Lapp Group EPIC POWERLOCK User manual

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EPIC® POWERLOCK
Assembly instruction for
Crimp and Set screw types
Electroustic Ltd www.electroustic.co.uk [phone]
L44420211EN 19.10.2016

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1. Overview
Due to the wide range of cables used in the market, to ensure that a satisfactory result is
obtained when EPIC®POWERLOCK connectors are terminated onto the end of the cables, the
type and method used needs to be evaluated. This guide is intended to provide details of how
to successfully terminate cables into EPIC®POWERLOCK connectors, either by crimping, set
screws or threaded post methods. This document provides guidelines on:
• how to perform a crimped termination.
• what type of crimp tools and dies to use with recommendations.
• how to perform a set screw termination.
• terminating a threaded post panel type connector.
2. Termination Methods
EPIC®POWERLOCK connectors can be terminated to cables by using one of the following
methods:
• Crimp termination.
• Set screw termination.
• Threaded post termination.
These recommended assembly methods are detailed below. If in doubt, consult Lapp.
2.1 Crimp Termination
It is essential to use the recommended crimp tool and die to ensure a satisfactory crimp. It is
important that you are satisfied that the crimped joint meets your requirements. Consult Lapp
for more details.
2.1.1 Crimp Connector Components
Shown below are the components supplied for both EPIC®POWERLOCK F6 drain and EPIC®
POWERLOCK D6 source connectors. Both connector types include the following:
• Cable Gland
• Contact
• Housing (Insulator)
• Retention Pin
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2.1.2 Crimp Die
The crimp die type and size are one of the most important aspects of the crimping operation
to achieve a satisfactory crimped joint. They vary depending on the actual cable / contact
combination to be crimped. A hexagon type crimp is recommended.
Across Flat Dimension Width Dimension
2.1.3 Crimp Tool
Depending on the application, various crimp tool and die set combinations can be used.
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2.1.4 Crimp Settings
C130 CRIMP TOOL
CRIMP TOOL C 130 44420337
CRIMP DIE C 50 44420330
CRIMP DIE C 70 44420331
CRIMP DIE C 95 44420332
CRIMP DIE C 120 44420333
CRIMP DIE C 150 44420334
CRIMP DIE C 185 44420335
CRIMP DIE C 240 44420336
Crimpwerkzeug
Crimp Die
Type
Description
Crimp Die Details
Die Across Flat
Dimension
(mm)
Die Width
Dimension
(mm)
C 130
44420330
44420331
44420332
44420333
44420334
44420335
44420336
C 25
C 35
C 50
C 70
C 95
C 120
C 150
C 185
C 240
C 240
C 300
7,6
9,0
10,0
12,0
14,0
16,0
17,3
19,0
21,5
23,57
23,0
9,0
12,0
12,0
12,0
12,0
12,0
12,0
12,0
12,0
12,0
12,0
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2.1.5 Crimp Assembly Tools
The tools listed below are recommended:
Cable Stripping tool
Cable shear
Soft hammer/Press
2.1.6 Double Crimp Arrangement
The default recommended method is to double crimp although single crimps may be suitable
for crimping 120mm² cables and smaller. Each crimp should be positioned centrally within
the contact crimp area. The crimp area is between inspection hole and end of contact. If a
single crimp is used, the crimp should be positioned centrally within the crimp. Crimp in the
order shown to ensure a satisfactory crimp. Consult the factory if any additional information
or advice is required.
Crimp
Screw
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2.1.7 Recommended Assembly Procedure
1. Remove the Cable Gland from the Insulator and remove the contact.
2. Slide the Cable Gland onto the cable being terminated.
3. Carefully strip back the cable insulation by 42mm taking care not to damage any of the
conductors stranding.
4. Insert the conductor stranding into the crimp bucket at the rear of the contact. Ensure that
the cable is straight within a distance of 1 metre of the crimping location. This ensures that
the individual cable wire strands are not distorted or displaced to each other caused by
bending the cable. With the crimping tool, crimp the contact twice making sure that the cable
is being forced into the contact and ensuring that the cable conductor is visible through the
inspection hole.
5. Examine the crimped joint to ensure that the crimp is satisfactory. Ensure that all of the
conductor strands are contained within the crimped area.
