408-7558 [TE]
This specification covers the requirements for application of CHAMP Cable Connectors;型号: | 408-7558 |
厂家: | TE CONNECTIVITY |
描述: | This specification covers the requirements for application of CHAMP Cable Connectors |
文件: | 总10页 (文件大小:258K) |
中文: | 中文翻译 | 下载: | 下载PDF数据表文档文件 |
Application Specification
CHAMP*
Cable Connectors
(Standard and Shielded)
114-6041
25 APR 11 Rev B
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and
inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2_.
Figures and illustrations are for identification only and are not drawn to scale.
NOTE
i
1. INTRODUCTION
This specification covers the requirements for application of CHAMP Cable Connectors (standard and
shielded). These requirements are applicable for hand or automatic machine installation. These CHAMP Cable
Connectors are intermateable and interchangeable with existing connectors of a similar design. The CHAMP
Connector product line is ideally suited for use in all phases of the telecommunications industry, computer
terminals, test equipment, business and copying machines, telemetering, and various equipment used in the
security industry. The standard CHAMP Cable Connectors are available in 14--, 24--, 36--, 50--, and 64--position
sizes. The shielded CHAMP Cable Connectors are available in 24--, 36--, and 50-- position sizes.
When corresponding with TE Connectivity personnel, use the terminology provided in this specification to
facilitate your inquiries for information. Basic terms and features of this product are provided in Figure 1.
Plug Connector
Assembly
Receptacle Connector
Assembly
Standard CHAMP
Connector
Housing Color Dot Code
(on back of plug and
receptacle connector)
Contact Letter Code
Locking Tabs
Shielded CHAMP
Connector
Figure 1
E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change.
1 of 10
PRODUCT INFORMATION 1--800--522--6752
For latest revision and Regional Customer Service,
visit our website at www.te.com
LOC B
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
114-6041
2. REFERENCE MATERIAL
2.1. Revision Summary
S Updated document to corporate requirements.
2.2. Customer Assistance
Reference Part Number 229974 and Product Code 1210 are representative numbers that identify the CHAMP
Cable Connectors. These numbers are used in the network of customer service to access tooling and product
application information. This service is provided by your local TE Representative or, after purchase, by calling
the Product Information number at the bottom of page 1.
2.3. Drawings
Customer Drawings for specific products are available from the responsible TE Engineering Department via the
service network. The information contained in the Customer Drawings takes priority if there is a conflict with
this specification or with any other technical documentation supplied by TE.
2.4. Specifications
Product Specification 108--6005 provides applicable performance requirements and test data relative to
CHAMP Cable Connectors.
2.5. Instructional Material
The following list includes available instruction sheets (408--series) that provide assembly procedures for
product, operation, maintenance and repair of tooling, as well as setup and operation procedures of
applicators; and customer manuals (409--series) that provide setup, operation, and maintenance procedures of
machines.
Document Number
Document Title
408--3133
408--3137
408--3159
408--3160
408--3188
408--7558
408--7559
408--7564
408--7642
408--7787
409--5411
409--5771
CHAMP Discrete Wire Tooling Assembly 231593--2
CHAMP Laminated Cable Tooling Assembly 231592--2
Strain Relief Hardware For CHAMP Connectors
Mounting Hardware For CHAMP Connectors
Shielded CHAMP 180 Connector Kits and Cover Kits
CHAMP T--Handle Wire Insertion Tool 229384--1
CHAMP Portable Hand Operated Tool (MI--1) 229378
CHAMP Cable--to--Cable and Cable--to--Panel Connectors
Palm Grip Hand Tool Kit 229764--2
Insertion/Extraction Tool 230238--1
CHAMPOMATOR* Insertion Machine
CHAMPOMATOR 3A Terminating Machine
3. REQUIREMENTS
3.1. Wire
A. Selection
Contacts are available for the wire sizes specified in the chart in Figure 2. Housing assemblies (plug/
receptacle) are also specified in Figure 2. The wires may be solid or stranded.
B. Wire Size
The color dots on the housings and the letter codes on the contacts designate wire size.
2 of 10
Rev B
114-6041
WIRE SIZEH
HOUSING COLOR
DOT CODE
CONTACT
LETTER CODE
SOLID
22
7 STRAND
22
22
Green
Brown
Blue
C
FD
B
22
24--26
-- -- --
24
26--27--28
Yellow
E
NOTES: HAll connector styles may not be available in each position and each wire size. DConnectors for
large insulation diameter wire (1.42 mm [.056 in.]) maximum.
Figure 2
C. Wire Placement
Wire must be below transition of lead--in to contact slot as indicated in Figure 3. See Figure 4 for F slot
contact wire placement.
Inserter imprint in conductor insulation acceptable to one-half of
Thinning of Insulation is
insulation wall thickness. Thinning to point where insulation
Acceptable to Point
appears translucent is acceptable.
