HVA280-2phi High-Voltage Plug Connector

Application Specification

114-13259

18 OCT 12 Rev D

DANGER

STOP

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.

NOTE i

All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters. Unless otherwise specified, dimensions have a tolerance of ±0.13 and angles have a tolerance of ±2°. Figures and illustrations are for identification only and are not drawn to scale.

1. INTRODUCTION

This specification covers the requirements for application of the sealed two-position HVA280-2phi high-voltage plug connector. This plug connector is designed for an application voltage of up to 600 VDC. The plug connector incorporates conductive EMI shields to prevent excess radiated emissions in the application. The plug connector assembly body is molded in RAL2003 orange to denote a high-voltage system.

The plug connector incorporates up to two MCP 2.8-mm receptacle terminals, which mate with up to two 2.8-mm blade terminals in the header assembly. Termination tooling is available for both types of terminals and the plug connector ferrules (the inner ferrules will be crimped inside of the outer ferrules).

When corresponding with personnel, use the terminology provided in this specification to facilitate your inquiries for information. Basic terms and features of this product are provided in Figure 1.

Cable Seal Retainer

Cable Seal

Shielded High-Voltage

Cable

Inner Ferrule

MCP 2.8-mm

Receptacle Terminal

Outer Ferrules

Plug Connector

Assembly

Figure 1

© 2012 Tyco Electronics Corporation, a TE Connectivity Ltd. company

All Rights Reserved

*Trademark

TOOLING ASSISTANCE CENTER 1-800-722-1111

PRODUCT INFORMATION 1-800-522-6752

This controlled document is subject to change.

For latest revision and Regional Customer Service, visit our website at www.te.com

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or company names may be trademarks of their respective owners.

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114-13259

2. REFERENCE MATERIAL

2.1. Revision Summary

Revisions to this application specification include:

•

Removed cable sizes from Section 1

•

Modified Figure 2, combined Paragraphs 2.6 and 3.5

•

Added “shielded” and validation clarity to Paragraph 3.5

•

Modified Step 9 of Paragraph 3.6

•

Moved referenced specifications from Section 4 to Paragraph 2.5

•

Added tooling to Section 5

2.2. Customer Assistance

Reference Product Base Part Number 1587819 and Product Code K28 are representative of HVA280-2phi high-voltage plug connector. Use of these numbers will identify the product line and help you to obtain product and tooling information. Such information can be obtained through a local Representative, by visiting our website at www.te.com, or by calling PRODUCT INFORMATION or the TOOLING ASSISTANCE CENTER at the numbers at the bottom of page 1.

2.3. Drawings

Customer Drawings for product part numbers are available from the service network. If there is a conflict between the information contained in the Customer Drawings and this specification or with any other technical documentation supplied, the Customer Drawing takes preference.

2.4. Specifications

Product Specification 108-2394 provides product performance and test information.

Application Specification 114-18148 provides product description and application requirements of MCP 2.8-mm receptacle terminals.

2.5. Standards and Publications

Standards and publications developed by the International Electrotechnical Commission (IEC) and the Society of Automotive Engineers (SAE)/United States Council for Automotive Research (USCAR) provide industry test and performance requirements. Documents available which pertain to this product are:

IEC 60529, “Degrees of Protection Provided by Enclosures (IP Code)”, IP6K9K (Mated), IP67 (Mated), and IP2xB (Unmated)

SAE/USCAR-2, “Performance Specification for Automotive Electrical Connector Systems”

SAE/USCAR-37, “High-Voltage Connector Performance Supplement to SAE/USCAR-2”

3. REQUIREMENTS

3.1. Safety

Do not stack product packages so high that the shipping containers buckle or deform.

3.2. Shelf Life

The product should remain in the shipping containers until ready for use to prevent deformation to the terminals or damage to the connectors. Product should be used on a first in, first out basis to avoid storage contamination that could adversely affect signal transmissions.

3.3. Chemical Exposure

Do not store product near any chemicals listed below, as they may cause stress corrosion cracking in the product.

Alkalies

Amines

Ammonia

Carbonates

Citrates

Nitrites

Phosphates Citrates

Sulfur Nitrites

Sulfur Compounds

Tartrates

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114-13259

3.4. Material

The plug connector assembly is made of thermoplastic materials and the terminals are silver over copper. The connector shields and ferrules are made of tin over copper.

3.5. Cable Selection and Termination Components

The HVA280 connector system accepts shielded cable sizes 2.0, 2.5, 3.0, and 4.0 mm². Cable and termination component combinations validated by TE should be used to ensure optimum connector performance.

At the time of publication of this document, combinations for cable sizes 2.0 and 2.5 mm² have not been validated by TE. For validation testing, contact PRODUCT INFORMATION at the number at the bottom of page 1.

Combinations for cable sizes 3.0 and 4.0 mm² are listed in Figure 2.

Alternative cable may be used after ensuring performance through validation testing by TE.

