Miniature Circular Plastic Connector (CPC)

Transcription

1 Mnature Crcular Plastc Connector (CPC) Applcaton Specfcaton MAR 11 All numercal values are n metrc unts [wth U.S. customary unts n brackets]. Dmensons are n mllmeters [and nches]. Unless otherwse specfed, dmensons have a tolerance of ±0.13 [±.005] and angles have a tolerance of ±2. Fgures and llustratons are for dentfcaton only and are not drawn to scale. 1. INTRODUCTION Ths specfcaton covers the requrements for applcaton of the Mnature Crcular Plastc Connector (CPC). The connector system s avalable n wre-to-wre, wre-to-board (vertcal and rght-angle), and wre-to-panel confguratons. The connector s avalable n two shell szes: Sze 8 (1-4), or Sze 11 (5-9) contact postons. The Mn-Unversal MATE-N-LOK* contacts used n these connectors are desgned to accept a wre sze range of 30 through 18 AWG and applcaton may be done by machne for reel-mounted contacts, or by hand for replacement of loose-pece contacts. Refer to Applcaton Specfcatons or for all termnaton, applcaton nformaton, and procedures for the contacts whch are used n the Mnature CPC. When correspondng wth TE Connectvty personnel, use the termnology provded on ths specfcaton to help facltate your nqury for nformaton. Basc terms and features of components are provded n.fgure 1. Optonal Rght-Angle Stran Relef and Cable Clamp Optonal Cable Clamp and Stran Relef Socket Contact Numbered Cavtes Plug Housng Wre Entry Seal Inserton Tp Jam Nut Seal Retenton Plate Algnment Dots Panel Seal Pn Contact Postve Lock Indcator Wre Entry Seal Receptacle Housng Seal Retenton Plate Perpheral Seal Algnmnent Dot Optonal Dust Cap Fgure Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company TOOLING ASSISTANCE CENTER All Rghts Reserved PRODUCT INFORMATION TE Connectvty, TE connectvty (logo), and TE (logo) are trademarks. *Trademark. Other logos, product and/or Company names may be trademarks of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at 1 of 14 LOC B

2 2. REFERENCE MATERIAL 2.1. Revson Summary Change the company logo 2.2. Customer Assstance Reference base part numbers and , and product code H314 are representatve numbers of Mnature CPC. Use of these numbers wll dentfy the product lne and expedte your nqures through a servce network establshed to help you obtan product and toolng nformaton. Such nformaton can be obtaned through a local TE representatve or, after purchase, by callng the Toolng Assstance Center or the Product Informaton number at the bottom of page Drawngs Customer Drawngs for specfc products are avalable from the responsble TE Engneerng Department va the servce network. The nformaton contaned n the customer drawngs takes prorty f there s a conflct wth ths specfcaton or wth any other techncal documentaton suppled by TE Specfcatons Applcaton Specfcatons and provde nformaton for termnaton and crmp requrements of the contacts used n these connector assembles. Product Specfcaton provdes product performance and test results Instructonal Materal The followng lst ncludes avalable nstructon sheets (408-seres) that provde assembly procedures for product, operaton, mantenance and repar of toolng, as well as setup and operaton procedures of applcators; and customer manuals (409-seres) that provdes setup, operaton, and mantenance of machnes Preparng Reel of Contacts for Applcaton Toolng Extracton Tool Straght Acton Hand Tool Inserton Tool Checkng Termnal Crmp Heght or Gagng De Closure Inserton Tool Heavy Duty Mnature Quck-Change Applcators (Sde-Feed Type) Heavy Duty Industral (HD-I) Sde-Feed Type Applcators Ocean Sde-Feed Applcators Fne Adjust Assembly [ ] for Heavy Duty Industral (HD-I) Type Applcators CERTI-CRIMP* II Straght Acton Hand Tools and Crmp Qualty Montor Applcators for Sde-Feed and End-Feed Applcatons Handlng of Reeled Products PRO-CRIMPER* III Hand Crmpng Tool Frame Assembly PRO-CRIMPER III Hand Tool Assembly wth De Assembly PRO-CRIMPER III Hand Tool Assembly wth De Assembly PRO-CRIMPER III Hand Tool Assembly wth De Assembly of 14