Where Material
Appears Translucent
Strain-Relief Slot
Barrier Pad
B
B
Contact
Slot
Window Height
Insulated Conductor Must Extend
0.89 mm [.035 in.] Below Contact Slot
A
Wire Must be
Below
Transition of
Lead-In to
Contact Slot
Conductor
A
Section B -B
Section A -A
Figure 3
Rev B
3 of 10
114-6041
Strain-Relief
Slots
Distance
2
Barrier Pad
B
Window Height
3
B
Contact Slot
Section A -A
A
0.30 [.012]
Y
Wire Must Be Below
Transition Of Lead-In
To Contact Slot
Large Wire Contact Terminating Inspection
- Notes on Customer Manual 409-5411 apply
- Additional allowances are:
Terminal perpendicularity of 0.30 mm [.012 in.] to Datum -Y-.
Maximum distance after conductor termination is 3.30 mm [.130 in.].
Maximum marking of surface 0.25 mm [.010 in.] from noted edge, typical.
--- Y---
1
2
3
A
Section B -B
Figure 4
D. Wire Exposure
Insulated conductor must extend 0.89 mm [.035 in.] below contact slot.
E. Insulation Range
Insulation range for standard cable connectors should be 1.14 mm [.045 in.] maximum diameter for tools
that mass terminate conductors on one side at a time. For tools that insert one conductor per side at a
time, 1.09 mm [.043 in.] insulation diameter is the maximum. Insulation range for F slot contacts is
1.42 mm [.056 in.] maximum diameter.
F. Workmanship
Minor nicks and scrapes or saddling of the metal bridge are acceptable provided the two slots remain
parallel to each other and perpendicular to the housing. Minor plastic shaving and rolling over of barrier
pads are acceptable provided that contacts are not damaged. Shaving of barrier pads is acceptable up to
0.15 mm [.006 in.] maximum in direction of connector length. Nicks in the insulation above the connector
should not exceed one half of insulation wall thickness.
4 of 10
Rev B
114-6041
G. Inserter Imprint
Inserter imprint in conductor insulation should not exceed one half of insulation wall thickness. Thinning of
insulation is acceptable to the point where the insulation appears translucent.
3.2. Shielded CHAMP Cable Connectors
Shielded CHAMP Cable Connectors consist of contacts on 2.16 mm [.085 in.] centerlines; pre--assembled
housings with 24, 36, or 50 slotted contacts; a choice of two wire slot sizes, B or E; bail--lock or screw--lock
hardware, with metric hardware for IEEE applications; 180_ cable entry; and the same full tooling capabilities
that are used with standard CHAMP Cable Connectors.
The main design difference in shielded CHAMP Cable Connectors is the addition of small holes or windows
around the peripheral skirt of each plug housing. These holes accept the spring fingers of a two--piece
wraparound metal shield. The spring fingers interact with the contact plates on the receptacle connector and
thus provide minimal leakage and maximum shielding effectiveness.
The application requirements are basically the same (except where noted otherwise) for shielded and standard
CHAMP Cable Connectors.
3.3. Locking Hardware
Locking hardware is used to secure mating CHAMP Connectors and to prevent accidental separation. Refer to
Instruction Sheet 408--3160 for further information. See Figure 5 for the different types of locking hardware.
A. Locking Latch (CHAMP-LOK* Connector Design)
Standard CHAMP connectors (except for IEEE applications) have guide tracks and slots (on plugs) and
lead--in ramps (on receptacles) to allow the use of a metal locking clip for securing connectors.
B. Screw-Lock Hardware
Screw--lock hardware is used in applications where positive locking is required to secure connectors to pc
boards, to panels, and/or to each other. In cable--to--cable applications, two captive screws threaded into
pre--tapped holes are generally the only screw--lock requirements.
C. Bail-Lock Hardware (Standard or Bent)
Bail--lock hardware provides both locking and quick--release capabilities at both ends of mated connectors.
Flanges on CHAMP plug connectors must be open ended for all bail--lock applications. The open--end
flanges accept bail clips which are used primarily with right angle (90_) cable terminations where space is
limited.
D. J-Hook Hardware
The J--hook is a precision--formed metal bracket used as an alternate quick--fastening method for
assembly hardware. Two tabs fit into recesses in the connector housing flange for screw--fastening. The
inverted end of the J--hook snaps on the end of a mating connector, and holds it in place.
Rev B
5 of 10
114-6041
B. Screw -Lock Hardware
A. CHAMP -LOK :Locking Latch
C. Bail -Lock Hardware (Standard/Bent 90_)
D. J -Hook Hardware
Figure 5
6 of 10
Rev B
114-6041
90_ Snap -On Strain Relief Cover
180_ Snap -On Strain Relief Cover
Low -Profile Strain Reliefs (Hermaphroditic)
Figure 6
3.4. Accessories
CHAMP cable connectors are compatible with the accessories shown in Figures 6 and 7. The instructional
material listed with each accessory provides details for product selection and assembly procedures.
