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Amphenol SurLok Plus Manual

Right angle plug connector 3.6mm surlok+
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AI-9-1
CABLE ASSEMBLY WORK INSTRUCTION
3.6mm SurLok Plus
Right Angle Plug Connector
™
3.6mm SurLok+
C10-754726-()

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Summary of Contents for Amphenol SurLok Plus

  • Page 1 AI-9-1 CABLE ASSEMBLY WORK INSTRUCTION 3.6mm SurLok Plus Right Angle Plug Connector ™ 3.6mm SurLok+ C10-754726-()

  • Page 2: Package Contents

    Part 1: Package Contents Connector Body 1-1: Barrel sealing (not included when there is no sealing requirement) 1-2: O-Ring (not included when there is no sealing requirement) 6mm² Barrel (only provided when the 6mm² option is selected) Grommet (not included with non-sealed option) Backshell Part 2: Plug Assembly...
  • Page 3 Cut and strip wire, per illustration below (applies to 10mm & 6mm cables) Strip conductor: 7±0.5mm Conductor Insulation As shown below, slide the barrel onto the wire (for the 10mm² option, skip this step). Then install the barrel into the backshell and use the threading fixture to install the grommet into the backshell and thread the wire.
  • Page 4 ATION MAY NOT BE DISCLOSED TO OTHERS FOR MATERIAL SPEC PROCESS SPEC LEGENDS: OR USED FOR MANUFACTURING PURPOSES =FLAG NOTE CALL OUT SIZE CAGE CODE DOCUMENT NUM REFERENCE TEN PERMISSION FROM THE AMPHENOL CORP. THIRD ANGLE PROJECTION FX3-0042- 77820 SKD11 SCALE: REF:...
  • Page 5 CABLE ASSEMBLY WORK INSTRUCTION 3.6mm SurLok Plus Receptacle Connector Busbar Type ™ 3.6mm SurLok+ C10-754727-X1XX...
  • Page 6 Part 1: Package Contents Gasket Receptacle connector for busbar type Note: There will be no gasket provided when there is no sealing requirement Part 2: Receptacle Assembly Tighten M4 nut onto Busbar (recommended torque is 1.2~1.5N.m) Allen key Mount Panel M4 Bolt Busbar or other application M4 Washer...
  • Page 7 CABLE ASSEMBLY WORK INSTRUCTION SurLok Plus 5.7mm Plug Inline Type ™ 5.7mm SurLok+ C10-762230-XXXX...
  • Page 8 Part 1: Package Contents Connector Body 1-1: O-Ring (not included when there is no sealing requirement) Grommet (not included when there is no sealing requirement) Backshell Part 2: Plug Assembly Unscrew the backshell (grommet should remain within the backshell) Slide the grommet/backshell onto the cable as shown...
  • Page 9 Wire cutting and stripping (applies to 16mm & 25mm cables). Strip conductor: 12±1mm Conductor 12±1mm Insulation Install the cable conductor into the connector body lug Part 1 Keep tight to cable jacket Crimp wire well as shown below Recommended crimp length is 8±0.5mm Reference gap is 1mm MAX Recommended crimp Cable Size...
  • Page 10 Recommended crimping tool: Manual hydraulic crimper Die: 25mm² die for 25mm² cable 16mm² die for 16mm² cable Assemble the grommet and backshell. Tighten backshell to the indicated location shown in the below picture by hand or tool. The recommended torque is shown in the table below. Recommended torque of rear shell Cable Size Cable O.D.
  • Page 11 CABLE ASSEMBLY WORK INSTRUCTION SurLok Plus 5.7mm Receptacle Inline Type ™ 5.7mm SurLok+ C10-762231-XXXX...
  • Page 12 Part 1: Package Contents Connector Body 1-1: O-Ring (not included when there is no sealing requirement) Grommet (not included when there is no sealing requirement) Backshell Part 2: Receptacle Assembly Unscrew the backshell (grommet should remain within the backshell) Slide the grommet/backshell onto the cable as shown...
  • Page 13 Wire cutting and stripping (applies to 16mm & 25mm cables). Strip conductor: 12±1mm Conductor 12±1mm Insulation Install the cable conductor into the connector body lug Keep tight to cable jacket Part 1 Crimp wire well as shown below Recommended crimp length is 10±0.5mm Reference gap is 1mm MAX Recommended crimp Cable Size...
  • Page 14 Recommended crimping tool: Manual hydraulic crimper Die: 25mm die for 25mm cable 16mm die for 16mm cable Assemble the grommet and backshell. Tighten backshell to the indicated location shown in the below picture by hand or tool. The recommended torque is shown in the table below. Recommended torque of rear shell Cable Size Cable O.D.
  • Page 15 CABLE ASSEMBLY WORK INSTRUCTION SurLok Plus 8.0mm Plug Inline Type ™ 8.0mm SurLok+ C10-754487-XXXX...
  • Page 16 Part 1: Package Contents Connector Body 1-1: O-Ring (not included when there is no sealing requirement) Grommet (not included when there is no sealing requirement) Backshell Part 2: Plug Assembly Unscrew the backshell (grommet should remain within the backshell) Slide the grommet/backshell onto the cable as shown...
