TE Connectivity HVA280 RA User manual

Application
Specification
114-32332
13 MAR 2019 Rev A
Document Class 1
©2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
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LOC
HVA280 RA header with HVIL
Contents
1. Introduction ....................................................................................................................................2
Content ...................................................................................................................................2
Processing Notes ....................................................................................................................2
2. Applicable Documents ...................................................................................................................2
Customer drawings and documents........................................................................................2
Application Specification provides termination procedures and application requirements. ..2
3. Cable selection and termination components.................................................................................2
Header ....................................................................................................................................2
4. Assembly Instructions ....................................................................................................................3
Assembly overview ................................................................................................................3
Security Advice......................................................................................................................4
Header Connector Assembly..................................................................................................5
5. Mating plug with header , Lock CPA.............................................................................................9
6. Connector unmating .....................................................................................................................10
HIGH-VOLTAGE –MORTAL DANGER
- This connector is intended for use in high-voltage applications. Special care must be
applied to ensure that the connector functions as intended.
- If you suspect that the connector has been modified, damaged, contaminated, or
otherwise compromised, please discontinue its use immediately.
-This connector should only be serviced by a trained and qualified technician.

Application
Specification
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1. Introduction
Content
This application specification provides the guidelines to be followed for HVA280 RA header with HVIL.
Processing Notes
The processor is responsible for ensuring the quality of the manufacturing process and the proper
function of the system. The warranty and liability are excluded, if quality deficiency or damages occurs
by failing compliance to this specification or using not specified, not released tools and connector
components.
The assembly should only be performed by trained personnel.
2. Applicable Documents
The following mentioned documents are part of this specification. If there is a conflict between the
information contained in the documents and this specification or with any other technical documentation
supplied, the last valid customer drawings take preference.
Customer drawings and documents
2323914
HVA280 RA Header Assy
2323989
HVA280 RA Header, Inner housing assy, unit side
968853
AMP MCP 2.8 Contact
968220
MQS 0.63 CB Contact
968221
MQS 0.63 CB Contact
108-2394
Product Specification HVA280 2phi
Application Specification provides termination procedures and application requirements.
114-18148
Application Specification AMP MCP 2.8 Contact
114-18021
Application Specification MQS 0.63 CB Contact
3. Cable selection and termination components
Header
HV contact CABLE
RECOMMENDED CABLE-SPECIFIC
TERMINATION COMPONENTS
PART NUMBER
DESCRIPTION
Cable Construction: 3.0mm2 Un-shield HV cable
Supplier Cable Part Number: SPL/JS21.235-12
TE Part Number: 2209499-X
1-968853-3
AMP MCP 2.8 Contact
Cable Construction: 4.0mm2 Un-shield HV cable
Supplier Cable Part Number: HS/84098103
TE Part Number: 2103041-X

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Specification
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4. Assembly Instructions
Assembly overview
Figure 1
HVIL contact CABLE
RECOMMENDED CABLE-SPECIFIC
TERMINATION COMPONENTS
PART NUMBER
DESCRIPTION
Cable Construction: 0.2-0.35 mm2
5-968220-6
MQS 0.63 CB Contact
Cable Construction: 0.5 mm2
5-968221-6
MQS 0.63 CB Contact

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Specification
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Security Advice
The assembly should only be performed by trained personnel.
Avoid prolonged or repeated skin contact with silver plating terminal. (wear protective gloves).
ATTENTION!
- HIGH VOLTAGE APPLICATION -
CABLE INSULATION MUST NOT BE DAMAGED!

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Specification
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Header Connector Assembly
Step 1 Strip the outer jacket off of the cable, the dimension defined in Application Specification as
shown in Figure 3.
Figure 2
Step 2 Apply terminals to cable using the tooling, method and dimensions and inspections
detailed in Application Specification as shown in Figure 3.
Figure 3
Step 3 Check before inserting contacts if the TPA of inner housing is in Pre-lock position. If not,
move it to the pre-lock position as described in Figure 6.
Step 4 Insert the cable assembly (MQS0.63 Contact) into inner housing until the locking lance of
contact (primary lock) fully locked. Complete locking can be examined by gently pulling back
the terminals.
ACC. TO SPEC. 114-18148
ACC. TO SPEC. 114-18021
ACC. TO SPEC. 114-18148
ACC. TO SPEC. 114-18021

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Specification
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Figure 4
Step 5 Insert the cable assembly (MCP2.8 Contact) into inner housing until the locking lance of
contact (primary lock) fully locked. Complete locking can be examined by gently pulling back
the terminals.
Figure 5
Step6 Locking TPA to finial position by pushing TPA surface.
If the TPA does not fully close, move it to the open position, ensure that all contacts are
fully seated, then try again, DO NOT force the TPA to close.
Cavity Marking
Alignment of contacts to
the housing cavity
Alignment of contacts to
the housing cavity
Cavity Marking

