Amphenol Industrial Operations 40-60 Delaware Avenue Sidney, NY 13838-1395 USA Tel: 1-520-285-5114 1-888-364-9011 Fax: 1-520-397-7169 Amphenol Industrial Operations Europe Via Barbaiana 5 I-20020 Lainate (MI) ITALY Tel: +39 02 93254.204 Fax:+39 02 93254.444 Amphenol Middle East Enterprises FZE Office C-37 PO Box 21107 Ajman Free Zone UAE Tel: +9716-7422494 Fax:+9716-7422941 Amphenol Technology Shenzhen Ltd Block 5 Fuan 2nd Industrial Park, Dayang Rd Fuyong Town, Baoan, 518103 Shenzhen CHINA Tel: +86 755 2881 8389 Fax:+86 755 2991 8310 AMPHENOL HELIOS H4 ASSEMBLY INSTRUCTIONS If, during self assembly, parts and tools other than those stated by Amphenol are used or if the preparation and assembly instructions described here are disregarded then neither safety nor compliance with the technical data can be guaranteed. For protection against electric shock, PV-connectors must be isolated from the power supply while being assembled or disassembled. The end product must provide protection from electric shock. Unplugging under load: PV plug connections must not be unplugged while under load. They can be placed in a no load state by switching off the DC/AC converter or breaking the DC circuit interrupter. Plugging and unplugging while under voltage is permitted. It is unadvisable to use non-tinned cables type H07RN-F, since with oxidized copper wires the contact resistances of the crimp connection may exceed the permitted limits. Disconnected connectors should be protected from dirt and water with sealing caps. Touch protection, mated/unmated Rated current Ambient temperature range Rated voltage Upper limiting temperature Safety class NEC 2008/690.33 Certification UL Certification TUV IP68/IP2X 40A (2,5mm/14AWG)/48A (4mm/10AWG)/56A (6mm/10AWG)/60A (10mm) -40 ...+90C 1500V (IEC/CEI) and 1000V (UL) 120C (IEC/CEI) II YES E339277 R50157783/R72131001 1 H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 -OCTOBER 2014 Amphenol Industrial Operations 40-60 Delaware Avenue Sidney, NY 13838-1395 USA Tel: 1-520-285-5114 1-888-364-9011 Fax: 1-520-397-7169 Amphenol Industrial Operations Europe Via Barbaiana 5 I-20020 Lainate (MI) ITALY Tel: +39 02 93254.204 Fax:+39 02 93254.444 Amphenol Middle East Enterprises FZE Office C-37 PO Box 21107 Ajman Free Zone UAE Tel: +9716-7422494 Fax:+9716-7422941 Tools required Crimping tool with built-in positioner and crimping insert for stamped and formed contacts or in alternative Crimping tool with built-in positioner crimping insert for solid contacts Stripping pliers Open end spanner - plastic wrench tool Tools optional Crimp-Interchangeable dies for stamped and formed contacts Crimp-Interchangeable dies for solid contacts Metal wrench insert for wrench tool Metal secure tool Metal M12 nut secure tool Complete toolbox H4TC0002 H4TC0001 H4TS0000 H4TW0001 H4TD0002 H4TD0001 H4TE0000 H4TF0000 H4TG0000 H4TK0000 2 H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 -OCTOBER 2014 Amphenol Technology Shenzhen Ltd Block 5 Fuan 2nd Industrial Park, Dayang Rd Fuyong Town, Baoan, 518103 Shenzhen CHINA Tel: +86 755 2881 8389 Fax:+86 755 2991 8310 Amphenol Industrial Operations 40-60 Delaware Avenue Sidney, NY 13838-1395 USA Tel: 1-520-285-5114 1-888-364-9011 Fax: 1-520-397-7169 Amphenol Industrial Operations Europe Via Barbaiana 5 I-20020 Lainate (MI) ITALY Tel: +39 02 93254.204 Fax:+39 02 93254.444 Amphenol Middle East Enterprises