3 Basc AMP-O-LECTRIC* Model "K" Termnatng Machnes, and Accessores AMP-O-LECTRIC Model "G" Termnatng Machnes [ ] AMPOMATOR* CLS III-G Lead Makng Machne [ ] AMPOMATOR CLS IV Lead Makng Machne [ ] AMPOMATOR CLS IV+ Lead-makng Machne [ ] AMP-O-MATIC* Sde Feed Strpper-Crmper III Machne [ ] AMP-3K/40* Termnatng Machne [ ] and AMP-5K/40* [ ] Strppng Modules and Strppng Modules and REQUIREMENTS 3.1. Safety Do not stack product shppng contaners so hgh that the contaners buckle or deform Storage A. Reeled Contacts When usng reeled contacts, store col wound reels horzontally and traverse wound reels vertcally. B. Ultravolet Lght Prolonged exposure to ultravolet lght may deterorate the chemcal composton used n the connector materal. C. Shelf Lfe The contacts and connectors should reman n the shppng contaners untl ready for use to prevent deformaton to components. The components should be used on a frst n, frst out bass to avod storage contamnaton that could adversely affect performance. D. Chemcal Exposure Do not store the contacts or connectors near any chemcal lsted below as they may cause stress corroson crackng n the components. Alkales Ammona Ctrates Phosphates Ctrates Sulfur Compounds Amnes Carbonates Ntrtes Sulfur Ntrtes Tartrates Where the above envronmental condtons exst, phosphor-bronze contacts are recommended Materals The wre entry seals are made of yellow or whte elastomer, the perpheral seal s made from gray elastomer. The housng, couplng rng, and seal retenton plate are made from black thermoplastc, the jam nut s made from nckel plated brass. The contacts are avalable n ether a pre-tnned duplex fnsh plated wth gold n the matng areas and tn-lead plated n the crmpng area over nckel underplate on entre contact. The sockets are also avalable n brass or phosphor bronze. 3 of 14

4 3.4. Characterstcs The wre entry seals are color-coded for dentfcaton of the correct wre nsulaton range. The connectors have a pre-postoned 1/4 turn couplng rng wth postve lock and algnment feature. As the couplng rng on the plug s threaded onto the receptacle t engages the postve lock. A slght turn beyond that pont locks the connector together. The unque contact pattern for each poston sze helps prevent accdental matng wth other poston szes. Connector housngs wth recessed matng faces have polarzng slots and those wth flush matng faces have polarzng embossments to assure proper matng of crcuts. Front or rear jam nut mountng s avalable, and alternate keys are avalable. No keyng plugs are requred snce specfc cavty amounts from 1 to 9- postons are avalable. See Fgure Component Selecton Each connector must be used wth specfc seals and related components to ensure a sealed assembly for the requred applcaton. Matng connectors must have dentcal number of postons. A cross-reference of connector-to-seal and connector-to-connector s lsted n Fgure 2. SHELL SIZE PLUG HOUSING RECEPT ASSY RECEPT ASSY (PANEL MOUNT) PANEL SEAL STRAIGHT STRAIN RELIEF RIGHT ANGLE DUST CAP JAM NUT SOCKET INSRTN TIP [ ] [ ] [ ] [ ] [ ] [ ] Open Style Wth Cover 3.6. Crcut Identfcaton Fgure 2 Contact cavtes are numbered on the plug and receptacle assembly on the wre entry and matng face of the housng. See Fgures 1 and Wre Selecton and Preparaton A. Type The wre sze range for Mnature CPC s 30 to 18 AWG stranded wre wth an nsulaton dameter range of [ ]. See Fgure 3. 4 of 14

5 B. Preparaton Strp the wres accordng to the dmensons gven n Fgure 3. CAUTION Reasonable care should be taken not to nck, scrape, or cut any strands durng the strppng operaton.! Strp Length Conductor Insulaton WIRE SIZE RANGE STRIP LENGTH CRIMP HEIGHT [ ] Refer to the documentaton suppled wth the applcaton toolng provded n SECTION 5 of ths document or n Applcaton Specfaton(s) or Contact Termnaton Fgure 3 Strp form contacts are desgned to be crmped wth a mnature applcator n a sem-automatc or automatc machne. Loose pece contacts are desgned to be crmped wth a hand crmpng tool. Refer to the table n Fgure 10 for the approprate hand tools, applcators, and machnes. Refer to Paragraph 2.5, Instructonal Materal, for nformaton on crmp toolng and nstructons. Termnate the contacts accordng to the dmensons and procedures provded n Applcaton Specfcatons and , and the referenced toolng documentaton Panel Mount Layout If stran relefs are used, make sure they have been sld over the wres and out of the way before wre termnaton. Mnature CPC can be mounted to the front or back of a panel usng the layout dmensons shown n Fgure 4. Ø 16 ± 0.1 [.630 ±.004] Sze 8 Panel Mount Ø 19.2 ± 0.1 [.756 ±.004] Sze 11 Panel Mount 14.9 ± 0.1 [.587 ±.004] Fgure ± 0.1 [.726 ±.004] 5 of 14

