Amphenol PL183 30 Series User manual

www.amphenol-gec.com
键位
X 键
Y 键
Key
X
Y
高压互锁
0：无
1：有
HVIL
0：NO
1：WITH
线缆大小
Cable Size
mm2
50
70
线缆类型
5：HS cable
G2 Connector
PL183(X)-30(X)-XX-2-5
三芯2代直头组装式连接器安装说明
The Assembly Manual
For 3POS PowerLok G2 180D Plug Connector
Document No: 8P1092
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不带高压互锁端子的绝缘筒 Insulation sleeve without HVIL contact ×2
④带密封圈的R4端子组件 R4 terminal Assy with O-ring ×3
⑤锁块 （两个） Lock housing （2PCS）×3
⑥塑料卡簧 Plastic Clamp spring ×3
⑦螺旋弹簧 Coil spring ×3
⑧外铜环 Outer Copper ring ×3
⑨内铜环 Inside Copper ring ×3
⑩金属垫圈 Metal gasket ×3
⑪密封圈 Sealing ×3
⑫尾盖 End cap ×3
第一部分：包装清单
Part 1：Package contents
三芯2代直头组装式连接器安装说明The Assembly Manual for 3POS PowerLok G2 180D Plug Connector
01-07
Rev.05 20211123 Document No: 8P1092
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
③
④
⑤
⑥
⑦
⑧ ⑨
⑩ ⑪
⑫

第二部分：插头组装
Part 2: Plug Assembly
1-2 取各1pcs的⑫尾盖, ⑪密封圈， ⑩金属垫圈和 ⑨内铜环, 从右边依次穿过线缆
1-2 Take each 1pcs of ⑫end cap, ⑪Sealing, ⑩Metal gasket and ⑨Inside Copper ring, and make them
pass through the cable from right in sequence.
连接器
Connector
线缆尺寸
Cable size
线缆外径
Accepted cable OD (mm)
屏蔽线缆
Shield Cable
301/300系列
301/300 Series
50mm² 14.9±0.3 HS 84096257
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)
301/300系列
301/300 Series
50mm² 37±0.5 19 +1/-0.5 7±1
70mm² 37±0.5 19 +1/-0.5 7±1
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 C mm(see table), 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
步骤2：剥线皮，按表2尺寸剥离线缆绝缘皮和外被
Step 2: Stripping, Strip off cable insulation and jacket as following size from the table 2
三芯2代直头组装式连接器安装说明The Assembly Manual for 3POS PowerLok G2 180D Plug Connector
⑫End Cap
尾盖
⑪Sealing
密封圈
⑩Metal gasket
金属垫片
⑨Inside Copper Ring
内铜环
02-07
Rev.05 20211123 Document No: 8P1092

Step 3: Crimping Copper ring
3-1 将⑨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 ⑨inside copper ring from the right side to the side below the shield. The shield line is covered on
the surface of the copper ring
步骤3：压接铜环
3-2 取1pcs ⑧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 ⑧Outer 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)
表3：铜环与线缆屏蔽编织层压接规格&拉拔力要求
Table 3：Copper Ring and Cable braids Crimping spec & retention force requirement
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
301/300系列
301/300 Series
50mm² 14.9±0.3 18.0±0.25 150N
70mm² 17.0±0.3 20.3±0.25 150N
⑴建议使用安费诺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
压接工具：油压机
Crimping tool : Hydraulic press
50mm²压模：195195150D50
50mm²Die： 195195150D50
70mm²Die: 220220150D70
70mm²压模： 220220150D70
三芯2代直头组装式连接器安装说明The Assembly Manual for 3POS PowerLok G2 180D Plug Connector
03-07
⑨Inside 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
⑧Outer 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 20211123 Document No: 8P1092

