Amphenol Wind-Lok Series User manual

CONNECTOR INSTALLATION INSTRUCTIONS
Wind-Lok Series
AI-8

2
1. Plug Package Contents
1: Plug assembly
2: O-Ring
3: Front insert
4: Contact assembly
5: Rear insert
6: Retaining ring
7: Adapter
8: Cable gland
Part 1: 
1
1
7
7
8
8
6
6
2
2
5
5
3
3
4
4
2. Receptacle Package Contents
1: Receptacle assembly
2: O-Ring
3: Front insert
4: Contact assembly
5: Rear insert
6: Retaining ring
7: Adapter
8: Cable gland

3

The pin insert can only be mutually matched with the pin contact, and the socket insert can only be mutually
matched with the socket contact. The two can not be confused and installed!
Pin insert
Socket insert
Pin contact
Socket contact

4
Part 2: Product Assembly
Step 1: Stripping
Figure 1
Table 1
As shown in figure 1, cut the cable according to the stripping length specified by the contact in Table 1. When cut-
ting, ensure that the cut surface of the insulation layer is flush, the cable isnot damaged, and the cut surface of the
cable is flush;
Note: The contact type can be obtained by referring to the 8th bit of Wind-Lok coding logic in Appendix 1.
Corresponding contact stripping length
Contact Type Cable Size Length "L"
14/0 AWG-120 SQ MM 29mm
2262 KCMIL-150 SQ MM 29mm
2b 38mm
3a 313 KCMIL-185 SQ MM 29mm
3b 38mm
4a 373 KCMIL-200 SQ MM 29mm
4b 38mm
5a 444 KCMIL-240 SQ MM 29mm
5b
38mm
6535 KCMIL
7646 KCMIL
7a 300 SQ MM
8777 KCMIL

5
Step 2: Contact crimping
Step 3: Connector assembly
Put the contact on the cut cable until it is completely close to the cable insulation (the contact well and the cable in-
sulation layer should not exceed 1.5mm), and check whether the cable is installed in the correct position through the
observation hole of the contact (in the observation hole.) To see the cable conductor, use the corresponding contact
crimping tool to crimp the contact (see Appendix 2 for the recommended crimping tool or use other tools). Be careful
not to press into the observation hole of the contact when crimping, as shown in Figure 2 below.
As shown in Figure 3, first put the O-ring on the front insert (for easy identification, the color of the O-ring is
changed from the actual black to red), and then install the front insert into the plug/socket assembly.
Then, as shown in Figure 4, first put the gland, adapter, retaining ring and rear insert into the cable first, put the
crimped cable contact into the front insert and then sleeve the rear insert, and then put the retaining ring Clamp it
into the groove of the shell. (as shown in Figure 5, the color of the shell components is changed to yellow for easy
identification). In order to confirm that the retaining ring is completely stuck, pull the contact backward to confirm
whether the contact can be pulled out. Finally, tighten the adapter and glands respectively installed to complete the
assembly.
Note: Please refer to Appendix 3 for the tightening torque of adapter and glands; refer to Appendix 4 for adapter
tightening tools.
REVISIONS
ZONE
REV. DESCRIPTION DATE
4
A
123
D
C
B
2 14 3
C
B
A
D
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION AND
SUCH INFORMATION MAY NOT BE DISCLOSED TO OTHERS FOR
ANY PURPOSE OR USED FOR MANUFACTURING PURPOSES
WITHOUT WRITTEN PERMISSION FROM THE AMPHENOL CORP.
MATERIAL SPEC
AMPHENOL CORPORATION
Amphenol Technology (Zhuhai) Co. Ltd.
No. 63 Xinghan Road, Sanzao Town, Jinwan, Zhuhai, PRC
SIZE CAGE CODE DOCUMENT NUMBER REV
SHEET 1 OF 1
C
SCALE: 2:1 REF:
APPROVALS DATE
1800/1/2
PREPARED BY:
UNLESS OTHERWISE SPECIFIED
PROCESS SPEC
LEAD/PRODUCT ENGINEER:
ENGINEERING MANAGER:
PRODUCT GROUP:
AIPG DIVISION:
THIRD ANGLE PROJECTION
U
C&I
AIO
Next Assembly
NOTES
LINEAR DIMENSIONS ARE IN INCHES
TOLERANCES:
.XXXX =
.0005
.XXX =
.010
.XX =
.03
.X =
.1
ANGLES =
2
Amphenol STANDARDS PER 9-3800
Figure 2
Figure 3
Cable
Contact
Observaon hole

6
Through direcon
Groove
Figure 4
Figure 5

7
Part 3: 
As shown in Figure 6 is the M50 gland with EMI function. During the connector installation, the shielding layer needs
to be cut for the second part of the first step of stripping. The cutting length of the shielding layer is reserved 15mm
to ensure that the shielding layer can contact the reed of the gland, as shown in Figure 7 below.
Figure 6
L= 15mm
Figure 7
As shown in Figure 8 is the M63 gland with EMI function. In the connector installation, it is necessary to increase the
shielding layer for the second part of the first step of stripping. The cut length of the shielding layer is about 38mm
between the cable cut and the outside of the gland nut to ensure that the shielding layer can contact the shielding
layer of the gland, as shown in Figure 9 below.
Note:
Figure 8
L= 38mm
Figure 9

