408-160030

Instruction Sheet

21APR2021 REV B

HC-STAK25-2phi High Voltage 4-Bolt Header
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-STAK25-Header.
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.

Figure 1: Exploded View HC-STAK25, 4-Bolt Header© 2021 TE Connectivity Ltd. family of companies.
All Rights Reserved.
*Trademark

PRODUCT INFORMATION 1-800-522-6752

This controlled document is subject to change.
For latest revision and Regional Customer Service,visit our website at www.te.com.

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

Revision A - Initial release

2.2.

Customer Assistance

Revision B – Update Section 3.8 (Pogo Pin Dimensions)Base product drawing number 2343034 (4 Bolt header) and Product Code L983 represent the HC-STAK25
Header assembly. Use of this base number and product code will identify the product line and expedite yourinquiries through a service network established to help you obtain product and tooling information. Suchinformation can be obtained through a local TE Representative or, after purchase, by calling the Product
Information Center at the number at the bottom 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.

2.3.2 Reference drawings
Reference Drawing C-2379307 is available for part number relationships only and is not asaleable item. Refer to this drawing only for compatible part numbers for customer inquiry. For more
information on Reference Drawing, call PRODUCT INFORMATION at the number at the bottom ofpage 1.

2.4. Cable and Subcomponent SpecificationConductor Core

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

Outer Jacket

Figure 2: Single Conductor Cable

A. Cable Specification (HVIL Connection)
Construction:

Conductor: 0.5mm2, stranded bare copper
Outer Jacket: Cross-linked polyethylene

Voltage rating: 600V (per ISO 6722)
Temperature rating :125°C
RECOMMENDED SUBCOMPONENTSHEADER SERIES

4-Bolt HeaderPART NUMBER
3-2343034-1 OR
3-2343034-2
2359563-1
2360888-1
5-963716-3

Quantity
1122

DESCRIPTION
HC-STAK25 Header Assembly, Key-A OR
HC-STAK25 Header Assembly, Key-B
Inner Header Sub Assembly
HC-STAK 25 TAB TERMINALMQS Terminal

Table 1: TE Part numbers for cable assembly

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See the reference drawing C-2379307 for specific validated wire sizes and part numbers

3. REQUIREMENTS
3.1. Safety
Do 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 Citrates
Sulfur Nitrites

Sulfur Compounds
Tartrates

3.4. MaterialThe connector assemblies are made of thermoplastic materials and the terminals, shields, and ferrules are tinand 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.

Figure 3: Circuit Identification

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3.6. Header 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.
Step 1In the orientation shown in Figure 4, HVIL MQS pin terminals selection and preparation must be in accordancewith Customer Drawing 929453-C and application spec 114-18021.

Figure 4: Crimp the terminals to the cables

Step 2In the orientation shown in Figure 5, push the HVIL terminals into the header cavities until a tactile and audible“click” is felt and heard. Pull back slightly to confirm the terminal is latched into the primary locked position.

Figure 5: HVIL cable sub-assembly inserting in the Header assembly

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Step 3In the orientation shown below Figure 6A, Align poka-yoke slot on the inner housing, with the correspondingpoka-yoke post on the header outer housing, push the header inner assembly into the header outer assembly
until a tactile and audible “click” is felt and heard. Pull back slightly to confirm the header Inner assembly islocked to the shield.
In case the inner housing assembly is assembled to the outer housing in the wrong orientation, the poka-yoke
post on the outer will interfere and prevent full assembly as shown in Figure 6B.

Figure 6: Inner Header Assembly shown before locking & After Locking

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Step 4In the orientation shown in Figure 7A & 7B, push the tabs into the header cavities until a tactile and audible“click” is felt and heard. Pull back slightly to confirm the terminal is latched into the primary locked position.

Figure 7A: Tabs shown before locking
Insertion Forces of the weld tabs range from 60N-200N so manual assembly is difficult. The weld tabs need to
be assembled using fixtures/press to ensure proper mating/locking.

Figure 7B: Tabs in locked position

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3.7. Connector Application
A. Header Mating on the Header Plate
The following procedures provide steps to mate the high-voltage header assembly and the BatteryFlange.
Step 1
Align the header locating posts with locating holes on device as shown in Figure 8A. In case toassembly the header in the wrong orientation, the header will not allow to seat properly, and thebattery flange holes will be unaligned with the compression limiter holes as shown in Figure 8B.

Figure 8: 4-Bolt Header positioned on a device

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Step 2Torque the four M4 screws (Figure 9). The Torque recommended is 1.92-3.28Nm.

Figure 9: 4-Bolt Header fixed on battery flange
3.8. Power Contact Probe Area
For end of line continuity testing on the power contacts, the areas shown below are the preferred locations forEOL checks or probing. Any deviations to this must be approved by TE engineering.

Figure 10: Pogo pin requirement

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3.9. Keying Capability

Figure 11:4-Bolt Header Assembly Keying Capability

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3.10. Connector Mating
1.
If the assembly is shipped with the Lever and/or red Connector Position Assurance (CPA) in the closed
position, first if necessary, actuate the CPA to the open position, then open the lever to the open position asshown in Figure 12.

Figure 12: Assembly Lever and CPA Closed

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2.

Align the plug and header connectors as shown in Figure 13.
Make sure that the lever is still in the fully open position prior to engagement with the mating header.

Figure 13: 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 14. Lever may start to rotate slightly at thispoint.

Figure 14: 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 inFigure 15.

Figure 15: Lever Actuation from Open to Close

5.

Push the red CPA forward until it stops as shown in Figure 16.

Figure 16: CPA Actuation from Open to Close
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-don point is recommended. See example:Rev B

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3.11. Connector Unmating
1.

Push the red CPA forward until it stops as shown in Figure 17.

Figure 17: Lever from Close to Open2.
Rotate the lever away from the connector body until it is completely in the open position as shown inFigure 18.

Figure 18: 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 in
Figure 19.
Do not use the lever as a handle to pull the plug apart.

Figure 19: Plug and Header Unmate

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3.12. Inspecting
For the inspection, refer to the customer drawing number 2343034-C (4-Bolt header).

3.13. Other
The following table specifies the sealable loose parts.
Table 2: TE Part Numbers for saleable loose parts

RECOMMENDED SUBCOMPONENTSHEADER SERIES

4-Bolt Header

PART NUMBER

Quantity

3-2343034-1 OR
3-2343034-2
2359563-1
2360888-1
5-963716-3

1122

DESCRIPTION
HC-STAK25 Header Assembly, Key-A OR
HC-STAK25 Header Assembly, Key-B
Inner Header Sub Assembly
HC-STAK 25 TAB TERMINALMQS Terminal

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

5. VISUAL AID
Refer to the reference drawings 2379307-C for visual aid.
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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