好后需要做绝缘电阻和耐压测试，建议客户参考下面的测试参数
Step12: Need to do the Insulation Resistance and DWV test after cable assembly. It is recommended that the
customer refer to the following test parameters
Positions
位置
Test voltage（DC）
测试电压（直流）
测试时间（推荐）
Test Time
（
recommended)
Insulation resistance
绝缘电阻
Cable(power) to shell
电缆芯线到壳体 1000 V 5S > 500 MΩ
Cable(power) to HVIL
电缆芯线到高压互锁 1000 V 5S > 500 MΩ
HVIL to shell
高压互锁到壳体 1000 V 1S > 100 MΩ
12-1 绝缘电阻测试
12-1 Insulation Resistance test
操作到位的效果图
The effect of
operation in place
⑩Sealing
密封圈
06-07
单芯2代14mm直头组装式连接器安装说明 The Assembly Manual for 1POS 14mm PowerLok G2 180D Plug Connector
步骤10：②绝缘筒按图示方向插入到①屏蔽壳组件, 并使其触底，注意确认HVIL位置以及卡簧是否到位。
Step 10: Plug the ②Insulation sleeve into ①Shield shell assembly as shown in photo , and make it reach
the bottom, take care to ensure HVIL in right place and pull back wire to ensure clamp spring in position .
①Shield Shell Assembly
屏蔽壳组件
②Insulation Sleeve
绝缘筒
HVIL
Position
CPA
装到底后轻摇线材使卡簧到位
再后拉线材应不松脱
After installation, gently shake
the wire to ensure the spring in
place, pull back wire should not
be pulled out.
端子不能损伤变形
HVIL terminal cannot
be damaged or
deformed
⑪End Cap
尾盖
Rev.05 20211124 Document No: 8P1097

07-07
单芯2代14mm直头组装式连接器安装说明 The Assembly Manual for 1POS 14mm PowerLok G2 180D Plug Connector
12-3 测试说明:
警告:建议的电气测试及其参数应根据终端应用要求进行审查，以确保安全性并防止损坏其他部件。提供的参数
是基于PowerLok连接器和其峰值1000VDC额定。提供的测试参数可能超出电缆组件或设备上使用的其他部件/
材料的限制。
12-3 Test note:
caution: Recommended electrical tests and their parameters should be reviewed against end
application requirements to ensure safety and to prevent damage to other components. Parameters
provided are based on the PowerLok connectors and their peak 1000VDC rating. Test parameters
provided may exceed the limit of other components/materials used on the cable assembly or device.
Rev.05 20211124 Document No: 8P1097
步骤13：补充说明
Step 13: Other notes
13-1：在连接器搬运和高压线束搬运过程中，推荐使用插头防尘盖，和插头防护盖。 避免搬运过程中碰伤、
损坏。 要求详见 安装指引 8P1129。.
13-1: In the process of connector handling and high-voltage harness handling, it is recommended to use
plug dust cover and plug protective cover. Avoid bumping and damage during handling. See installation
guideline 8P1129 for detail requirements.
Optional protective cover Plug dust cover

Amphenol Technical Products International provides the above product specifications for the standard PowerLok series of
connectors to assist users in identifying the correct product for the system to which the connectors may be applied. Specifications are
subject to change without notice. Contact your nearest Amphenol Corporation Sales Office for the latest specifications. All statements,
information and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility
of any kind, expressed or implied. Statements of suggestions concerning possible use of our products are made without representation or
warranty that any such use is free of patent infringement and are not recommendations to infringe any patent. Specifications are typical
and may not apply to all connectors. Note that these specifications are derived from relevant global standards used in the automotive and
industrial transportation markets, but they are not a substitute for system level design validation testing, which is the sole responsibility of
the system designer and/or end user.
Asia Pacific
GuangZhou, China
Tel: [phone]
Add: 9th Floor, No. 10, the 4th Street, Kehui Jingu, Huangpu District, Guangzhou, Guangdong
P.C: 510663
North America
Winnipeg, Canada
Tel: [phone]
Add: 2110 Notre Dame Avenue
Europe
Milano, Italy
Tel: [phone]
Add: Via Barbaiana 5, 20020 Lainate(MI)
Email: [e-mail]
Asia Pacific
ChangZhou, China
Tel: [phone]
Add: No.11 Fengxiang Road, New District, Changzhou, Jiangsu
P.C: 213001