Amphenol PL283 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
PL283(X)-30(X)-XX-2-5
Document No: 8P1093
Rev.04
三芯2代弯头组装式连接器安装说明
The Assembly manual
For 3POS PowerLok G2 90D Plug Connector

第一部分：包装清单
Part 1：Package contents
①摇杆Latch ×1
③外铜环Outer Copper ring ×3
⑤外壳 Shell ×3
⑦金属垫片 Metal gasket ×3
⑧尾壳组件 Tail shell assembly ×1
⑨R4端子组件 R4 and terminal assembly ×3
⑩一套绝缘套 A set of Insulation sleeve ×3
⑪W 锁块（带凸台）Clamp W（With convex platform）×1
⑫W/O锁块Clamp W/O ×1
⑬M6平垫圈 M6 flat washer ×2
⑭M6弹簧垫圈 M6 spring washer ×2
⑮M6×18螺丝 M6×18 Screw ×2
②螺旋弹簧Coil spring ×3
④内铜环Inside Copper ring ×3
⑥密封圈Sealing ×3
三芯2代弯头组装式连接器安装说明 The Assembly manual for 3POS PowerLok G2 90D Plug Connector
01-10Rev.04 20211124 Document No: 8P1093
①
②
③
④⑤⑥
⑦
⑧⑨
⑩
⑫
⑬
⑭⑮
⑪

1-2 取各1pcs的⑦金属垫片，⑥密封圈， ⑤外壳和④内铜环, 从右边依次穿过线缆
1-2 Take each 1pcs of ⑦Metal gasket, ⑥Sealing, ⑤shell and ④Inside Copper ring have cable insert
through their holes from right in sequence
第二部分：插头组装
Part 2：Plug assembly
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)
300系列
300 Series
50mm² 32±1 17±1 7±1
70mm² 32±1 17±1 7±1
连接器
Connector
线缆尺寸
Cable size
线缆外径
Accepted cable OD (mm)
屏蔽线缆
Shield Cable
300系列
300 Series
50mm² 14.9±0.3 HS 84096257
70mm² 17.0±0.3 HS 84100298
注意 : 剥皮完成之后，裁剪屏蔽保留Cmm(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) ,and fold back the shielding braid
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
表1：线材规格
Table 1：Cable size
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 2z
表2：剥线长度
Table 2：Strip length
三芯2代弯头组装式连接器安装说明 The Assembly manual for 3POS PowerLok G2 90D Plug Connector
02-10
④Inside Copping Ring
内铜环
⑤Shell
外壳
⑥Sealing
密封圈
⑦Metal
gasket
垫片
The chamfer faces right in the graphic
在图示中有倒角的面朝右侧方向
Rev.04 20211124 Document No: 8P1093

步骤3：压接铜环
Step 3: Crimping Copper Ring
3-1 将④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 ④inside 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 ③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 ③Outer 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
300系列
300 Series
50mm² 14.9±0.3 18.0±0.25 150N
70mm² 17.0±0.3 20.3±0.25 150N
压接工具：油压机
Crimping tool : Hydraulic press
50mm²压模： 195195150D50
50mm²Die： 195195150D50
70mm²压模： 220220150D70
70mm²Die: 220220150D70
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;
步骤4：取1pcs的②螺旋弹簧安装在③ 外铜环上
Step 4: Take a Coil spring ，and install it on ③Outer Copper ring
三芯2代弯头组装式连接器安装说明 The Assembly manual for 3POS PowerLok G2 90D Plug Connector
03-10
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
④Inside Copper Ring
内铜环
③Outer Copper ring
外铜环
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
5+/-1
外铜环紧靠外被口
Outer Copper Ring Close to the outer Jacket
②Coil spring
螺旋弹簧
③Outer Copper Ring
外铜环
Rev.04 20211124 Document No: 8P1093