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6. Following the crimping operation, any contact material deformed between the crimp dies
which prevents the contact assembly from being fitted into the Insulator assembly should be
removed, in line with normal working practices.
7. Fit the crimped contact into the insulator and visually align the Retention pin holes.
8. Fit the Retention pin, tapered end first into the insulator/contact using either a press or a
soft hammer. Note that the Retention pin should only be used once. Re-using the Retention
pin will invalidate the IP67 rating.
9. Ensure that the Retention pin is visible from both sides of the assembly after fitting and is
flush/sub flush with the insulator.
10. Screw the cable gland into the insulator, tightening to a torque of 13Nm.
11. Finally inspect overall assembly.
Inspection hole:
Copper strands visible
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2.2 Set Screw Termination
It is essential to use the recommended assembly method, reduction sleeves and set screw
tightening torques to ensure a satisfactory termination.
2.2.1 Screw Connector Components
Show below are the components supplied for both line drain and line source connectors. Both
connector types include the following:
• Cable Gland
• Contact
• Insulator
• Retention Pin
• Reduction Sleeves
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2.2.2 Recommended Assembly Procedure
1. Remove the Cable Gland from the insulator and take out the contact.
2. Slide the Cable Gland onto the cable being terminated.
3. Carefully strip back the cable insulation by ~33mm taking care not to damage any of the
conductors stranding.
4. Select the appropriate reduction sleeves (see Table 1 below) and slide on in sequence over
the exposed conductor stranding. All sleeves down to the size recommended for the cable in
use should be used. i.e. for the 50m2 cable, the R120, R95, R70 and R50 sleeves should all
be used. The sleeves fit inside each other to give a gradual reduction in diameter. The flared
end of the sleeves should be against the cable insulation.
Cable Size (mm²)
Reduction Sleeve
Required
Set Screw Torque
Minimum (Nm)
Cable Jacket Strip
Length (mm)
120mm²
120
10.5
33
90 mm²
120 + 95
10.5
33
70mm²
120+95+70
10.5
33
50mm²
120+95+70+50
10.5
33
Table1. Set Screw Assembly Data
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5. Slide the cable and reduction sleeves into the rear of the contact ensuring that they are
fully seated inside of the contact. Using a 5mm A/F Allen key tighten the set screws to the
appropriate torque setting.
6. Fit the contact into the front insulator and visually align the Retention pin holes.
7. Fit the Retention pin, tapered end first into the insulator/contact using either a press or a
soft hammer. Note that the Retention pin should only be used once. Re-using the Retention
pin can invalidate the IP67 rating.
8. Ensure that the Retention pin is visible from both sides of the assembly after fitting and is
flush/sub flush with the insulator.
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9. Screw the cable gland into the insulator, tightening to a torque of 13Nm minimum.
10. Finally inspect overall assembly.
Note for users of fine stranded cables When using fine stranded power cables it is advisable
to use the maximum number of sleeves and increase the torque setting. This will protect the
individual cable strands from mechanical damage and allow greater compression of the
conductor.
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2.3 Panel Mount Termination
Panel receptacles are supplied fully assembled with contacts (See Figure 12 below.) An M12
nut and a spring washer are also supplied loosely fitted onto the contact. Termination to the
panel connector is made by fitting the cable lug or other accessory using the nut and washer.
2.3.1 Panel Mount Connector Components
Shown below in figure 13 are the components supplied for both line drain and line source
panel connectors. Both connector types include the following:
•Housing (Insulator)
•Contact with
• Retention pin
• M12 Nut
• M12 Washer
2.3.2 Recommended Assembly Procedure
1. Fit the contact into the front insulator and visually align the Retention pin holes.
2. Fit the Retention pin, tapered end first into the insulator/contact using either a press or a
soft hammer. Note that the Retention pin should only be used once. Re-using the Retention
pin can invalidate the IP67 rating.
3. Ensure that the Retention pin is visible from both sides of the assembly after fitting and is
flush/sub flush with the insulator.
4. Remove the M12 nut and washer from the threaded post.
5. Fit terminal or accessory over the threaded post.
6. Refit the M12 washer and nut onto the threaded post and tighten to a maximum value of
12 Nm
7. Finally inspect overall assembly.
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U.I. Lapp GmbH
D-70565 Stuttgart/Germany
www.lappgroup.com
A company of the Lapp Group
Electroustic Ltd www.electroustic.co.uk [phone]