  • Page 17 Wire cutting and stripping (applies to 16mm & 25mm cables). Strip conductor: 18±1mm Conductor 18±1mm Insulation Install the cable conductor into the connector body lug Keep tight to cable jacket Part 1 Crimp wire well as shown below Recommended crimp length is 10±0.5mm Reference gap is 1mm MAX Recommended crimp Cable Size...
  • Page 18 Recommended crimping tool: Manual hydraulic crimper Die: 25mm die for 25mm cable 35mm die for 35mm cable 50mm die for 50mm cable Assemble the grommet and backshell. Tighten backshell to the indicated location shown in the below picture by hand or tool.
  • Page 19 CABLE ASSEMBLY WORK INSTRUCTION SurLok Plus 8.0mm Receptacle Inline Type ™ 8.0mm SurLok+ C10-754487-XXXX...
  • Page 20 Part 1: Package Contents Connector Body 1-1: O-Ring (not included when there is no sealing requirement) Grommet (not included when there is no sealing requirement) Backshell Part 2: Plug Assembly Unscrew the backshell (grommet should remain within the backshell) Slide the grommet/backshell onto the cable as shown...
  • Page 21 Wire cutting and stripping (applies to 16mm & 25mm cables). Strip conductor: 18±1mm Conductor 14.5±1mm Insulation Install the cable conductor into the connector body lug Keep tight to cable jacket Part 1 Crimp wire well as shown below Recommended crimp length is 10±0.5mm Reference gap is 1mm MAX Recommended crimp Cable Size...
  • Page 22 Recommended crimping tool: Manual hydraulic crimper Die: 25mm die for 25mm cable 35mm die for 35mm cable 50mm die for 50mm cable Assemble the grommet and backshell. Tighten backshell to the indicated location shown in the below picture by hand or tool.
  • Page 23 CABLE ASSEMBLY WORK INSTRUCTION 5.7 & 8.0mm SurLok Plus Connector Inline Type ™ Mating and Unmating Work Instruction 5.7mm & 8.0mm SL+ 5.7mm SurLok Plus Connector: Plug: C10-752785-() Receptacle: C10-762231-() 8.0mm SurLok Plus Connector: Plug: C10-731951-() Receptacle: C10-754488-()
  • Page 24 Part 1: Keyway Description Minor Keyway Minor Keyway Master Keyway Master Keyway Plug Receptacle Part 2: Mating Operation Initial mating: Align the master keyway of the receptacle and plug (skip this step if there is no keyway/key option), and push the plug vertically into the receptacle as shown in the diagram. Continue mating plug into receptacle, until you hear an audible "click"...
  • Page 25 Part 3: Unmating Operation After shutting down the electical current, press the button and pull the plug horizontally from the receptacle, in the direction shown below. Button Note: For end use, the separation active space required is 129mm minimum, this does not include the active space for hand or tool operation.
  • Page 26 ASSEMBLY WORK INSTRUCTION 8.0 mm Surlok Plus Plug Part Number: C10-765467-( )
  • Page 27 Part 1: Plug Components Item Components Description Quantity Connector Body 1 set Bracket 1 pcs Grommet 1 pcs Rear Shell 1 pcs Part 1: Plug Cable Assembly Step 1: Un-assemble rear attachments Screw out the rear shell then take out the bracket. Notes: The grommet should be kept inside of rear shell.
  • Page 28 Step 3: Preloaded rear attachments Wire pass through rear shell and grommet, then take off the cut insulator. Finally put the conductors of cable into the lug of connector body. Step 4: Crimping the lug Crimp lug together with cable conductor according to below table. Recommended crimping parameter Cable size Cable O.D.
  • Page 29 Step 5: Assemble rear attachments Put the bracket onto the lug of connector body, then tighten rear shellto the indicated location shown as picture by hand or wrench (recommended torque is 1.2±0.1N.m). Rear shell should tie with connector body closely...
  • Page 30 ASSEMBLY WORK INSTRUCTION 8.0mm Surlok Plus Receptacle 1500V Busbar Type Part Number: C10-765468-X1XX...
  • Page 31 Part 1: Package Contents Receptacle shell Gasket 1-1: Gasket (Not included when no sealing requirement) Part 2: Receptacle Assembly Step 1: Tighten housing onto the panelwith M4 screws (recommended torque as 0.8±0.1N.m) Recommended screw is GB 9074.13 M4. The height should not greater than 5mm Notes: The customer shall verify the recommended torque base on your application and modify it if necessary.
  • Page 32 Step 2: Connect receptacle terminal with customer's busbar copper M6 Bolt, Plate, and Washer M6 Nut Customer's busbar Recommended torque is copper 6.5±0.1N.m Notes: The customer shall verify the recommended torque base on your application and modify it if necessary.
  • Page 33 ASSEMBLY WORK INSTRUCTION 10.3mm Surlok PIus 1500V Right Angle Plug Connector 2.0 Version Part Number: C10-7651278-( )

