INSTRUCTION MANUAL H4 PV Cable Connector Series Dual

INSTRUCTION MANUAL H4 PV Cable Connector Series Dual
INSTRUCTION MANUAL H4 PV Cable Connector Series Dual Approval (UL+IEC/TUV) REVISION RECORD DESCRIPTION DATE REV A FIRST RELEASE July/28/2011 B IMPROVED LAYOUT Sep/6/2011 C UPDATE TORQUE Nov/3/2011 D UPDATE THE S&F REQUIREMENT Dec/8/2011 E ADD ENLARGE H4 REQUIREMENT July/24/2012 F UPDATE ELECTRIACL RATING Aug/22/2013 File Name: PV‐692239‐000 Page 1 of 8 INSTRUCTION MANUAL Electrical rating: 1500V DC (IEC/TUV) 1000V DC (UL) Current rating: 32A (2.5mm²/14 AWG) 40A (4.0mm²/12 AWG) 44A (6.0mm²/10 AWG) 65A (10mm²/8 AWG) Protection degree: IP68 mated and IP2X unmated Safety class: II Operation Temperature Range: ‐40℃ to +90℃ CAUTION: 1) The connector must be isolated and disconnected from the power supply during the assembling or disassembling process. 2) Do not disconnect under load. 3) The use of PV cable is recommended. 4) The use of tin plated cable is recommended. 5) The connectors are IP68 rated, and can be positioned for short time under 1MT of water. 1) Product picture: File Name: PV‐692239‐000 Page 2 of 8 INSTRUCTION MANUAL 2) Connector part numbering: 3) Stamped and formed contact part numbering: Note: Machined and screw contact are supplied standard with the connectors. File Name: PV‐692239‐000 Page 3 of 8 INSTRUCTION MANUAL 4) Required tools: Crimp tool for machined contacts: Crimp die for machined contacts: Crimp tool stamped and formed contacts: Crimp die for stamped and formed contacts: Strip tool for 2.5/4.0/6.0mm² PV cable: Wrench tool: Open‐end back cap spanner: File Name: PV‐692239‐000 H4TC0001 H4TD0001 H4TC0002 TBD H4TD0002 TBD H4TS0000 H4TW0001 H4TE0000 Page 4 of 8 INSTRUCTION MANUAL Socket wrench: H4TF0000 Complete tool kit for installers: H4TK0000 5) 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 1 and 2. Picture 2 Picture 1 6) Crimp process machined contacts: Insert striped cable into contact barrel and insure all conductor strands are captured in the contact barrel and the conductors are visible in the inspection hole. See below pictures 3 and 4 Picture 3 Inspection hole Picture 4 Crimp contact barrel by using the hex or 4‐ident crimping die, by putting the contact barrel with striped cable in the corresponding crimping notch or locator. See below picture 5 and 6. Amphenol specified strip tool (H4TC0001) can be used in this step. File Name: PV‐692239‐000 Page 5 of 8 INSTRUCTION MANUAL Female contact Male contact Picture 5 Picture 6 See below pictures 7 and 8 for crimp result for hex crimp and pictures 9 and 10 for the 4‐ident crimp result Picture 7 Picture 8 Picture 9 Picture 10 The pull‐out forces requirement will have to be the following: Cable size Cable pull –out force requirement 2.5 mm² Min. 230 N 4.0 mm² Min. 310 N 6.0 mm² Min. 360 N 10.0 mm² Min. 380 N 7) Crimp process stamped and formed contacts: Insert striped cable into contact barrel and insure all conductor strands are captured in the contact barrel. See below pictures 11 and 12. Picture 11 Picture 12 Crimp contact barrel by using the crimping die, and be careful NOT to hurt the second row wings See below pictures 13 and 14 for crimping result. Picture 13 File Name: PV‐692239‐000 Picture 14 Page 6 of 8 INSTRUCTION MANUAL Amphenol specified crimp tool (PV‐692209‐000) can be used in this step. If the customer wants to use the automatic crimping machine, we suggest that the die of the machine should be like the following: Cable Size 2
2.5mm 4.0mm2 6.0mm2 Crimping Height(A) Crimping Width(B) 2.45±0.05mm 2.30±0.05mm 2.42±0.05mm 2.80±0.10mm 4.50±0.10mm 4.50±0.10mm Cable size Cable pull –out force requirement
2.5 mm² Min. 230N 4.0 mm² Min. 310N 6.0 mm² Min. 360N 8) Termination process screw contacts: See below pictures 15 and 16 for screw result for Allen driver (2mm). Picture 15 Picture 16 9) 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 17‐20. Female coupler Picture 17 Picture 18 Male Coupler Picture 19 Picture 20 H4 PV cable connector back cap must be closed using a torque between 2.6 and 2.9 N·M and Enlarge H4 PV cable connector back cup must be tightening between 3.2 to 3.5 N·M. Note: These torque force apply to Amphenol PV cable only. And H4 PV connector should have different torque force for different customer PV cable. File Name: PV‐692239‐000 Page 7 of 8 INSTRUCTION MANUAL Amphenol specified 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). See below picture 21 and 22. Note: Pneumatic wrench tools are NOT recommended since torque control is very difficult. Picture 21 Picture 22 10) 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 can be used in this step. See below picture 23 and 24. WRENCH TOOL DISCONNECT UNIVERSAL TOOL DISCONNECT Picture 23 Picture 24 File Name: PV‐692239‐000 Page 8 of 8 
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