步骤5：取出⑨ R4端子组件（样品参照下面的图片）
Step 5: Take 1pcs ⑨R4 and terminal assembly (sample refer to picture below)
步骤6：取1pcs的⑨ R4端子组件自左端穿上线缆，并压接在其上(规格参照表4)
Step 6: Take a ⑨R4 and terminal assembly , load it to the cable end on the left, then crimp(refer to table 4)
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
300系列
300 Series
50mm² 14.9±0.3 11.34 ±0.25 2800N
70mm² 17.0±0.3 13.18 ±0.25 3400N
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
⑶横截面
⑶Cross section
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
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
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代弯头组装式连接器安装说明 The Assembly manual for 3POS PowerLok G2 90D Plug Connector
04-10
⑨R4 and Teminal assembly
R4端子组件
防触摸 Pin
Inner Pin
⑨R4 terminal
assembly
R4 端子组件
Crimp cable here
此处压接线束
Rev.04 20211124 Document No: 8P1093

步骤7：取出一套⑩绝缘套，将绝缘套卡入端子处
Step 7: Take a set of ⑩Insulation sleeve , install it into the terminal
步骤8：把连接头前端固定,以10~12N∙M拧紧⑤外壳
Step 8: Secure the front end of the connector, ⑤shell tight with torque 10~12N∙M
步骤9：将⑥密封圈推入屏蔽壳组件内部的底部
Step 9: Push the ⑥sealing to the bottom of Shield shell assembly
步骤10：取出⑧尾壳组件（样品参照下面的图片）
Step 10: Take each 1pcs of ⑧Tail shell assembly(sample refer to picture below)
Key mark on connector
连接器标示
X Y
三芯2代弯头组装式连接器安装说明 The Assembly manual for 3POS PowerLok G2 90D Plug Connector
05-10
⑩Insulation Sleeve
绝缘套
⑤Shell
外壳
The effect of operation in place
操作到位的效果图
⑥Sealing
密封圈
Key mark on connector
连接器标示
⑧Tail Shell Assembly
尾壳组件
Rev.04 20211124 Document No: 8P1093

步骤11 （手压机） ：
11-1 将⑧ 尾壳组件放置于桌面
11-2 将连接头的密封圈推入⑧尾壳组件内部
11-3 将产品放入治具T60014，启动开关将卡簧压合到位，
11-4 摇动手柄将接头压入尾壳组件，并保持位置，
11-5 左手松开气动开关，右手继续将接头往下压，听到“嗒”的声音， 卡簧安装到位。
Step11(manual press) ：
11-1 Place ⑧Tail shell assembly on the desktop
11-2 Push the sealing of the connecting head into the inner part of the ⑧tail shell assembly
11-3 Put the product into the fixture T60014, start the switch to press the clamp spring in place,
11-4 Crank the handle to press the connector into the tail housing assembly, And stay in this position,
11-5 Release the pneumatic switch with the left hand, and continue to press the joint down with the right
hand to confirm that the installation is in place.. it’s in position when it clicks
11-1 11-2
11-4
11-3
11-5
三芯2代弯头组装式连接器安装说明 The Assembly manual for 3POS PowerLok G2 90D Plug Connector
06-10Rev.04 20211124 Document No: 8P1093

步骤11 （手压钳） ：
11-1 将⑧ 尾壳组件放置于桌面
11-2 将连接头的密封圈推入⑧尾壳组件内部
11-3 用治具T00281夹紧卡簧，确认卡簧收缩到位，
11-4 用手将接头压入尾壳组件，并保持位置,
11-5 松开手压钳，继续将接头往下压，听到“嗒”的声音， 卡簧安装到位。
Step11(Hand pressure pliers) :
11-1 Place ⑧Tail shell assembly on the desktop
11-2 Push the sealing of the connecting head into the inner part of the ⑧tail shell assembly
11-3 Clamp the metal gasket with hand pressure pliers T00281 to ensure that the metal gasket is in position,
11-4 Push the connector into the tail housing assembly by hand, And stay in this position,
11-5 Release the hand pressure pliers, and continue to press the joint down to confirm that the installation is
in place. it’s in position when it clicks.
11-1 11-2
11-4
11-3
11-5
三芯2代弯头组装式连接器安装说明 The Assembly manual for 3POS PowerLok G2 90D Plug Connector
07-10
T00281
确认卡环开口在红色区域内
Make sure the clip ring opening is
in the red area
Rev.04 20211124 Document No: 8P1093