FZE Office C-37 PO Box 21107 Ajman Free Zone UAE Tel: +9716-7422494 Fax:+9716-7422941 Amphenol Technology Shenzhen Ltd Block 5 Fuan 2nd Industrial Park, Dayang Rd Fuyong Town, Baoan, 518103 Shenzhen CHINA Tel: +86 755 2881 8389 Fax:+86 755 2991 8310 Connector for cable mounting (1,5-2,5mm/AWG14) (4,0-6,0mm/AWG10-12) Female stamped and formed contacts H4CFC2D..S H4CFC4D..S Male stamped and formed contacts H4CMC2D..S H4CMC4D..S (2,5mm/AWG14) (4,0mm/AWG12) (6,0mm/AWG10) (10,0mm/AWG8) Female solid contacts H4CFC2D.. H4CFC4D.. H4CFC6D.. H4CFC8D.. Male solid contacts H4CMC2D.. H4CMC4D.. H4CMC6D.. H4CMC8D.. .. = packaging (I= individual packaging/C=100 PCS packaging / M=500 PCS packaging Connector for panel mounting (1,5-2,5mm/AWG14) (4,0-6,0mm/AWG10-12) Female stamped and formed contacts H4CFC2D..S H4CFC4D..S Male stamped and formed contacts H4CMC2D..S H4CMC4D..S (2,5mm/AWG14) (4,0mm/AWG12) (6,0mm/AWG10) (10,0mm/AWG8) Female solid contacts H4CFM2D.. H4CFM4D.. H4CFM6D.. H4CFM8D.. Male solid contacts H4CMM2D.. H4CMM4D.. H4CMM6D.. H4CMM8D.. .. = packaging (I= individual packaging/C=100 PCS packaging / M=500 PCS packaging 3 H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 -OCTOBER 2014 Amphenol Industrial Operations 40-60 Delaware Avenue Sidney, NY 13838-1395 USA Tel: 1-520-285-5114 1-888-364-9011 Fax: 1-520-397-7169 Amphenol Industrial Operations Europe Via Barbaiana 5 I-20020 Lainate (MI) ITALY Tel: +39 02 93254.204 Fax:+39 02 93254.444 Amphenol Middle East Enterprises FZE Office C-37 PO Box 21107 Ajman Free Zone UAE Tel: +9716-7422494 Fax:+9716-7422941 Amphenol Technology Shenzhen Ltd Block 5 Fuan 2nd Industrial Park, Dayang Rd Fuyong Town, Baoan, 518103 Shenzhen CHINA Tel: +86 755 2881 8389 Fax:+86 755 2991 8310 Cable preparation and stripping process Strip cable 0.276 inches (7.0 mm) and be careful NOT to nick conductors. Amphenol specified strip tool (H4TS0000) can be used in this step. Adjust the striper stopper and put the cable in corresponding notch to strip the length of 7mm. See below pictures. Cable against stopper Stripped cable Crimp process solid contacts When you insert striped cable into contact barrel, always insure all conductor strands are captured in the contact barrel and the conductors are visible in the inspection hole. See below pictures. Pin solid contact Inspection hole Socket solid contact Insert the contact into the corresponding crimping notch or locator (male or female) taking into account the cable size used. Press the pliers gently together until the crimp lugs are properly located within the crimping die. Insert the stripped cable end until the insulation comes up against the crimp insert. Completely close the crimping pliers. See below pictures. Amphenol specified crimp tool (H4TC0001) should be used in this step. Positioner Crimper with die See below pictures for crimp result solid contacts. Crimped solid pin Crimped Solid socket 4 H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 -OCTOBER 2014 Amphenol Industrial Operations 40-60 Delaware Avenue Sidney, NY 13838-1395 USA Tel: 1-520-285-5114 1-888-364-9011 Fax: 1-520-397-7169 Amphenol Industrial Operations Europe Via Barbaiana 5 I-20020 Lainate (MI) ITALY Tel: +39 02 93254.204 Fax:+39 02 93254.444 Amphenol Middle East Enterprises FZE Office C-37 PO Box 21107 Ajman Free Zone UAE Tel: +9716-7422494 Fax:+9716-7422941 Amphenol Technology Shenzhen Ltd