CABLE

Supplier: HUBER+SUHNER

Construction: 4 mm²

Part Numbers: 12582674 (Orange)

85002132 (Orange/Black)

Supplier: LEONI

Construction: 4 mm²

Part Number: 76231175A (Orange)

Supplier: Judd Wire Inc.

Construction: 3 mm²

Part Number: C09494 (Orange)

RECOMMENDED CABLE-SPECIFIC

TERMINATION COMPONENTS

PART NUMBER

1-968853-3

1587828-3

DESCRIPTION

MCP 2.8-mm Receptacle Terminal

Inner Ferrule

1587829-3

1587826-3

1587827-3

1-968853-3

1587828-3

1587829-3

Outer Ferrule

Cable Seal

Cable Seal Retainer

MCP 2.8-mm Receptacle Terminal

Inner Ferrule

Outer Ferrule

1587826-3

1587827-3

1-968853-3

1587828-2

1587829-2

1587826-2

1587827-2

Cable Seal

Cable Seal Retainer

MCP 2.8-mm Receptacle Terminal

Inner Ferrule

Outer Ferrule

Cable Seal

Cable Seal Retainer

Figure 2

3.6. Preparation and Assembly

Steps for preparing the cable and assembling the plug connector components onto the cable are as follows:

1. Assemble the cable seal retainer and cable seal in the order and direction shown in Figure 3, Detail A.

Note that circuit numbers are shown on the cable seal retainer. Make sure that the correct cable is inserted

into each cavity. See Figure 3, Detail B.

Detail A

Cable Seal

Retainer

Detail B

Cable

Circuit

Numbers

Cable Seal

HUBER+SUHNER and LEONI are trademarks of their respective owners.

Rev D

Figure 3

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2. With the cable seal retainer and cable seal safely out of the way, strip the outer jacket and braided cable

shield off of each cable. See Figure 4.

CAUTION

!

Make sure that the stripping equipment has not nicked, scraped, or cut the conductor insulation during the stripping operation and that there are no remaining cable shield strands.

Note: Not to Scale

11.60 mm

(Ref)

Outer Jacket and

Braided Shield

Stripped Away

Figure 4

3. Strip the outer jacket further so that the combined exposed strip length of braided cable shield and

conductor insulation. See Figure 5.

CAUTION

!

Make sure that the stripping equipment has not nicked, scraped, or cut the braided cable shield strands during the stripping operation.

Note: Note to Scale

Outer Jacket

Stripped Away

19.10 mm

(Ref)

Figure 5

4. Insert an inner ferrule onto each cable and over the outer jacket as shown in Figure 6.

Rev D

Inner Ferrule

Figure 6

Inner Ferrule

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5. Fold the braided cable shield back over the inner ferrule, taking care to try to keep inner ferrule positioned

such that its edge is flush with the stripped edge of the outer jacket as shown in Figure 7.

Braided Cable Shield Folded

Back Over Inner Ferrule

Fold

Figure 7

6. Strip the conductor insulation off of each cable to the dimension defined in Application Specification

114-18148. See Figure 8.

Note: Not to Scale

Refer to 114-18148 for Conductor

Insulation Strip Length

Conductor Insulation

Stripped Off

Figure 8

7. Apply a receptacle terminal to each cable using the tooling, method, dimensions, and inspections detailed in Application Specification 114-18148. The trailing edge of the receptacle terminal box should be located from

the stripped edge of the outer jacket to the dimension (approximately) given in Figure 9.

NOTE i

While these steps provide the correct procedure to complete the assembly, this step (Step 7) may be performed prior to

Steps 4 and 5.

Stripped Edge of

Cable Outer Jacket

23.75 mm

(Ref)

Trailing Edge of

Receptacle Terminal Box

Figure 9

Rev D

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114-13259

8. Insert an outer ferrule onto each cable in the orientation shown and over the inner ferrule and folded back

braided cable shield. See Figure 10.

Outer Ferrule Outer Ferrule

Figure 10

9. Crimp each outer ferrule using the tooling specified in Section 5. Using a blade micrometer, measure each outer ferrule crimp over the most compressed area three times: one on top and one on each opposing side.

Use the lowest measurement as the passing criteria. The crimp height is given in Figure 11.

The distance between the leading edge of the outer ferrule and trailing edge of the receptacle terminal box

must be maintained at the dimension given in Figure 11.

CAUTION

!

Any loose strands of the braided cable shield seen protruding from below the outer ferrule should be trimmed, taking special care not to cut any insulation or leave any detached strands attached to the assembly.

X

Leading Edge of

Outer Ferrule

Section X-X

Crimp Height

(See Table)

X

18.10±1.00 mm

OUTER FERRULE

PART NUMBER CRIMP HEIGHT

1587829-2

1587829-3

6.80±0.1 mm

7.40±0.1 mm

Figure 11

Trailing Edge of

Receptacle Terminal Box

Rev D

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114-13259

3.7. Cable Assembly Inspection Summary

Refer to Figure 12.

