MT-30
Installation, Operation & Maintenance
06225-03H.doc
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AeroVironment, Inc
Appendix II: DC I/O Connector Assembly
General (
Electrical Connector Tech 16DSS-204MA
)
The male and female contacts are attached to the cable (Cu only) by means of a double
set screw. Acceptable cord types include SC, SCE, EISL and Type W. The double set
screw contact has a tapped screw hole that will accept a stress relieved, cad coated
screw with an insulated plastic head to secure and hold the contact inside the santoprene
insulator sleeve.
Assembly Procedures
1.
Cut off cable end of insulator to match cable size and push cable through insulator
from the cable end. (To make assembly easier, Coat cable jacket and inside walls of
insulators at both ends with ECT Silicone Spray Lube, or cable pulling compound.)
2.
A short piece of bare copper wire is furnished. It provides an excellent strain relief
to prevent cable jackets from pulling away from connectors: Strip the cable jacket
to approximately 1-7/16". At a point 3/8" to ½" from end of cable jacket, or 1-3/16"
to 1-15/16" from end of stripped conductor and at the halfway point of the bare
copper retainer wire, twist retainer wire tightly' around jacket with pliers. Bend the
ends down against conductor and squeeze twisted portion tightly against cable
jacket so that is will clear inside of insulator lock ring during assembly. Cut loose
ends of wires off flush with end of conductor. (Optional). Copper shims are
available, which can be wrapped around the bare cable conductor before inserting
into rear of contact. One or two shims may be necessary depending on cable size
and stranding.
For Catalog Numbers (1" diameter contact) 16DS-204M&F, 16DSS-204M&F, 18DS-
204M&F, 18DSS-204M&F; two copper shims for 2/0 cable and one copper shim for
3/0 or 4/0 cable.
3.
Attach male and female contacts to cable ends by inserting the cable wire into the
end of the contact and position the strain relief wire in the cable hole on the
opposite side of the contact from the set screws. Place the ½-20 set screws into the
threaded holes in the contact and tighten to 120 inch lbs. Torque.
4.
To assemble the male or female contact into the insulator sleeve, coat cable jacket
and contact with lubricant as in step #1. Line up the tapped hole in the male or
female contact with the screw port in the sleeve and pull the male or female contact
into the insulator sleeve until the tapped hole in the contact lines up with the screw
hole in the port of the insulating sleeve. Insert the thermoplastic head screw into the
port in the sleeve, use a screwdriver to thread into place, and secure the contact in
the sleeve.
Disassembly Procedures
1.
It is simple to remove the male or female contact from the insulator sleeve. Use a
screwdriver to unthread the screw from the contact through the porthole in the
insulating sleeve. Once the screw is removed, push the insulator back on to the
cable. The contact can then be removed by unthreading the '/2-20 set screws and
pulling the contact off the cable conductor.
