114-162001

Application Specification

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HC-STAK 25-2phi High Voltage Connector
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are inmillimeters. Unless otherwise specified, dimensions have a tolerance of ±0.13 and angles have atolerance of ±2°. Figures and illustrations are for identification only and are not drawn to scale.

HIGH-VOLTAGE - MORTAL DANGER•••
1.

This connector is intended for use in high-voltage applications. Special care must be appliedto 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.

INTRODUCTION

This specification covers the requirements for assembly and mating/un-mating of the HC-STAK 25-2phi Plug.
These high-voltage connectors must NOT be mated with any other type of connector.

When corresponding with TE Connectivity Personnel, use the terminology provided on this specification to help
facilitate your inquiry for information. Basic terms and features of components are provided in Figure 1.

Plug Sub-Assembly

Tab Contact

Inner FerruleSpacer Seal
Ferrule SleeveColletOuter Ferrule
Rear CoverFigure 1: Exploded View HC-STAK 25-2phi© 2024 TE Connectivity Ltd. family of companies.
All Rights Reserved.
| Indicates Change*Trademark. 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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2.

REFERENCE MATERIAL

2.1.

Revision Summary
A. Initial release of documentB. 2.2.: replaced 2840569 with 2840439
2.3.B: replaced 2840569 with 2840439
Table 1: replaced 2840569 with 2840439
added 2840712 (collet)
3.6.2: replaced 2x46±1 with 2x45±1
3.6.5.: replaced 2x27.0±0.5 with 2x27.5 MAX
3.6.6.: new layout
3.6.7.: added
 Presence and orientation of all components
 No deformation to the rectangular section of the inner ferrule No damage (scratches, etc.) to the HV tab contact surfaces
3.6.8.: was Install the cable assembly into the plug sub-assembly in the orientation shown until it isfully locked as shown in Figure 9. Verify that the cable assembly is completely installed by gently
pulling back on the cable.
Figure 9: removed “Click”
added bottom view
3.6.11.: was Slide the rear cover forward on the cable and latch to the plug sub-assembly as shownin Figure 12. Verify that both of the rear cover latches are fully locked.
3.6.12.: added 1.0mm MAX gap
5.: added
6.: added
C. 3.7.: added HVIL shunt probing note
added Figure 14
D. 2.4 : PART# x-2840572-x changed to x-2329023-x
E. 3.6.: Pt.6 Fig 8 – Added note “If using a knurled tab (2840393-2) knurling is on welded side.
Removed all references to low volume tooling in sec 2.2,2.3 and 2.4 – Table 1.
F. 3.6.7: Added Champlain 50mm² and 25mm² dimensions on the ferrule crimp. Added USCAR38 spec
for ultrasonic weld parameters
2.4: Removed table with component part numbers.
2.2 – Replaced customer drawing PN with 2349157.
3.8.6 – Added Point 6 and Image to show tie-down point
G. 3.6.6: Criteria and weld tensile strength replaced with mechanical and electrical
H. 3.6.5:– Added Coroplast 50mm² cable information for ferrule crimp dimensions
J. 3.6:- Updated Table 2: Hex Crimp Dimensions

2.2.

Customer Assistance

Reference drawing 2349157 and Product Code L983 are represent the HC-STAK 25. Use of this basenumbers and product code will identify the product line and expedite your inquiries through a service network
established to help you obtain product and tooling information. Such information can be obtained through alocal TE Representative or, after purchase, by calling the Product Information Center at the number at thebottom of page 1.

2.3.

Drawings

2.3.1 Customer 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 othertechnical documentation supplied, the Customer Drawing takes preference.

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2.3.2 Reference drawings
Reference Drawing C-2349157 is available for part number relationships only and is not asellable item. Refer to this drawing only for compatible part numbers for customer inquiry. For more
information on Reference Drawings, call PRODUCT INFORMATION at the number at the bottom ofpage 1.

2.4. Cable and Subcomponent Specification
The following cable and subcomponent combinations must be used together to ensure optimum connector
performance.
Conductor CoreDo NOT nick, scrape, or cut
the wire conductor during
the stripping process.

Inner Jacket
Braided Cable Shield
Outer Jacket
Figure 2: Single Conductor
Cable

See the reference drawing C-2349157 for specific validated wire sizes and part numbers
09-

3. REQUIREMENTS
3.1. SafetyDo not stack contact packages so high that the shipping containers buckle or deform.

3.2. Shelf LifeThe contacts should remain in the shipping containers until ready for use to prevent deformation to the contacts
and/or damage to the housings. The products 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 contacts near any chemicals listed below, as they may cause stress corrosion cracking in thecontacts.
AlkalisAminesAmmonia
Carbonates

Citrates
Nitrites

Phosphates CitratesSulfur Nitrites

Sulfur Compounds
Tartrates

3.4. Material
The connector assemblies are made of thermoplastic materials and the terminals, shields, and ferrules are tin
and silver plated copper alloy.