— samples match examples shown in the figures in this document

— cables are inserted in correct cavity openings in seal retainer

— seal is not rolled or damaged

— outer jacket or conductor is not damaged

— no loose or protruding strands from braided cable shield and ferrule crimp

— terminal crimp meets requirements outlined in Application Specification 114-18148

— outer ferrule hex crimp height is correct and outer ferrule is not distorted and is straight relative to the cable

Completed Cable Assembly

Conforms to Inspection Summary

Figure 12

3.8. Receptacle Terminal Installation

Steps for installing the receptacle terminals into the plug connector are as follows:

1. Orient the cable assembly so that the bridge feature on the cable seal retainer is aligned with the plug

connector latch as shown in Figure 13.

Plug Connector Latch and Cable Seal

Retainer Bridge Feature Aligned

Figure 13

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114-13259

2. Insert the receptacle terminals into their respective plug connector circuit cavities until they are fully locked,

and an audible and tactile “click” is detected. See Figure 14.

The installation of the ferrule into the contact springs of the connector shield will cause some resistance, so it is important to verify that the receptacle terminals are fully inserted by pulling back lightly on the cables.

Receptacle Terminals

Fully Inserted into

Plug Connector

Cable Seal Retainer

Cable Seal

Figure 14

3. Fully insert the cable seal until it stops inside the back of the plug connector. See Figure 15, Detail A.

4. Fully install the cable seal retainer over the back of the plug connector, making sure that the bridge feature

is correctly aligned with the plug connector latch feature. See Figure 15, Detail B.

Verify that both locking features are fully engaged.

Detail A Detail B

Locking Features

Fully Engaged

Cable Seal Retainer

Fully Installed

Cable Seal

Fully Inserted

Cable Seal Retainer

Figure 15

Rev D

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3.9. Connector Mating and Unmating

A. Mating

1. Align the plug connector and header assembly as shown in Figure 16.

114-13259

Figure 16

2. Push the plug connector and header assembly together fully until they stop (two clicks will be heard).

Verify that the plug connector and header assembly are fully locked with a light tug and by visually

verifying the location of the indicator slot on the floating latch as shown in Figure 17.

Indicator Slot

Figure 17

B. Unmating

1. Fully depress the thumb actuation pad on the plug connector flexible latch (orange). See Figure 18.

2. Pull the plug connector back (approximately 4.5 mm) into the intermediate position. At this point, the

HVIL circuit has been opened, but the HV terminals are still making contact.

Note: Do NOT pull on the cables.

Flexible Latch Thumb Actuation Pad

Figure 18

Rev D

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114-13259

3. Fully depress the thumb actuation pad on the floating latch (red). See Figure 19, Detail A.

4. Pull the plug connector until it is fully separated from the header assembly. See Figure 19, Detail B.

Note: Do NOT pull on the cables.

Detail A

Floating Latch Thumb Actuation Pad

Detail B

Figure 19

4. QUALIFICATIONS

No outside agency approval was defined for the HVA280-2phi high-voltage plug connector at the time of publication of this document.

5. TOOLING

Tooling recommendations covering the full cable size range for crimping the receptacle terminals is provided in

Application Specification 114-18148.

A hand crimping tool frame and electric bench terminator are available to crimp the outer ferrule. The tool frame and terminator each accept a die assembly designed to crimp the specific outer ferrule. Tooling part numbers for

crimping the outer ferrule, and instructional material packaged with the tooling, are shown in Figure 20.

NOTE i

Modified designs and additional tooling concepts may be available to meet other application requirements. For additional information, contact TOOLING ASSISTANCE CENTER or PRODUCT INFORMATION at the numbers at the bottom of page 1.

OUTER

FERRULE

1587829-2

1587829-3

DIE ASSEMBLY

(No Document)

2063013-3 (Type 1) 6.80-mm Hex

2063013-6 (Type 2) 7.40-mm Hex

Rev D

SDE-SA Hand Crimping Tool

Frame Assembly 9-1478240-0

(408-8851)

Figure 20

SDE Electric Bench Terminator

1490076-2 (409-10052)

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6. VISUAL AID

The illustration below shows a typical application of HVA280-2phi high-voltage plug connector. This illustration should be used by production personnel to ensure a correctly applied product. Applications which DO NOT appear correct should be inspected using the information in the preceding pages of this specification and in the instructional material shipped with the product or tooling.

NOTE i

Refer to 114-18148 for application requirements for terminated terminals.

FLOATING LATCH MUST BE PRESENT

AND FULLY INSTALLED (INDICATOR

SLOT MUST NOT BE VISIBLE)

THERE MUST BE NO

CONTAMINATION IN

MATING AREA OF

PLUG CONNECTOR

CABLE SEAL RETAINER MUST BE LOCKED

IN PLACE (PULL BACK GENTLY TO

ENSURE LOCKING ENGAGEMENT)

RECEPTACLE TERMINALS MUST BE

FULLY INSTALLED

PLUG CONNECTOR MUST NOT

BE DAMAGED OR CRACKED

PLUG CONNECTOR AND HEADER

ASSEMBLY MUST BE FULLY MATED

AND LOCKED IN PLACE

FIGURE 21. VISUAL AID

Rev D

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