6 3.10. Housng Assembles Plug and receptacle housng assembles are avalable n Sze 8 (4-poston), or Sze 11 (9-poston) confguratons. Fgure 5 shows these housngs and numbered cavtes for contacts. Sze 8 Connectors Plug Assembly Receptacle Assembly Matng End Wre End Matng End Wre End Sze 11 Connectors Plug Assembly Receptacle Assembly Matng End Wre End Matng End Wre End Installng Contacts nto Housng Fgure 5 Locate the desred crcut nto whch the ndvdual contact wll be loaded, (refer to the crcut cavty numbers on the seal retenton plate). The pn contact s nserted nto the receptacle housng and the socket contact s nserted nto the plug housng. The contact must be nserted through the gland n the wre entry seal, thereby puncturng the gland and nto the contact cavty from the wre end of the plug or receptacle housng untl t bottoms (there should be an audble "clck"). Each contact must be locked nto place. Gently pull on the wre to ensure proper contact lockng. TE recommends usng a socket nserton tp, (Part Number ), to nsert the socket contacts nto the plug housng wth small nsulaton dameters of [ ]. The nserton tp prevents the matng end (blunt end) of the socket contact from beng damaged when nserton nto the seal s made. Once the contact s fully seated, the nserton tp s removed from the front of the connector and reused for the remanng socket contacts. Refer to Fgure 6. The nserton tp s nserted nto the socket body pror to nsertng the socket contact nto the seal. Normally an nserton tool s not requred to nsert contacts nto housngs. However f the contact and fral wres need some assstance, the use of an nserton tool s recommended. Refer to the nformaton provded on Instructon Sheet 7984 for contact nserton usng Inserton Tool of 14

7 3.12. Stran Relef If wre at the rear of the housng s subjected to stran, then stran relef kts are avalable for each connector sze. Each ncludes a stran relef housng and two clamps. They can be attached to free-hangng or panel-mounted plug and receptacle connectors, and they can be placed on the cable before or after crmpng contacts to the conductors; however, the stran relef must be placed on the cable before the contacts are nserted nto the housng. After all the contacts have been nserted nto ther respectve housng, slde the stran relef body up the cable and thread t onto the back of the connector before the clamp s secured. Select the proper lockng nsert clamp based on cable dameter and press n nto the stran relef body untl t locks n place wth the desred clampng force. See Fgure 7. Pn Contact Wre Entry Seal Wre Entry Seal Socket Contact wth Inserton Tp Seal Retenton Plate Seal Retenton Plate Receptacle Housng Plug Housng Fgure 6 Plers may be requred to push the lockng nsert nto the stran relef body to the desred clampng locaton. Stran Relef Threaded to Back of Connector Correctly Szed Cable Clamp Locked n Place Fgure 7 7 of 14

8 3.13. Wre Dress If a stran relef s used on the connector, the wres may be dressed to an angle at the end of the stran relef. However, wthout use of a stran relef, the wres should not be dressed closer than 2.50 nches from the back of the housng. To prevent damage to contacts and/or housng, avod exertng stress on wre. If necessary, wres can be bundled together and supported wth cable tes or smlar devce. Wres must not be stretched or confned n any way. Therefore, the wres must reman perpendcular to the connector and avod an excessvely sharp bend radus. The mnmum dstance for the cable te off, measured from the housng at the wre end of the connector to the cable te s shown n Fgure 8. It s also recommended that ndvdual wres be dressed to a bend radus of at least ten tmes the wre outsde dameter. Lkewse, cable bundles should be dressed to a bend radus of at least ten tmes the dameter of the bundle. Wre Support Fxture Te-Off Back of Connector Connector Matng Fgure 8 When matng the plug and receptacle connector, make sure the algnment dots are algned pror to matng the connectors. Ths ensures proper algnment and matng wthout damage to the connectors. See Fgure 9 Receptacle Housng Plug Housng Algnment Dot Algnment Dots Fgure 9 8 of 14