3.5. Circuit Identification
The terminal cavities are numbered on the outer housing of the connector at the wire entry end.

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3.6. Assembly Procedures
The following procedures show the details of the cable assembly and insertion instructions into the plug
subassembly.
Refer to Table 1 for the various components of the cable as shown in an end view of the cable.

1.
From the plug end of the cable, slide the rear cover, collet, and spacer seal in the order and orientation
as shown in Figure 3.

Plug EndSpacer Seal

ColletRear Cover

Figure 3: Rear cover, collet, and spacer seal loaded on cable
Strip and remove the outer cable jacket, foil (if present), braided shield, and inner jacket from the plugend as shown in Figure 4.

2x45±1

Conductor
Inner Jacket
Braided Shield
ShieldOuter Cable Jacket
Figure 4: Cable Stripping

Do not cut, nick or scrape the conductive wires during the stripping process.

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2.
Slightly compress the inner ferrule sleeve and install into the inner ferrule from the cable end as shownin Figure 5.

Figure 5: Inner ferrule sleeve into inner ferrule
Slide the outer ferrule over the outer cable jacket then the inner ferrule sub-assembly under the braided
cable shield up as shown in Figure 6.

6b6b(2x) Inner Ferrule
Sub-Assembly(2x) Outer Ferrule(2x) Braided Shield
ShieldFigure 6a: Slide the outer ferrule over the outer cable jacket
Braided Shield
ShieldInner Ferrule Sub-Assembly

Figure 6b: Slide the inner ferrule under the braided shield

The shielding braid must be spread uniformly on the circumference of the ferrule.

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3.
Slide the outer ferrule into position over the braided cable shield and crimp in place as shown in Figure
7 using dimensions in Table 2.
2x27.5 MAX

2x27.5 MAX

Figure 7b Section

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Figure 7a: Ferrule Crimp

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Hex crimp dimple and crimp wings must be correctly oriented (Long sides of the inner ferrule box)

BDimpleDimpleXYZA

Figure 7b: Hex Crimp

Figure 7c: Bellmouth

Table 2: Hex Crimp Dimensions
Cable

Dim X

Dim Y

Dim Z

Dim A

Dim B

14.8±0.2

15.2 Max15.2 Max

20 Max

2.2 Max

12.1±0.1
12.35 Max 12.35 Max* GEBAUER & GRILLER, Champlain and Coroplast are trademarks of the respective owners

15.7 Max

1.8 Max

GEBAUER & GRILLER X8663 50mm2
Coroplast 9-2611 (FLR2GCB2G) 50mm²
Champlain 15-08403-XXX 50mm2
Champlain 15-08126-XXX 25mm2

Wire insulation shall NOT be cut or broken during the crimping operation, nor shall the insulation becrimped into the ferrule
Any loose strands of the braided cable shield seen protruding from the outer ferrule should be trimmed,taking special care not to leave any detached strands attached to the assembly.
Periodic inspections must be made to ensure crimped contact formation is consistent as shown.

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4.
Ultrasonic weld HV Tab as shown in Figure 8. See SAE/USCAR-38 for weld bond appearance,mechanical and electrical requirements. Ensure that the keep-out zones are not violated. This is critical toensure proper assembly.

3 Min
1.2 Min2x3.4±0.5 Offset

Tab Retainer
Keep OutZone

Keep Out Zones

CableCenterlines

2x3.7 Max

2x25.4 Min

2x2.0 Max Cable Jacket Location
2x46.1 +2.0/-0.5

HV TabArea to be free ofmarkings fromwelding process(2x2° Max Clockwise/Counterclockwise alignment)

If using a knurledtab (2840393-2),
knurling is on
welded side

Figure 8: HV Tab ultrasonic welding

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5.