Block 5 Fuan 2nd Industrial Park, Dayang Rd Fuyong Town, Baoan, 518103 Shenzhen CHINA Tel: +86 755 2881 8389 Fax:+86 755 2991 8310 Crimp process stamped and formed contacts: Insert the contact into the corresponding crimping notch or locator (male or female) taking into account the cable size used. Open barrel socket S&F contact Open barrel pin S&F contact Press the pliers gently together until the crimp lugs are properly located within the crimping die. Insert the stripped cable end until the insulation comes up against the crimp insert. Completely close the crimping pliers. See below pictures of crimp result Amphenol specified crimp tool (H4TC0002) should be used in this step Closed barrel socket S&F contact Closed barrel pin S&F contact The cable pull-out forces requirement will have to be the following: Cable size Cable pull -out force requirement 2.5 mm Min. 230 N (~50 Lbs) 4.0 mm Min.310 N (~70 Lbs) 6.0 mm Min. 360.0 N (~80 Lbs) 5 H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 -OCTOBER 2014 Amphenol Industrial Operations 40-60 Delaware Avenue Sidney, NY 13838-1395 USA Tel: 1-520-285-5114 1-888-364-9011 Fax: 1-520-397-7169 Amphenol Industrial Operations Europe Via Barbaiana 5 I-20020 Lainate (MI) ITALY Tel: +39 02 93254.204 Fax:+39 02 93254.444 Amphenol Middle East Enterprises FZE Office C-37 PO Box 21107 Ajman Free Zone UAE Tel: +9716-7422494 Fax:+9716-7422941 Amphenol Technology Shenzhen Ltd Block 5 Fuan 2nd Industrial Park, Dayang Rd Fuyong Town, Baoan, 518103 Shenzhen CHINA Tel: +86 755 2881 8389 Fax:+86 755 2991 8310 Assembly process connector: Insert contact cable assembly into back of male and female connector. A "click" should be heard or felt when the contact cable assembly is seated in correct position. Contacts cannot be removed once seated. See below pictures. Connector cable female Connector cable male Back cap must be closed using a torque between 2.6 and 2,9NM. Amphenol specified hand wrench tool (H4TW0001) can be used in this step or electric torque controlled wrench tool with as well the Amphenol open-end back cap spanner (H4TE0000) or socket wrench (H4TF000). See below picture for hand wrench. Note: Pneumatic wrench tools are NOT recommended since torque control is very difficult. Double spanner cap closing operation 6 H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 -OCTOBER 2014 Amphenol Industrial Operations 40-60 Delaware Avenue Sidney, NY 13838-1395 USA Tel: 1-520-285-5114 1-888-364-9011 Fax: 1-520-397-7169 Amphenol Industrial Operations Europe Via Barbaiana 5 I-20020 Lainate (MI) ITALY Tel: +39 02 93254.204 Fax:+39 02 93254.444 Amphenol Middle East Enterprises FZE Office C-37 PO Box 21107 Ajman Free Zone UAE Tel: +9716-7422494 Fax:+9716-7422941 Amphenol Technology Shenzhen Ltd Block 5 Fuan 2nd Industrial Park, Dayang Rd Fuyong Town, Baoan, 518103 Shenzhen CHINA Tel: +86 755 2881 8389 Fax:+86 755 2991 8310 Connector mating and un-mating: For mating align the 2 half connectors and mate them together by hand until a "click" is heard and/or felt. For un-mating, since the Amphenol H4 connector complies with the NEC 2008 690.33, a tool is required to disconnect the connector once mated. Amphenol specified wrench tool (H4TW0001) or Universal tool (H4TU0000) should be used in this step. See below pictures. WRENCH TOOL DISCONNECT UNIVERSAL TOOL DISCONNECT 7 H4 ASSEMBLY INSTRUCTIONS ENGLISH REV3 -OCTOBER 2014