步骤4：取1pcs的④R4 端子组件 自左端穿上线缆，并压接在其上(规格参照表4)
Step 4: Take a ④R4 terminal Assy, load it to the cable end on the left, then crimp(refer to table 4)
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
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
301/300系列
301/300 Series
50mm² 14.9±0.3 11.34 ±0.25 2800N
70mm² 17.0±0.3 13.18 ±0.25 3400N
⑴建议使用安费诺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
步骤5：取1pcs的⑦螺旋弹簧安装在⑧外铜环上
Step 5: Take 1pcs ⑦Coil spring and install on ⑧Outer Copper ring
步骤6：取2pcs的⑤锁块，将2pcs ⑤锁块前端的台阶放置入端子和内皮之间的间隙
Step 6: Take 2pcs ⑤lock housing, Place the front step of the 2pcs ⑤lock housing into the space between
the terminal and the Insulation
⑶横截面
⑶Cross section
压接工具：油压机
Crimping tool : Hydraulic press
50mm²压模：L113130150D50
50mm²Die： L113130150D50
70mm²压模：L132153150D70
70mm²Die: L132153150D70
三芯2代直头组装式连接器安装说明The Assembly Manual for 3POS PowerLok G2 180D Plug Connector
04-07
Be sure the gap here is 2±0.5mm
确保这里的间隙是1.5mm到2.5mm之间
④R4 terminal Assy
Crimp cable here
此处压接芯线
⑧Outer Copper Ring
外铜环
⑦Coil spring
螺旋弹簧
⑤Lock Housing
锁块
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 20211123 Document No: 8P1092

步骤7：取出② ③绝缘筒，插入 ④R4 组件中, 并使其触底
Step 7: Take a ②③Insulation sleeve ,plug it to ④R4 Assy , 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）
Step 9: Take each 1pcs of ①Shield shell assembly (sample refer to picture below)
Key mark on connector
连接器标示
X Y
Inner Pin color
防触摸Pin颜色
Orange
橙色
Black
黑色
三芯2代直头组装式连接器安装说明The Assembly Manual for 3POS PowerLok G2 180D Plug Connector
步骤8：取出 ⑥塑料卡簧安装到② ③绝缘筒和 ⑤锁块之间的间隙，并确认卡簧活动顺畅
Step 8: Take a ⑥plastic Clamp spring, install into the space between the ②③Insulation sleeve and the ⑤
lock housing, and make sure clamp spring can be moved freely.
有倒角的面朝左侧方向
The chamfer faces left A-A
A A
②Insulation Sleeve
绝缘筒
⑤Lock Housing
锁块
⑥plastic Clamp spring
塑料卡簧
05-07
④R4 Assy
R4 端子组件
②③Insulation sleeve
绝缘筒
③without
HVIL contact
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
防触摸 Pin
Inner Pin
①Shield Shell Assembly
屏蔽壳组件
连接器标示
Key mark on
connector
Rev.05 20211123 Document No: 8P1092

步骤11：将 ⑩金属垫圈和⑪密封圈推入屏蔽壳组件内部的底部，接着将⑫尾盖扣住①屏蔽壳组件，完成此端线
束的组装
Step 11: Push the ⑩metal gasket and ⑪sealing to the bottom of Shield shell assembly，and then make the
⑫end cap fasten the ①shield shell assembly to finish the assembly.
三芯2代直头组装式连接器安装说明The Assembly Manual for 3POS PowerLok G2 180D Plug Connector
06-07
步骤10：②③绝缘筒插入到①屏蔽壳组件, 并使其触底,带高压互锁绝缘筒②装入位置B，不带高压互锁的绝缘
筒③装入位置A 与C，注意确认HVIL位置以及卡簧是否到位。
Step 10: Plug the ②③Insulation sleeve into ①Shield shell assembly , and make it reach the bottom.
Insulation sleeve with HVIL ②is in the position B，and Insulation sleeve without HVIL ③is in the position A
and C. take care to ensure HVIL in right place and pull back wire to ensure clamp spring is in position.
HVIL端子不能
损伤变形，请
注意插入方向
HVIL terminal
cannot be
damaged or
deformed
Take care of
sleeve plug
direction
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.
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
Step 12: Need to do the Insulation Resistance and DWV test after cable assembly，It is recommended that
the customer refer to the following test parameters
12-1 绝缘电阻测试
12-1 Insulation Resistance .
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
C
B
A
②
③
③
依次将装好③与②绝缘筒的线材装入到①屏蔽壳组件
Assemble wire assy with insulation sleeve ②or ③into ①Shield shell
assembly PinC, PinB and PinA in sequence. .
⑫End Cap
尾盖
⑪Sealing
密封圈
操作到位的效果图
The effect of
operation in place
Rev.05 20211123 Document No: 8P1092

12-2 Dielectric Withstand Voltage
12-2 耐压测试
三芯2代直头组装式连接器安装说明The Assembly Manual for 3POS PowerLok G2 180D Plug Connector
07-07
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
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 20211123 Document No: 8P1092
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.
Plug dust cover
Optional protective 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, Luogang 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