CGE2E2222H9H2FWB05

CGE High Power Connectors HS-5/1199 CGE Contents Introduction .......................................... 2 Connector Design .............................. 2 How to order ....................................... 3 Mateability ......................................... 3 Polarization ........................................... 3 Technical Data ...................................... 4 Panel Cut-Outs ..................................... 5 Connector Dimensions .......................... 6 Accessories ........................................... 9 Contacts and Tools ............................... 10 Product Safety Information .................. 11 Introduction The Cannon CGE connectors are designed to transmit very high current at low voltage, as for example in the electrical equipment of military land- and sea-borne vehicles and in industrial applications. The connectors meet the mating dimensions, mechanical features and rear panel installation requirements of VG 95234. Ultraflexible shielded welding cables acc to MTV 6145-005 are terminated to the connectors. The contacts made of copper or a copper alloy with hard silver finish are designed for crimping or termination to solid copper conductors with threaded bolts. The mechanical durability is a minimum of 500 mating cycles. The crimp contacts accept wires according to DIN 46438 (25 – 240 mm2). Contact retention is achieved by the two-piece insulator which is fixed to the shell with a snap-in ring. This allows unlimited exchange of the crimp contacts. The bayonet coupling assures fast and reliable mating and unmating. Audible snap-in and colour-coded snap-in points indicate positive mating. Plugs and receptacles are waterproof in mated condition up to 1 bar (35 feet of water). Connector Design The high power connectors CGE feature one contact in a two-piece rigid insulator. The aluminum shell has a chromate finish over cadmium. The operating temperature ranges from –55 to 125°C. Connector Design O-Ring Shell Insulator Contact Cylindrical Contact front side O-Ring Insulator Contact rear side Spring ring Spring ring Insulator Contact rear side O-Ring contact Spring Insulator Contact front side Barrel assembly 2 Dimensions are mm (inches) Subject to changes CGE Polarization To avoid mismating of identic connectors the keyways of CGE connectors are available in two different positions: Standard position Position W = 180° = 120° How to order Series Cannon Designation Shell style 0 - wall mounting receptacle with flange 1 - cable connecting plug 2 - box mounting receptacle with flange 6 - straight plug 8 - plug 90° 9 - bulkhead Class E - environmental, JP07 acc to DIN 40050 Shell size 16 - 18 - 22 - 28 - 32 Contact arrangement 16H2 - shell size 16, 1 contact H2 18H5 - shell size 18, 1 contact H5 22H9 - shell size 22, 1 contact H9 28H15 - shell size 28, 1 contact H15 32H24 - shell size 32, 1 contact H24 Contact size H2 - 25 mm2 H5 - 50 mm2 H15 - 150 mm2 H24 - 240 mm2 Contact type F - spring contact Z - cylindrical contact Keyway polarization W - 120° Bayonet coupling CGE 6 E 32 H 24 F W B * Keyway positions of receptacles and cable connecting plugs Modification 05 - through-holes in flange 03 - adapter for heat shrink boots, metric crimp contact 04 - rear panel mounting, threaded holes, metric crimp contact 04-05 - same as -04, however, with through-holes 14 - shielded version, metric crimp contact 16 - thread bolt termination, front panel mounting, O ring for sealing between wall and receptacle (for CGE2EB only) Mateability Keyway positions of straight and 90° plugs Receptacles and cable connecting plugs mate with CGE2E-B04, CGE-B-04-05 CGE2E-B-16 CGE0E-B-03, CGE-B-05-05 CGE1E-B-03 Plugs, straight / 90° CGE6E-B-03 CGE6E-B-14 CGE8E-B-03 CGE8E-B-14 3 CGE Technical Data Admissible ambient temperature –55/125°C Class JP07 acc to DIN 40050 Test pressure 1 bar overpressure