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Specification
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Figure 6
Step7 Check the outer housing sub-assembly that if the seal is present on the header.
Align the polarization feature of the header with the polarization hole in the device, then push
the header onto the device until it is seated against the face of device refer to Figure 8.
Secure the outer housing sub-assembly to the device using four customer-supplied M4
fasteners (with 8.7-mm maximum head diameter) as shown in Figure 8. Tighten the fasteners to
a torque between 2.0 and 2.5 N-m
Figure 8
Seal
Polarization
Feature
Polarization Hole in
Device
M4 Mounting
Fasteners (4 Places)
Header Mounting
Hole (4 Places)
TPA IN PRE-LOCK POSITION
TPA IN FINAL LOCK POSITION

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Specification
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Figure 8
CAUTION Ensure that the fasteners are compatible with the header assembly and are capable of
meeting the required torque.
Step8 Align the polarization feature with inner housing to the outer housing sub-assembly. Insert the
inner housing (with the contacts) into the outer housing subassembly until there is an audible or
tactile “click” refer to Figure 9.
Figure 9
NOTE The inner housing is keyed to the outer housing subassembly and can be inserted in only one
orientation.
Step9 Test. Contact probing is not recommended on the header assembly due to the possible
presence of high-voltage power. If continuity checks are necessary, disable the high-voltage power.
Seal
Polarization
Feature
Polarization Hole in
Device
M4 Mounting
Fasteners (4 Places)
Header Mounting
Hole (4 Places)
Alignment of inner housing to
the outer housing sub-assembly

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Specification
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CAUTION To avoid damage to the header assembly, ensure that the high-voltage power is disabled before
conducting any continuity checks.
CAUTION Avoid any probing that could damage the contacts or contact plating.
5. Mating plug with header, Lock CPA
NOTE For mating with plug assemblies 4-2103177-[ ], refer to 114-13259 for specific mating instructions.
Step1 Align the mating face of the plug assembly and header assembly. See Figure 10.
Figure 10
Step2 Push the assemblies together until the primary latch and secondary latch engage. Note that
there are two latches; therefore, there will be two audible “clicks” when the assemblies are fully mated.
See Figure 11.
Figure 11
CAUTION If the assemblies are not fully mated, the HVIL circuit could open, and shut down the electrical
system.
Align mating faces
Primary Latch
Secondary Latch

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Specification
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If the assemblies do not fit together easily, check the following:
—the keying of the header assembly matches the keying of the plug assembly
—the header assembly and plug assembly are oriented 180 degrees
Step3 Pull lightly on the plug assembly to ensure that the assemblies are fully mated. Seat the plug
assembly by pushing it toward the header assembly. See Figure 17.
Figure 17
6. Connector unmating
NOTE For unmating from plug assemblies 4-2103177-[ ], refer to 114-13259 for specific unmating
instructions.
Step1 Disable the high-power voltage power.
DANGER To avoid personal injury, exercise extreme caution to verify that the high-voltage power is
disabled before unmating the header assembly and plug assembly
Step2 Open the plug assembly CPA by pulling it away from the header assembly. See Figure 18.
Figure 18
Plug CPA (ref)
Plug CPA (ref)

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Specification
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Step3 Depress the primary latch (located at the back of the plug assembly), and simultaneously pull
the plug assembly straight away from the receptacle assembly until it stops. DO NOT pull the cable or
cable seal retainer. DO NOT force the assemblies apart as the assemblies are not yet fully unmated.
See Figure 19.
Figure 19
Step4 Depress the secondary latch (located in the window in front of the primary latch). While
depressing the secondary latch, pull the plug assembly and header assembly apart. DO NOT pull the
cable or cable seal retainer. See Figure 20.
Figure 20
The header assembly and plug assembly are now unmated and disconnected as shown in Figure 21.
Figure 21
Depress Primary Latch
Cable seal retainer (ref)
Depress Secondary Latch

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Specification
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LTR
REVISION RECORD
DWN
APP
DATE
A
NEW REVISED EDITION FOR SERIES PARTS
R.Z
I.Y
29MAR19
DR
TE Connectivity
(Shanghai) Co., Ltd
HEMS CONNECTOR /Automotive
CHINA
R.ZHANG
29MAR2019
CHK
E.JIANG
29MAR2019
APP
NO.
114-32332
REV A
LOC
I.YIN
29MAR2019
TITLE
Application Specification for
HVA280 RA header with HVIL