The following items at a minimum should be inspected and verified: Hex crimp dimensions per Table 2 No large burrs/flash on the ferrule crimp
 No visible cracking of the ferrule or shields

Figure: Cracked ferrule after improper crimp – Not acceptable No loose or detached shield braid strands
 The cable insulation is not pinched abraded or cut The cable jacket to outer ferrule dimension
 Weld Nugget, brush, conductor strands, etc. do not violate keep out zone dimensions
 Presence and orientation of all components
 No deformation to the rectangular section of the inner ferrule No damage (scratches, etc.) to the HV tab contact surfaces

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Verify cable jacket to outer ferrule dimension just prior to installation into plug assembly
6.
Install the cable assembly into the plug sub-assembly in the orientation shown until BOTH HV Tabs are
fully contacting the Plug Inner Housing front surface as shown in Figure 9.
Terminal Cavity Position

Cable Assembly

Plug Sub-Assembly

BOTH HV Tabs fully contacting Plug Inner Housing front
surface

Figure 9: Cable Assembly

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7.
Slide the spacer seal forward on the cable and into the cable exit end of the plug sub-assembly until it
stops against the inside of the plug sub-assembly as shown in Figure 10.

Spacer Seal

Figure 10: Spacer Seal Assembly
8.

Slide the collet forward on the cable and into the spacer seal as shown in Figure 11.

ColletFigure 11: Collet Assembly

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9.
With BOTH HV Tabs fully contacting the Plug Inner Housing (refer to Figure 9), slide the rear coverforward on the cable and latch to the plug sub-assembly as shown in Figure 12. Verify that all four rear coverlatches are fully locked.

Rear Cover
ClickFigure 12: Rear Cover Assembly
10.

Verify the gap between BOTH HV Tabs and the plug inner housing is 1.0mm MAX

as shown in Figure 13.
1.0mm MAX gap

Figure 13: HV Tab Gap

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3.7. Contact Probing
Avoid probing the tabs in an area that could damage the plating.

Avoid probing the shunted receptacle contacts as shown in Figure 14. This could damage the contact
geometry and/or plating.
Shunted Receptacle Contacts

Figure 14: Shunted Receptacle Contacts

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3.8. Connector Mating
1.
If the assembly is shipped with the Lever and/or red Connector Position Assurance (CPA) in the closedposition, first if necessary, actuate the CPA to the open position, then open the lever to the open position asshown in Figure 15.
CPA shown inclosed position

Lever shown inclosed position

2nd

1st

Lever shown inopen position

CPA shown inopen position

Figure 15: Assembly Lever and CPA Closed

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2.

Align the plug and header connectors as shown in Figure 16.
Make sure that the lever is still in the fully open position prior to engagement with the mating header.

Figure 16: Plug and Header Alignment

3.
Holding the Plug connector body, push the connector halves together until the Header gear teeth
completely engage with the Lever gear teeth as shown in Figure 17.

Figure 17: Plug and Header Pre-Lock

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4.
Rotate the lever towards the connector body until it is completely in the closed position as shown in
Figure 18.

Figure 18: Lever Actuation from Open to Close

5.

Push the red CPA forward until it stops as shown in Figure 19.
CPA shown inopen position

CPA shown inclosed position

Figure 19: CPA Actuation from Open to Close

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6.
Ensure that the cables are rigidly secured at harness tie-down point as shown, and that the tie-down
point is static relative to the header mounting location. A single tie-down point is required, but at least one
additional tie-down point is recommended. See example:(50 mm)≤100 mm

3.9. Connector Unmating
1.

Push the red CPA forward until it stops as shown in Figure 20.
CPA shown inclosed position

CPA shown inopen position

Figure 20: CPA Actuation from Close to Open2.
Rotate the lever away from the connector body until it is completely in the open position as shown in
Figure 21.

Figure 21: Lever from Close to Open

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3.
Holding the connector body pull the plug until it is completely separated from the header as shown inFigure 22.
Do not use the lever as a handle to pull the plug apart.

Figure 22: Plug and Header Unmate

4. TOOLING
A listing of tooling recommendations covering the full wire size range is provided in Figure 23. Modified designs
and additional tooling concepts may be available to meet other application requirements. For additional
information, contact one of the service groups at the bottom of page 1.

PNEUMATIC TOOLINGCABLEGEBAUER &GRILLER
X8663

DIE SETX-XXXXXXX-X

MANUALTOOLINGX-XXXXXXX-X

TOOL HOLDER
HAND ASSY

X-XXXXXXX-X

FOOT ASSY

X-XXXXXXX-X

RATCHETNON-RATCHETHEAD ASSY

X-XXXXXXX-X

X-XXXXXXX-X

X-XXXXXXX-X* GEBAUER & GRILLER is a trademark of its respective owners
Figure 23

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5. END OF LINE TESTING
If pressure testing is used to validate sealing function, pressure shall not exceed 7 PSI [48 kPa].

6. NOTE, CAUTION, AND DANGER STATEMENTS
NOTE
Highlights special or important informationoCAUTION
Denotes a condition which may result in product or equipment damage.
DANGER
Denotes an imminent hazard which may result in moderate or severe bodily injury.

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