A. 90_ Slide-On Strain Relief Covers
90_ Slide--On Strain Relief Covers (Instruction Sheet 408--3159) are available for 50 position CHAMP
cable connectors. The covers come in three versions — 90_ tapered, 90_ straight, 90_ straight (adjustable
or ratchet style). All three versions are designed for use in cable--to--cable applications; however, the
straight (ratchet style) is recommended for use with CHAMP--LOK Connector Locking Latch 552723--1.
B. Snap-On Strain Relief Covers
Snap--on strain relief covers (Instruction Sheet 408--3159) are available in both a 90_ version and a 180_
version.
C. Low Profile Strain Relief Covers
Low profile strain relief covers (Instruction Sheet 408--3159) are used in cable--to--panel applications
where height is a concern.
D. Dust Cover
Dust covers (Instruction Sheet 408--7564) are used to protect the mating face of connectors that are NOT
mated.
Rev B
7 of 10
114-6041
Dust Covers for Plugs, Receptacles
Cable Clamp
Tapered Style
Standard Style
Standard Style with
Adjustable Clamp
(Ratchet Style)
Three Types of Slide -On Covers for 90_ Entry (50 Positions Only)
Figure 7
4. QUALIFICATIONS
CHAMP Cable Connectors are Component Recognized by Underwriters Laboratories Inc. (UL) in File E28476
and Listed in File E81956. They are also Certified by CSA International in File LR7189.
5. TOOLING (Figure 8)
For insertion or extraction of CHAMP connector contacts, use Insertion/Extraction Tool 230238 (Instruction
Sheet 408--7787). For minor termination repair work, use T--Handle Wire Insertion Tool 229384. For field
applications and low volume production, the Palm Grip Hand Tool Kit 229764--2 is recommended. For field
applications and medium volume production, the Portable Hand Operated Tool 229378 (Instruction Sheet
408--7559) is recommended. It terminates all CHAMP connectors up to 50 positions with 90_ wire dress. For
information on other portable hand--operated tools, refer to Instruction Sheet 408--7559. For termination of
laminated cables, use CHAMP Arbor Tooling System 231592--2 (Instruction Sheet 408--3137. For termination
of discrete wires, use CHAMP Arbor Tooling System 231593--2 (Instruction Sheet 408--3133). For termination
of CHAMP connectors in high volume production, use the CHAMPOMATOR Insertion Machine “Model G”
(Customer Manual 409--5411) or CHAMPOMATOR 3A (Customer Manual 409--5771).
8 of 10
Rev B
114-6041
CHAMP T -Handle Wire
Insertion Tool
229384 -1
CHAMP Palm -Grip
Insertion Tool
229451 -1
Insertion/Extraction
Tool 230238 -1
CHAMP Portable Hand
Operated Tools
Multi -Insertion
(MI -1) 229378 -[ ] and
231925 -1
CHAMP Connector Applicator
231593 -2 for Discrete Wire/
Cable Terminations
CHAMP Connector Applicator
231592 -2 for Laminated
Cable Terminations
Figure 8
Rev B
9 of 10
114-6041
6. VISUAL AID
Figure 9 shows a typical application of CHAMP Cable Connectors. This illustration should be used by
production personnel to ensure a correctly applied product. Applications which DO NOT appear correct should
be inspected using the information in the preceding pages of this specification and in the instructional material
shipped with the product or tooling.
NON-ACCEPTABLE CONTACTS
WIRE END
MUST
PROTRUDE
FROM
INSPECTION FEATURES
3
2
1
SECOND
CONTACT
BEAM
ACCEPTABLE
6
5
DEFORMATION
SLOT MUST
REMAIN
WIRE SHOULD
BE BELOW
LEAD-IN
4
PARALLEL
7
WIRE SHOULD
BE IN BOTH
SLOTS
9
8
The following conditions constitute non-acceptable terminations, and the contact should be removed and re-
placed.
1. Shoulders are bent and not parallel.
2. Shoulders are bent, bowed, and not parallel.
3. Contact is broken.
4. Strain relief slot is bent inward.
5. Strain relief slot is bent outward.
6. Strain relief slot is bent outward and contact slot is bent inward.
7. Contact is loose and bent.
8. Contact is crushed.
9. Two wires are in the same slot.
NOTE: This condition is non-acceptable
only if the slot is not specifically
designed for a two-wire application.
CONNECTORS MUST BE FULLY
MATED AND HARDWARE EVENLY
AND FIRMLY TIGHTENED
FIGURE 9. VISUAL AID
10 of 10
Rev B
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