  • Page 34: Operation

    DEFAULT LINEAR TOLERANCES SEE TABLE INSIDE SPIDER C&I PROPRIETARY INFORMATION AND PRODUCT GROUP: DIM. & TOL. PER ASME Y14.5M-1994; 10.3MM SURLOK PLUS 1500V TYPE DRM PER MIL-DTL-31000; OT BE DISCLOSED TO OTHERS FOR AIPG DIVISION: OTHER AMPHENOL STANDARDS: 9-9318 MANUFACTURING PURPOSES...
  • Page 35 Part 2: Receptacle Assembly Step 1: Wire cutting and stripping (Apply for 70mm & 95mm Cable) Stripping conductor: 17±1mm 17±1mm Step 2: Un-assemble Grommet and rear cap over the cable as shown. Grommet Rear Cap Step 3: Use the tool (FX3-0067-001) to fit the grommet to the bottom of rear cap Tool...
  • Page 36 MATERIAL SPEC PROCESS SPEC FRIANYL A3 GF25 V0 LEGENDS: THIRD ANGLE PROJECTION 10-765499 77820 =FLAG NOTE CALL OUT WITHOUT WRITTEN PERMISSION FROM THE AMPHENOL CORP. SIZE CAGE CODE DOCUMENT NUMBER BK 9005 REFERENCE FRIANYL A3 GF25 V0 THIRD ANGLE PROJECTION...
  • Page 37 Step 7: Assemble rear shell NO Gap Tighten rear shell to the indicated location shown as picture above by hand or tool. The recommended torque as below: 1.5±2.0 Nm...
  • Page 38 ASSEMBLY WORK INSTRUCTION 10.3mm Surlok Plus 1500V Receptacle Connector Screw Type 2.0 Version Part Number: C10-765128-X2XX...
  • Page 39 Part 1: Package Contents Gasket Dust Cap Receptacle connector Notes: There will be no gasket when no sealing requirement. Part 2: Receptacle Assembly Step 1: Tighten M10x1.5 nut onto busbar (recommended torque is 13~14 Nm) Busbar or other applications M10 Spring M10x1.5 Nut Washer Mount Panel...
  • Page 40 Step 2: Tighten receptacle onto the panel with M4 bolts (recommended torque is 0.8~1.0 N.m) Recommended M4 bolts refer to GB/T 70.L-2000 ( eqv ISO 4762:7997) Recommended M4 spring lock washer refer to GB 93-87 Recommended M4 plain washer refer to GB 97.1-2002...
  • Page 41 ASSEMBLY WORK INSTRUCTION 10.3mm Surlok Plus 1500V Receptacle Connector Busbar Type 2.0 Version Part Number: C10-765128-X1XX...
  • Page 42 Part 1: Package Contents Gasket Dust Cap Receptacle connector Notes: There will be no gasket when no sealing requirement. Part 2: Receptacle Assembly Step 1: Tighten Nuts (recommended torque for nut is 4N.m max.) Allen key Panel Busbar or other application Adjustable wrench M6 Washer M6X1 Nut...
  • Page 43 Step 2: Tighten housing onto the panel with M4 screws (recommended torque is 0.8~1.0 N.m) Recommended M4 bolts refer to GB/T 70.L-2000 ( eqv lSo 4762:7997) Recommended M4 spring lock washer refer to GB 93-87 Recommended M4 plain washer refer to GB 97.1-2002...
  • Page 44 ASSEMBLY WORK INSTRUCTION 10.3mm Surlok Plus 1500V Connector Right Angle Mating and Unmating Work lnstruction Part Number: C10-765127-( ) C10-765128-( )
  • Page 45 Part 1: Plug Components Keyway Code (see Table) Keyway Benchmark Plug Receptacle Keyway Code Table Y° Keyway Code 20° 30° 45° Notes: This product is not suitable for live plugging and unplugging. ln order to prevent the plug from being pulled out by mistake, it is recommended to add a protection mechanism on the device...
  • Page 46 Part 2: Mating Operation Step 1: Preliminary mating: lnsert the plug and receptacle into the following positions shown in the figure. Step 2: Rotate the Plug and adjust the outgoing direction of the cable to the desired position. Step 3: Align the key with the keyway and push the plug vertically into the receptacle, until hear a "click"...
  • Page 47 Part 3: Unmating Operation After turn off the power, press the button and then pull out the plug horizontally in the direction shown below. Pull out Plug Button Step 1: For end use, the separation active space requires is 67.5mm minimum. Step 2: Do not deviate from the axis direction of the receptacle until it was separation complete, or it has a risk to damage the connector.

This manual is also suitable for:

C10-754726