Test duration 12 h Vibration 200 m/s2 for 10 – 2000 Hz Mechanical durability 500 mating cycles Contact resistance (mOhm max) Coupling torque in wired condition acc to VG95319, Part 2, Test No 5.8.2. Shell size 16 18 22 28 32 max closing / opening Nm 5,5 8,0 11,0 17,0 19,0 max opening Nm 0,5 0,6 0,8 0,9 1,0 Electrical Data Current rating (A) at 125°C ambient temperature Shell size Contact size Max Current rating (A) Max Short-time load, appr 0,5 – 1 sec (A) 16 H2 225 750 18 H5 350 1000 22 H9 570 2000 28 H15 750 3000 32 H24 950 5000 Air and creepage paths Air path Creepage path 3 mm min 5 mm min Insulator resistance min 5000 MOhm Contact retention acc to VG 95319, Part 2, Test No 5.4. Contact size H2 H5 H9 H15 H24 Test force N min 100 120 140 160 200 Contact size Contact resistance H2 0,6 H5 0,3 H9 0,15 H15 0,1 H24 0,07 Cables The connectors are designed for ultraflexible welding cable acc to MTV 6145-005. Shell size 16 18 22 28 32 Wire size 25 50 95 150 240 MTV 6145-005 designation shielded MTV 6145-005 H001 MTV 6145-005 H002 MTV 6145-005 H003 MTV 6145-005 H004 MTV 6145-005 H005 Materials Shell – Finish Insulator Contact – Finish O ring Aluminum alloy Olive chromate over cadmium PTFE Copper or copper alloy Hard silver FKM unshielded MTV 6145-005 G001 MTV 6145-005 G002 MTV 6145-005 G003 MTV 6145-005 G004 MTV 6145-005 G005 When selecting a cable type please consider self-heating of cable at the maximum operating voltage and the maximum ambient temperature (see page 5). 4 Dimensions are mm (inches) Subject to changes CGE Cable Data Approx. values for cable self-heating Wire size mm2 25 50 95 150 240 Cable Dimensions Max admissible operating voltage 250 300 500 600 1000 Approx over-temperature due to current load: ∆ T in °C 1/3 of max admissible 2/2 of max admissible max admissible operating voltage operating voltage operating voltage 35 52 95 15 25 55 10 33 70 5 23 60 8 30 75 Outer jacket Shielding braid, tinned Inner jacked Copper conductor Cable designation MTV6145-005+001 MTV6145-005+001 MTV6145-005+001 MTV6145-005+001 MTV6145-005+001 Shell size 16 18 22 28 32 Wire size mm2 25 50 95 150 240 a 7,5+/–0,5 11,0+/–0,5 16,0+/–0,5 20,5+/–0,5 26,5+/–0,5 b max 13,5 18,0 23,5 30,0 36,0 c max 10,2 14,3 19,7 25,4 32,5 d+/–10,5 14,0 15,0 20,5 30,0 30,0 Straight plug e1 +/–1,0 f1 +/–1,0 31,0 46,0 31,0 46,0 42,0 57,0 54,0 69,0 Plug 90° e2 +/–1,0 20,0 25,0 25,0 f2 +/–1,0 35,0 40,0 40,0 Panel Cut-Outs Panel cut-outs for rear and front panel mounting of receptacles Shell size 16 18 22 28 32 Receptacles, rear panel mounting CGE0E-B-03/14 CGE2E-B-04 H13 H12 c +0,15 d +0,15 d ± 0,15 4,5 27,7 24,6 4,5 31,1 27,0 4,5 37,8 31,8 5,5 47,1 39,7 5,5 53,8 44,5 Receptacles, front panel mounting CGE2E-B-16 H13 c 4,5 4,5 4,5 4,5 4,5 H12 thread M4 M4 M4 M4 M4 c ± 0,15 24,6 27,0 31,8 39,7 44,5 d 22,5 27,4 33,7 43,5 49,7 5 CGE CGE0E...B-03 Wall mounting receptacle, acc to VG 96929B1, rear panel mounting, four threaded holes in flange, adapter for heat shrink boot, metric crimp contacts Shell size 16 22 32 a – 0,15 27,4 37,4 53,4 d1 ± 0,15 20,0 45,8 45,8 d2 ± 0,3 22,1 49,2 49,2 d3 M4 M4 M5 e ± 0,1 24,6 31,8 44,5 g ± 0,1 3,2 3,2 3,5 h ± 0,2 12,0 20,8 28,0 l1 ± 0,3 41,0 55,0 66,8 l4 ± 0,3 20,0 23,15 29,0 l5 ± 0,15 3,2 4,0 4,0 l6 ± 0,3 32,5 41,0 57,0 CGE1E...B-03 Cable connecting plug, straigt, adapter for heat shrink boots, metric crimp contacts Shell size 18 22 28 32 a – 0,15 30,8 37,4 53,4 46,7 d1 ± 0,15 25,0 31,5 45,8 41,0 d2 ± 0,15 27,0 34,9 50,0 44,4 g ± 0,1 3,2 3,2 3,5 3,5 h ± 0,15 20,0 20,5 28,0 25,0 l1 ± 0,3 50,0 54,0 66,8 65,8 CGE1E...B-14 Cable connecting plug, shielded version, metric crimp contacts Shell size 18 a ± 0,15 37,4 b 42,0 c 37,0 d ± 0,3 25,5 g ± 0,2 22,5 h max 48,5 l1 max 95,5 SW1 34 SW2 38 6 Dimensions are mm (inches) Subject to changes CGE CGE2E...B-04 CGE2E...B-04-05 Box mounting receptacle, rear panel mounting, -04 – four threaded holes in