步骤12：将连接器如下图所示移动位置，并参照步骤11安装另外两条线束的卡簧
Step 12: Move the connector as shown in the figure below and install the gasket metal of the other two cables
in step 11
步骤13：
13-1 将金属垫片推到紧贴密封圈位置
13-2 将连接器水平放置与桌面
13-3 将⑪ W锁块安装到连接器尾部
13-4 将连接器反转放置
13-5 将⑫ W/O锁块安装到连接器尾部
13-6 检查两个锁块之间的缝隙小于1mm
13-7 各取出2pcs的⑮ M6×18螺丝、 ⑭M6弹簧垫圈和⑬ M6平垫圈，组装在一起
13-8 使用电批将螺丝锁在上面位置的锁孔(扭力为3N.M)
13-9 反转过来放置后，使用电批将另一个锁孔锁紧
Step 13：
13-1 Push the metal gasket to the position close to the sealing
13-2 Place the connector horizontally with the desktop
13-3 Install the ⑪Clamp W at the end of the connector
13-4 Inversion of the connector
13-5 Install the ⑫Clamp W/O at the end of the connector
13-6 Check that the gap between the two locking blocks is less than 1 mm
13-7 take each 2pcs of ⑮M6×18 Screw , ⑭M6 spring washer and ⑬M6 flat washer and assemble them
together
13-8 Lock the screw in the upper position with the batch(torque is 3N.M)
13-9 Turn it around and use the batch to lock another lock hole
13-3
13-2
13-1 13-4 13-5
13-6 13-7 13-8 13-9
三芯2代弯头组装式连接器安装说明 The Assembly manual for 3POS PowerLok G2 90D Plug Connector
08-10Rev.04 20211124 Document No: 8P1093

步骤15：①遥杆两端的孔位对准铁壳相应的位置装入铁壳,完成此线束的组装
Step 15: The holes at both ends of ①Latch are aligned with the corresponding positions of the iron shell and
loaded into the iron shell.，one end assembly done.
步骤14：取出①摇杆（样品参照下面的图片）
Step 14: Take 1pcs ①Latch(sample refer to picture below)
Key
按键
步骤16：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 16: Need to do the Insulation Resistance and DWV test after cable assembly. It is recommended that
the customer refer to the following test parameters
Key mark on connector
连接器标示
X Y
Key color
按键颜色
Orange
橙色
Black
黑色
16-2 Dielectric Withstand Voltage
16-2 耐压测试
16-1 绝缘电阻测试
16-1 Insulation Resistance .
三芯2代弯头组装式连接器安装说明 The Assembly manual for 3POS PowerLok G2 90D Plug Connector
①Latch
摇杆
09-10
Positions
位置
Test voltage/time
测试电压/时间
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 VDC 5S > 500 MΩ
Cable(power) to HVIL
电缆芯线到高压互锁 1000 VDC 5S > 500 MΩ
HVIL to shell
高压互锁到壳体 1000 VDC 1S > 100 MΩ
Positions
位置
Test voltage
测试电压
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 VDC 10S < 5mA
Cable(power) to HVIL
电缆芯线到高压互锁 5000 VDC 10S < 5mA
HVIL to shell
高压互锁到壳体 500 VDC 1S < 5mA
Rev.04 20211124 Document No: 8P1093

三芯2代弯头组装式连接器安装说明 The Assembly manual for 3POS PowerLok G2 90D Plug Connector
10-10
16-3 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。
16-3 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.04 20211124 Document No: 8P1093
步骤17：补充说明
Step 17: Other notes
17-1：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或损
坏。 要求详见安装指引 8P1129。.
17-1: 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.
此HVIL保护套使用前
需移除
This HVIL cap must be
removed before use
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: [email protected]
Asia Pacific
ChangZhou, China
Tel: [phone]
Add: No.11 Fengxiang Road, New District, Changzhou, Jiangsu
P.C: 213001