8
WL: Wind-Lok Connector
1: Contact Style
C: Crimp Contact
2: Shell Style
03: Square Flange Receptacle
06: Stright Plug
3: Protecon Cap


3: Color Style

BU: Blue Band Coat
OG: Orange Band Coat
YL: Yellow Band Coat
BN: Brown Band Coat
RD: Red Band Coat
WT: White Band Coat
GN: Green Band Coat
GY: Gray Band Coat
BK: Black Band Coat
5: Shell Size
32: Plug Shell Size 32
40: Plug Shell Size 40
6: Contact Style
S: Socket Contact
P: Pin Contact
7: Shell Key Rotaon





8: Wire Style
1: 4/0 AWG - 120 SQ MM Crimp Wire Well
2: 262 KCMIL - 150 SQ MM Crimp Wire Well, Well Length is 1.150
2b: 262 KCMIL - 150 SQ MM Crimp Wire Well, Well Length is 1.500
3a: 313 KCMIL - 185 SQ MM Crimp Wire Well, Well Length is 1.150
3b: 313 KCMIL - 185 SQ MM Crimp Wire Well, Well Length is 1.500
3a: 313 KCMIL - 185 SQ MM Crimp Wire Well, Well Length is 1.150
4a: 373 KCMIL - 200 SQ MM Crimp Wire Well, Well Length is 1.150
4b: 373 KCMIL - 200 SQ MM Crimp Wire Well, Well Length is 1.500
5a: 444 KCMIL - 240 SQ MM Crimp Wire Well, Well Length is 1.150
5b: 444 KCMIL - 240 SQ MM Crimp Wire Well, Well Length is 1.500
6: 535 KCMIL Crimp Wire Well
7: 646 KCMIL Crimp Wire Well
7a: 300 SQ MM Crimp Wire Well
8: 777 KCMIL Crimp Wire Well
9+10: Thread and EMI Funcon
M40E: Use M40 Non-EMI Metal Cable Gland and Non-EMI Adapter
M50E: Use M50 Non-EMI Metal Cable Gland and Non-EMI Adapter
M63E: Use M63 Non-EMI Metal Cable Gland and Non-EMI Adapter
MM40M: Use M40 EMI Metal Cable Gland and EMI Adapter
MM50M: Use M50 EMI Metal Cable Gland and EMI Adapter
MM60M: Use M60 EMI Metal Cable Gland and EMI Adapter
Appedix 1: Wind-Lok Coding Logic
Wind-Lok Code Logic
WL C 06 E RE 40 S W 7 M50 E
1 2 3 4 5 6 7 8 9 10
Wind-Lok Part Number Logic
WL: Wind-Lok Connector
1: Contact Style
C=C
2: Shell Style
06=6
3. Protecon Cap
Omit: N/A
E=E
4: Color Style
NC=0; BU=1; OG=2; YL=3; BN=4; RD=5; WT=6; GN=7; GY=8; BK=9
5: Shell Size
32=32
40=40
6+7: Contact Style+ Shell Key Rotaon (Refer to 9-2437)
SN= S; SW= H; SX= J; SY= L; SJ=A; PN= N; PW= G; PX=I; PY= K; PJ= M
8: Wire Style
1=1, 2=2, 3a=3A, 3b= 3B, 4a=4A, 4b=4B, 5a=5A, 5b=5B, 6=6,
7=7, 7a=7A, 8=8
9+10: Thread and EMI Funcon
M40E=4E, M50E= 5E, M63E=6E;
MM40M=M4, MM50M=M5, MM63M=M6
Example: Code Numer: WLC06ERD40SW3bM50E
Paper Numer: CWLC6E540H3B5E

9
Appedix 2: Recommended Crimping Tools
KLAUKE HK60/22
Cross Section MM² Crimp Die Part Number
120 R22120
150 R22150
185 R22185
240 R22240
300 R22300
ElPRESS V1311 or V1311C
Cross Section MM² Crimp Die Part Number CAT 5 Crimp Die Part Number CAT 6
120 B19 B22
150 B22 B25
185 13B25 13B27
240 13B27 13B30
300 13B32 13B32

10
GREENLLE HK06FT
Crimp from 24SQMM (AWG4) up to 400SQMM (750MCM) –Die is Included with Tool.

11
Appedix 3: Recommended Torque for Connector Accessories
1. Recommended Torque for Adapter
A
Connector Size Thread at A Recommended Torque (N . M)
32 1.8750-16UN 15.81-16.94
40 2.3125-16UNS 20.32-21.45
2. Torque at the Gland
A
B
Gland Thread
No EMI EMI
A (N .M) B (N .M) A (N .M) B (N .M)
M40 18-22 18-22 TBD TBD
M50 30-35 30-35 16-18 16-18
M60 TBD TBD 20 20
Note:

12
Appedix 4: Recommended Tightening Tools for Adapter
Strap Wrench
Daniels Part No. BT-BS-601
Torque Wrench
Daniels Part No. BT-ST-751
Appedix 5: Version Information
Version Description Date
AInitial Release 2021/5/25