flange, -04-05 – four through holes in flange Shell size 16 18 22 28 32 a – 0,15 27,4 30,8 37,4 46,6 53,4 d1 ± 0,15 22,1 27,0 34,9 42,7 49,2 d Mod 04 M4 M4 M4 M4 M5 Mod 05 4,3 4,3 4,3 4,3 5,3 e ± 0,1 24,6 27,0 31,8 39,7 44,5 h ± 0,2 20,0 23,15 23,15 29,0 l1 ± 0,3 41,0 50,0 54,0 65,3 66,8 l2 ± 0,3 32,5 35,0 41,0 50,8 57,0 n ± 0,1 3,2 4,0 4,0 4,0 4,0 CGE2E...B-16 Box mounting receptacle, front panel mounting, four through holes in flange, threaded bolt termination for solid copper rail Shell size 18 22 28 32 a – 0,15 30,8 37,4 46,6 53,4 d1 M8 M12 M12 M16 d2 – 0,15 26,9 33,2 42,8 49,2 d + 0,2 4,3 4,3 4,3 4,3 e ± 0,1 27,0 31,8 39,7 44,5 g ± 0,3 4,0 4,4 4,0 6,0 h 27,5 38,0 32,0 44,5 l1 max 55,0 65,5 61,0 73,0 l2 ± 0,3 23,15 23,15 24,15 29,0 l5 ± 0,5 15,0 25,3 20,0 22,0 l7 + 0,3 35,0 41,0 50,8 57,0 n ± 0,15 4,0 4,0 4,0 4,0 SW 3 6 6 8 CGE6E...B-03 Straight plug acc to VG 96929A2, adapter for heat shrink boots, metric crimp contacts Shell size 16 18 22 32 d1 max 32,0 36,5 43,1 60,1 d2 – 0,1 20,2 25,8 31,5 45,4 d3 max 22,3 28,0 35,0 49,2 g 4,3 4,3 4,3 4,3 h ± 0,2 27,0 31,8 39,7 44,5 l1 max 44,0 53,0 57,0 65,0 7 CGE CGE6E...B-14 Straight plug acc to VG 96929F, 360° HF shielding by grounding fingers, endbells for clamp connection of shielding braid and for heat shrink boots, metric crimp contacts Shell size 16 18 22 28 32 c ± 0,3 26,0 32,0 37,0 44,0 31,0 d1 max 32,0 36,5 43,1 53,0 60,1 d2 ± 0,15 24,0 28,7 33,7 40,0 47,2 d4 ± 0,1 15,5 20,0 25,5 32,0 38,0 g ± 0,1 1,0 1,0 1,0 1,0 1,0 h ± 0,4 25,5 26,0 26,0 26,0 28,0 l1 max 68,0 73,5 84,0 98,0 95,5 SW 26 32 38 50 54 CGE8E...B-03 90° plug with adapter for heat shrink boots, metric crimp contacts CGE8E...B-14 90° plug acc to VG 96929E, with grounding fingers, adapter for shielding braid and for use with heat shrink boots, metric crimp contacts Shell size 22 28 32 d1 max 43,1 53,0 60,1 d3 max 42,0 48,0 52,5 l1 ± 1,0 80,0 78,0 84,0 l3 max 41 41 41 l4 max 56 56 56 l6 ± 0,2 3,2 3,2 3,2 l max 101,0 102,0 112,0 SW 38 50 52 CGE9E...X-B-04 Bulkhead acc to VG 96929C2, with through holes in flange Shell size 22 a – 0,15 46,7 d1 5,3 e ± 0,1 39,7 l1 max 51,5 l2 ± 0,3 20,6 l3 ± 0,1 4,0 l4 ± 0,3 50,8 8 Dimensions are mm (inches) Subject to changes CGE Accessories Dust cap 121004 for plugs Order reference CA121004-4 CA121004-6 CA121004-8 CA121004-10 CA121004-11 Size 16S 18 22 28 32 a + 0,5 4,3 4,3 4,3 4,3 5,5 b ± 10,0 113 127 140 197 197 c max 29,0 30,0 30,0 30,0 30,0 d max 29,9 33,3 39,9 49,2 55,9 Dust cap 121003 for receptacles Order reference CA121003-4 CA12100436 CA121003-8 CA121003-10 CA121004311 Size 16S 18 22 28 32 a + 0,5 4,3 4,3 4,3 5,5 5,5 b ± 10,0 100 113 127 169 169 c max 19,5 25,4 25,4 25,4 25,4 d max 32,6 36,7 43,3 52,6 59,3 Dummy receptacle Order ref. 248-8504-000 248-8506-000 248-8508-000 248-8510-000 248-8511-000 Size 16S 18 22 28 32 a ± 0,3 32,5 35,0 41,0 50,8 57,0 b ± 0,15 24,6 27,0 31,8 39,7 44,5 d + 0,2 3,2 3,2 3,2 3,7 4,4 d1 M4 M4 M4 M5 M5 e ± 0,2 21,5 27,2 27,2 28,2 28,2 f +0,3 / – 0,1 18,3 23,15 23,15 24,15 24,15 g + 0,1 29,6 23,8 30,0 38,8 45,2 h + 0,15 27,4 30,8 37,4 46,7 53,4 9 CGE Accessories Sealing gaskets for rear panel mounting only Shell size 16 18 22 28 32 Order references Polychloroprene 075-8504-000 075-8505-000 075-8507-000 075-8509-000 075-8510-000 Order references Alu-Flex (shielded version) 075-8504-001 075-8505-001 075-8507-001 075-8509-001 075-8510-001 Contacts Order references for single contacts Shell size H24 Spring contact 031-8564-000 031-8567-000 031-8658-000 031-8663-000 031-8669-000 031-8701-004 031-8649-000 031-8660-000 031-8659-000 031-8655-000 031-8656-000 031-8616-000 – Cylindrical contact 330-8697-000 330-8696-000 031-8701-002 330-8719-000 031-8701-000 430-8561-009 330-8698-000 330-8695-000 031-8701-000 330-8710-000 330-8712-000 330-8623-000 031-8705-000 Contact type Crimp with threaded bolt for 90° plug with threaded bolt for 90° plug Crimp version Crimp