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HIGH VOLTAGE CABLE PROCESSING SOLUTIONS A FLEXIBLE APPROACH TO LARGE WIRE CABLE PROCESSING APPLICATION TOOLING /// HIGH VOLTAGE CABLE PROCESSING SOLUTIONS FLEXIBLE HIGH FORCE PROCESSING SOLUTIONS TE offers a wide range of wire processing solutions to handle challenging small wire applications up through complex 120mm2 high voltage cables. Our high force lineup gives you the power needed to process large wire applications in a fast, flexible, and affordable format. Challenges of High Voltage Cables High voltage cables require clean, precise cuts to maintain quality and safety standards. The TE suite of high force cable prep and termination equipment has been designed around those very high standards. APPLICATION TOOLING /// HIGH VOLTAGE CABLE PROCESSING SOLUTIONS HIGH FORCE TERMINATING SOLUTIONS HV Modular Die Sets 90° Charger Inlet HVP 800 Series HVP 800 Series PCON 12 Series PCON 18 Series PCON 21 Series This is only a cross section of die sets and terminals available. Our modular die holders can accommodate both TE and non-TE terminals. For a more complete list please visit tooling.te.com or contact your TE Application Tooling sales representative. HV Modular Die Holders — Loaded with Features Fine adjust feature allows for faster, more precise crimp height adjustment (+) (-) With Fine Adjust for HV-20 Machines For AT-66 Machines The multi-platform design of our modular HV die holders allows for use in a variety of TE and non-TE terminators Spring-loaded wire clamp assembly accommodates a variety of different wire sizes to match your processing needs The wire clamp assembly, handle and die sets can easily be adjusted to handle left or right side wire processing Modular Die Holder part Numbers Die Holders Description HV MOD Die Holder w/Fine Adjust HV MOD Die Holder w/o Fine Adjust For AT-66 Terminator only Part Number 2305470-1 2326378-1 (Can not be used in HV-20 or HF-20 Terminators) PAGE 3 HIGH VOLTAGE WIRE PROCESSING Take the complexity and long preparation times out of your high voltage cable processing with the new HV-CP machine from TE. This machine can process (10 - 120mm2) multi-layered conductors in as fast as 30 seconds! Multi-Step Stripping The HV-CP machine will strip the outer jacket, foil shield, braid shield, and inner insulation to meet your termination specifications. To confirm proper preparation of the cable, several unique quality control measures are in place. • The machine has the ability to confirm installation of the proper tooling before running • The HV-CP can self-calibrate the blade positions after tooling changeover • The machine confirms cable position before and after the prep process to onfirm proper strip lengths Part Number 2335400-1 Process complex multi-layered HV cables in as fast as 30 Seconds! For ease-of-use the HV-CP machine has an intuitive touch screen interface with a memory that accommodates up to 1,500 different profiles. Specifications Description Specification Description Specification Wire Cross Section 10 mm - 120 mm Increments for Incision Diameter 0.01 mm (0.0004 in) Max. Outer Diameter 25.0 mm (1 in) Increment for Stripping Length 0.01 mm (0.0004 in) Min Diameter of Inner Conductors 6.0 mm (0.24 in) Maximum Outer Jacket Strip Length 80 mm (3.15 in) Max Wire Cross Section for Cutting 2 mm2 / AWG 14 / 1.6 mm diam (0.063 in diam) Profile Library: Max Number of Articles 1500 Typical Cycle Time 30 sec Sequence Function: Max Number of Steps 100 2 2 APPLICATION TOOLING /// HIGH VOLTAGE CABLE PROCESSING SOLUTIONS High Voltage Cable Prep Spare Tooling Part Numbers Machine Part# 2335400-1 Cable Size (mm2) Outer Diameter Core Diameter Conductor Diameter (mm Max) Contour Blade Assembly Kit Part # Mandrel Assembly Kit Part # 10 8.8 (-0.6) 6.0 (-0.6) 4.5 2364113-1 2360456-1 16 10.2 (-0.6) 7.2 (-0.6) 5.8 2364113-2 2360456-2 25 12.2 (-0.6) 8.7 (-0.6) 7.2 2364113-3 2360456-3 35 14.4 (-0.6) 10.4 (-0.7) 8.5 2364113-4 2360456-4 50 15.8 (-0.6) 12.2 (-0.7) 10.5 2364113-5 2360456-5 60 16.9 (-0.6) 13.3 (-1.2) 11.6 2364113-6 2360456-6 70 18.2 (-0.6) 14.4 (-1.2) 12.5 2364113-7 2360456-7 95 20.9 (-0.6) 17.2 (-1.2) 14.8 2364113-8 2360456-8 Conductor Diameter 120 23 (-0.8) 19 (-1.2) 16.5 2364113-9 2360456-9 Outer Diameter HV-CP FEATURES Cutting Wheels Part # Core Diameter 2844837-1 381 mm Combining sophisticated controls, traceability system and equipped with ethernet and USB ports, the HV-CP high voltage cable prep machine is Industry 4.0 ready. 