9 3.15. Repar/Removal If a damaged contact s apparent before the contacts are nserted nto the housng, cut the wre n back of the contact, strp the wre end, and apply a new contact on the wre. Contacts are not reparable once a termnaton has been made. Any defectve contact should be removed and replaced wth a new one. Connector housngs, retenton plate seals, wre entry seals, panel seals, or cavty plug seals are not reparable. Any damaged or defectve component MUST NOT be used. The followng procedures should be observed when dsassemblng the Mnature CPC for contact removal or termnaton: 1. Remove wre entry seal lockng plate by usng a small, flat blade screwdrver to dsengage the seal retenton plate from the connector housng. 2. Use the same screwdrver to unseat the wre entry seal from the connector housng. The screwdrver s pushed down between the seal and the connector housng, then pred loose. Care should be taken not to tear the seal. 3. Slde the seal back along the wres. 4. Extract the contacts usng Extracton Tool Refer to Instructon Sheet Cut off the contact to be replaced, and re-termnate a new contact. 6. Insert the contacts back n the correct respectve crcuts. 7. Slde the seal back down the wres and seat t nto the connector housng. The screwdrver can be used to push the seal edges down to ensure proper seatng. 8. Replace the seal retenton plate by snappng t nto the slots n the connector housng. 4. QUALIFICATIONS Mnature CPC have been Recognzed by Underwrters Laboratores, Inc. (UL) n Fle E28476, and have been Investgated to CSA Internatonal Standards by UL. 5. TOOLING Ths secton provdes a selecton of tools for varous applcaton requrements. Modfed desgns and addtonal toolng concepts may be avalable to meet other applcaton requrements. For addtonal nformaton, contact one of the servce groups at the bottom of page 1. A lstng of toolng recommendatons coverng the full wre sze range s provded n Fgure 10. TE toolng engneers have desgned machnes for a varety of applcaton requrements. For assstance n settng up prototype and producton lne equpment, contact TE Toolng Engneerng through your local TE representatve or call the Toolng Assstance Center number at the bottom of page Hand Crmpng Tool Hand crmpng tools that accommodate the full wre sze range are desgned for prototype and low-volume applcatons such as repar of damaged contacts Applcator Applcators are desgned for the full wre sze range of strp-fed, precson formed contacts, and provde for hgh volume, heavy duty, producton requrements. The applcators can be used n bench or floor model power unts. Each applcator s shpped wth a metal dentfcaton tag attached. DO NOT remove ths tag or dsregard the nformaton on t. Also, a packet of assocated paperwork s ncluded n each applcator shpment. Ths nformaton should be read before usng the applcator; then t should be stored n a clean, dry area near the applcator for future reference. Some changes may have to be made to the applcators to run n all related power unts. Contact the Toolng Assstance Center number located at the bottom of page 1 for specfc changes. 9 of 14

10 5.3. Power Unts A power unt s an automatc or sem-automatc devce used to assst n the applcaton of a product. Power unt ncludes the power source used to supply the force or power to an applcator Inserton/Extracton Toolng Inserton Tools are desgned for contacts crmped to small fragle wre. They are desgned to stablze the contact durng nserton. For use of Inserton Tool whch may be used wth these contacts, refer to Instructon Sheet ; or Inserton Tool , use Instructon Sheet Extracton Tools are desgned to release the lockng lance nsde the connector housng wthout damagng the housng or contacts. For use of Extracton Tool whch may be used wth these contacts, refer to Instructon Sheet Inserton Tool or Typcal PRO-CRIMPER III Hand Crmpng Tool wth Des Extracton Tool SAHT and SAHT Fgure 10 (Cont d) 10 of 14

11 AMP-3K/5K and [ ] wth Optonal Strppng Module Fgure 10 (Con td) 11 of 14

12 WIRE SIZE RANGE, AWG INSULATION DIAMETER APPLICATOR POWER UNIT HAND TOOL INSERTION TOOL EXTRACTION TOOL , -3 ( ) ( ) ( ) [ ] ( ) , -2 ( ) ( ) , -4 ( ) ( ) or ( ) ( ) or ( ) ( ) ( ) [ ] ( ) [ ] ( ) , -3 ( ) , -3 ( ) [ ] ( ) ( ) , -2 ( ) ( ) , -4 ( ) ( ) or ( ) , -4 ( ) ( ) , -3 ( ) [ ] ( ) ( ) ( ) ( ) or ( ) ( ) or ) ( ) ) ( , -4 ( ) Fgure 10 (Cont d) 12 of 14

13 WIRE SIZE RANGE, AWG INSULATION DIAMETER APPLICATOR POWER UNIT HAND TOOL INSERTION TOOL EXTRACTION TOOL ( ) [ ] ) [ ] ( ) , -3 ( ) ( ( ) ( ) ( ) , -3 ( ) [ ] , -6, -71, and -76 ( ) ( ) ( ) ( ) or ( ) ( ) or ) ( ) , -72 ( ) [ ] ) [ ] ) , -3 ( ) , -6, -71, and -76 ( ) ( ) ) [ ] ($ ) [ ] ( ) Fgure 10 (End) 13 of 14

14 6. VISUAL AID Fgure 11 shows a typcal applcaton of a Mnature CPC. Ths llustraton should be used by producton personnel to ensure a correctly appled product. Applcatons whch DO NOT appear correct should be nspected usng the nformaton n the precedng pages of ths specfcaton and n the nstructonal materal shpped wth the product or tooln FIGURE 11. VISUAL AID 14 of 14