with threaded bolt for 90° plug crimp with threaded bolt crimp version for bulkhead Crimp sleeve 252-8583-000 252-8583-000 H15 H9 252-8583-000 H5 H2 H9 O Rings for sealing of front mounting receptacles are included in shipment Note: When choosing the contacts please make sure that the voltage carrying side of the connection is quipped with the cylindrical contact. Crimp Tools Description 1 Hand pump 2 Foot operation for hand pump 3 High pressure hose, length 2 m 4 Crimp head 5 Safety device incl. bench mounting 6 Positioner (to be used with 121086-3079 only) Designation 4601.00000.330 4601.51000.330 4604.00000.020 4632.00000.601 CT121086-3079 CT121086-3080 Order reference 121586-0027 121586-0008 121586-0023 121586-0031 121086-3079 121086-3080 Right hand photograph: Electro-hydraulic crimp tool HK12EL. Available upon request – please consult factory Crimp dies Contact size H2 H5 H9 H15 H24 Order reference upper crimp dies 317-8578-006 317-8578-008 317-8578-004 317-8578-002 317-8578-000 lower crimp dies 317-8578-007 317-8578-009 317-8578-005 317-8578-003 317-8578-001 Special Allen Wrenches for endbell assembly Shell size 16 18 22 28 Order reference CGE-SW26 CGE-SW26 CGE-SW26 CGE-SW26 10 Dimensions are mm (inches) Subject to changes CGE Product safety Information THIS NOTE SHOULD BE READ IN CONJUNCTION WITH THE PRODUCT DATA SHEET/CATALOGUE. FAILURE TO OBSERVE THE ADVICE IN THIS INFORMATION SHEET AND THE OPERATING CONDITIONS SPECIFIED IN THE PRODUCT DATA SHEET/ CATALOGUE COULD RESULT IN HAZARDOUS SITUATIONS. 1. MATERIAL CONTENT AND PHYSICAL FORM Electrical connectors do not usually contain hazardous materials. They contain conducting and non-conducting materials and can be divided into two groups. a) Printed circuit types and low cost audio types which employ all plastic insulators and casings. b) Rugged, Fire Barrier and High Reliability types with metal casings and either natural rubber, synthetic rubber, plastic or glass insulating materials. Contact materials vary with type of connector and also application and are usually manufactured from either copper, copper alloys, nickel, alumel, chromel or steel. In special applications, other alloys may be specified. 2. FIRE CHARACTERISTICS AND ELECTRIC SHOCK HAZARD There is no fire hazard when the connector is correctly wired and used within the specified parameters. Incorrect wiring or assembly of the connector or careless use of metal tools or conductive fluids, or transit damage to any of the component parts may cause electric shock or burns. Live circuits must not be broken by separating mated connectors as this may cause arcing, ionisation and burning. Heat dissipation is greater at maximum resistance in a circuit. Hot spots may occur when resistance is raised locally by damage, e.g. cracked or deformed contacts, broken strands of wire. Local overheating may also result from the use of the incorrect application tools or from poor quality soldering or slack screw terminals. Overheating may occur if the ratings in the Product Data Sheet/ Catalogue are exceeded and can cause breakdown of insulation and hence electric shock. If heating is allowed to continue it intensifies by further increasing the local resistance through loss of temper of spring contacts, formation of oxide film on contacts and wires, and leakage currents through carbonisation of insulation and tracking paths. Fire can then result in the presence of combustible materials and this may release noxious fumes. Overheating may not be visually apparent. Burns may result from touching overheated components. 3. HANDLING Care must be taken to avoid damage to any component parts of electrical connectors during installation and use. Although there are normally no sharp edges, care must be taken when handling certain components to avoid injury to fingers. Electrical connectors may be damaged in transit to the customers, and damage may result in creation of hazards. Products should therefore be examined prior to installation/use and rejected if found to be damaged. 