1470 mm (h) m 4m 100 Integrated air jets for automatic blade cleaning and an in-line vacuum to remove slugs keep the processing area clean and efficient. A removable container is located inside the chassis for easy waste disposal. (d) w) m( 238 kg (524 lb) m 687 PAGE 5 HIGH VOLTAGE WIRE TERMINATION The HF-20 and HV-20 are robust, compact, high force bench top machines capable of terminating cables up to 120mm2 Both models are eccentric presses capable of reaching 178kN (20T) of crimp force, with fast, repeatable accuracy. The HV-20 model comes with a CQM II digital interface for crimp force monitoring, variable speed and an integrated vacuum system to keep sensitive connections clean and clear of debris commonly associated with high voltage cable processing. Flexible Design To best fit the application process, the flexible design of the high force machines accommodates multiple processing orientations. The adjustable die holder platform can be easily rotated to handle processing from the left, front or right side of the unit. Side feed guarding is also available for all models to accommodate both loose piece and reeled terminal applications. Safe, Easy Operation Both models offer a simple push button design with multiple interlock features to confirm operator safety throughout the crimping process. High Force Terminator Part Numbers Press Part Number Terminator Description w/Loose Piece Guarding w/Side Feed Guarding (for reeled terminals) HF-20, High Force Terminator, 400V 2335500-1 2358697-1 HF-20, High Force Terminator, 200V 2335500-2 2358697-2 HV-20, High Voltage Terminator, 400V 2348822-1 2358698-1 HV-20, High Voltage Terminator, 200V 2348822-2 2358698-2 APPLICATION TOOLING /// HIGH VOLTAGE CABLE PROCESSING SOLUTIONS SIDE-BY-SIDE COMPARISON Force Max Wire Variable Stroke (Sec) Speed (RPM) Power Supply Stroke / Shut Height Weight Network/MES Particle Vacuum Guard Auto Lift CQM/CFM Competitor 1 Large Press Offering Competitor 2 Large Press Offering HF-20T HV-20T 178kN (20T) 178kN (20T) 150kN (17T) 178kN (20T) 120mm 120mm 100mm 120mm2 2 2 2 1.3 - 8.3 Sec 1.3 - 8.3 Sec 1.2 Sec (fixed) (fixed) 288 - 1800 RPM 288 - 1800 RPM 1420 RPM 1200 RPM 3kW 3kW 4kW 7.5 kW 200V & 400V 200V & 400V 400V 200V & 400V 44mm / 158.4mm 44mm / 158.4mm 50mm / 204.8mm 50mm / 190mm 390kg 390kg 500kg 1550kg RJ-45 / MQTT RJ-45 / MQTT - - - Yes No No Yes Yes Yes Optional - Yes Optional Optional HV-20T & HF-20T FEATURES Combining sophisticated controls, traceability system and equipped with ethernet and USB ports, the HV-20T and HF-20T benchtop terminators are Industry 4.0 ready. 974 mm (h) The integrated vacuum system design keeps sensitive connections clean and clear of debris commonly associated with high voltage cable crimping. 777 mm (d) 552 mm (w) PAGE 7 Let’s Connect To find the right TE tooling for your needs, call us at 717-810-2082 or email toolingSales@te.com. TE Technical Support Center USA: 1.800.522.6752 UK: Canada: 1.800.522.6752 France: +33.1.34.20.8686 +44.0800.267666 Mexico: +52.55.11.06.0800 Netherlands: +31.73.624.6999 Latin/S. America +54.11.4733.2200 China: +86.400.820.6015 Germany: +49.6151.607.1999 te.com TE Connectivity, and TE Connectivity (logo) are trademarks. All other logos, products and/or company names referred to herein might be trademarks of their respective owners. Contact us today to learn more North America (US, Mexico and Canada) The information given herein, including drawings, illustrations and schematics which are intended for illustration purposes only, is believed to be reliable. However, TE Connectivity makes no warranties as to its accuracy or completeness and disclaims any liability in connection with its use. TE Connectivity‘s obligations shall only be as set forth in TE Connectivity‘s Standard Terms and Conditions of Sale for this product and in no case will TE Connectivity be liable for any incidental, indirect or consequential damages arising out of the sale, resale, use or misuse of the product. Users of TE Connectivity products should make their own evaluation to determine the suitability of each such product for the specific application. • Wire processing equipment: 800-722-1111 or 717-810-3434 © 2019 TE Connectivity Ltd. family of companies All Rights Reserved. For locations outside North America visit tooling.te.com 2354336-1   11/19   Rev C www.te.com/fieldservice APPLICATION TOOLING /// HIGH VOLTAGE CABLE PROCESSING SOLUTIONS • Board processing equipment: 888-782-3349 or 610-893-9680 E-mail: fieldservicesnorthamerica@te.com • Web: www.te.com/fieldservice