4. DISPOSAL Incineration of certain materials may release noxious or even toxic fumes. 5. APPLICATION Connectors with exposed contacts should not be selected for use on the current supply side of an electrical circuit, because an electric shock could result from touching exposed contacts on an unmated connector. Voltages in excess of 30 V ac or 42.5 V dc are potentially hazardous and care should be taken to ensure that such voltages can not be transmitted in any way to exposed metal parts of the connector body. The connector and wiring should be checked, before making live, to have no damage to metal parts or insulators, no solder blobs, loose strands, conducting lubricants, swarf, or any other undesired conducting particles. Insulation resistance should be checked to make certain that no low resistance joints or spurious conducting path are existing between contacts and exposed metal parts of the connector body. Further the contact resistance of the connectors should be measured within the electrical circuit in order to identify high resistances which result in excessive connector heating. Always use the correct application tools as specified in the Data Sheet/Catalogue. Do not permit untrained personnel to wire, assemble or tramper with connectors. For operation voltage please see appropriate national regulations. IMPORTANT GENERAL INFORMATION. 1. Air and creepage paths/Operating voltage The admissible operating voltages depend on the individual applications and the valid national and other applicable safety regulations. For this reason the air and creepage path data are only reference values. Observe reduction of air and creepage paths due to PC board and/or harnessing. 2. Temperature All information given are temperature limits. The operation temperature depends on the individual application. 3. Other important information Cannon continuously endeavours to improve their products. Therefore, Cannon products may deviate from the description, technical data and shape as shown in this catalogue and data sheets. 4. Harnessing and Assembly Instructions If applicable, our special harnessing and/or assembly instruction has to be adhered to. This is provided at request. ITT Cannon manufactures the highest quality products available in the marketplace; however these products are intended to be used in accordance with the specifications in this catalog. Any use or application that deviates from stated operating specifications is not recommended and may be unsafe. No information and data contained in this catalog shall be construed to create any liability on the part of Cannon. Any new issue of this catalog shall automatically invalidate and supersede any and all previous issues. A limited warranty applies to Cannon products. Except for obligations assumed by Cannon under this warranty, Cannon shall not be liable for any loss, damage, cost of repairs, incidental or consequential damages of any kind, whether or not based on express or implied warranty, contract, negligence or strict liability arising in connection with the design, manufacture, sale, use or repair of the products. Product availability, prices and delivery dates are exclusively subject to our respective order confirmation form; the same applies to orders based on development samples delivered. This catalog is not be construed as an offer. It is intended merely as an invitation to make an offer. By this publication, Cannon does not assume responsibility or any liability for any patent infringements or other rights of third parties which may result from its use. Reprinting this catalog is generally permitted, indicating the source. However, Cannon's prior consent must be obtained in all cases. Cannon is a trademark of ITT Industries, Inc 11