408-7859 [TE]
Audio/Microphone Connectors;
| 型号： | 408-7859 |
| 厂家： | 
TE CONNECTIVITY |
| 描述： | Audio/Microphone Connectors |
| 文件： | 总11页 (文件大小：252K) |
| 中文： | 中文翻译 | 下载： | 下载PDF数据表文档文件 |
Application Specification
114-10011
Audio/Microphone Connectors
18 Mar 11 Rev C
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 the application of Audio/Microphone Connectors. The connectors
are designed to accept a wire size range of 18 through 28 AWG and are available in 4, 5, or 6 position. The
receptacle connector is panel mounted. Application may be done by machine for reel--mounted contacts and
by hand for replacement loose piece contacts.
‘When corresponding with TE 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.
Socket Contact
Mounting Fins
Polarizing Rib
(On Mating Face)
Locking Collar
Strain Relief
Collets
Engagement
Groove
Front (Ref)
Antirotation
Key
Locking Latch
Pin Contact
Polarizing
Groove
6-Position Receptacle
Housing (Typ)
Locking Tab
Entry Slot
Locking Tab
Plug Insert
Numbered
Contact
Cavities
Latch Slot
Alignment
Groove
Detent
Plug Body
Flexible Cable Guard
Figure 1
E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change.
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All Rights Reserved
PRODUCT INFORMATION 1--800--522--6752
For latest revision and Regional Customer Service,
visit our website at www.te.com
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks.
*Trademark. Other logos, product and/or Company names may be trademarks of their respective owners.
LOC B
114-10011
2. REFERENCE MATERIAL
2.1. Revision Summary
This paragraph is reserved for a revision summary of the most recent additions and changes made to this
specification which include the following:
S Updated document to corporate requirements.
2.2. Customer Assistance
Reference Part Number 207313 and Product Code 4989 are representative numbers of Audio/Microphone
Connectors. Use of these numbers 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 a local TE Representative or, after purchase, by calling the Tooling Assistance Center or Product
Information numbers at the bottom of page 1.
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. The information
contained in 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--10032 is available to provide test and performance results.
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 provides setup, operation, and maintenance of machines.
Document Number
Document Title
408--3295
408--4392
408--7347
408--7424
408--7819
408--7859
408--7901
408--8040
408--9816
409--5128
409--5842
409--5855
409--5866
Preparing Reel of Contacts for Application Tooling
Hand Crimping Tool 90715--1
Insertion Tools 91002--1 and --2
Checking Terminal Crimp Height or Gaging Die Closure
Audio Instrument Connectors
Extraction Tool 91136--1
Hand Crimping Tool 90363--1
Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type)
Handling of Reeled Products
Basic AMP--O--LECTRIC* Model “K” Terminating Machines, and Accessories
AMP--O--LECTRIC Model “G” Terminating Machine 354500--[ ]
AMP--O--MATIC* Side Feed Stripper--Crimper Model II Machine No. 854040--3 and --4
AMPOMATOR* CLS IV Lead--Making Machine 217500--[ ]
3. REQUIREMENTS
3.1. Storage
A. Reeled Contacts
When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically.
B. Shelf Life
The contacts and housings 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.
C. Chemical Exposure
Do not store contacts or housings near any chemicals listed below, as they may cause stress corrosion
cracking in the components.
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Rev C
114-10011
Alkalies
Amines
Ammonia
Carbonates
Citrates
Nitrites
Phosphates Citrates
Sulfur Nitrites
Sulfur Compounds
Tartrates
D. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housings.
3.2. Special Characteristics
These Audio/Microphone connectors include a panel mounted receptacle connector and a free--hanging plug
connector. The receptacle connector consists of a receptacle housing and the specified number of socket
contacts. The housing features a locking collar, two locking tab entry slots, an antirotation key, and four
mounting fins.
The plug connector consist of a plug insert, a plug body, and the specified number of pin contacts. The insert
features two cable strain relief collets, a locking latch, an alignment groove, and an engagement groove. The
body features two locking tabs, a latch slot, a detent, and a flexible cable guard.
Each receptacle has a polarizing groove and each plug insert has a polarizing rib to ensure proper mating.
Contact cavities are numbered on the BACK of each connector to provide circuit identification. See Figure 1.
3.3. Panel Mounting Requirements
Audio/Microphone Connectors are designed for a combination of free--hanging and rear panel mount
application. For dimensions and layout design, refer to Figure 2.
17.78
[.700]
Panel Thickness
1.47-1.78
[.058-.070]
1.02 [.040]
3.18 [.125]
Figure 2
3.4. Wire Selection and Preparation
A. Type
The wire size range for Audio/Microphone Connectors is 18 through 28 AWG and may be solid or
stranded.
Contacts which accept a wire size range of 18 -20 AWG are special large conductor contacts which only fit into
customer -supplied audio/microphone connectors.
NOTE
i
B. Preparation
Prior to stripping the discrete wires, remove 20.65 mm [.813 in.] of the cable jacket.
NOTE
i
Rev C
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114-10011
The discrete wires must be stripped to the dimension provided in Figure 3.
Do not nick, scrape, or cut the wire conductor during the stripping operation.
CAUTION
!
Discrete Wire
Strip Length
Wire
Insulation
WIRE BARREL
INSULATION BARREL
INSULATION
DIAMETER
WIRE SIZE,
AWG
STRIP
LENGTH
CRIMP HEIGHT
CRIMP WIDTH
CRIMP HEIGHT
CRIMP WIDTH
3.18--3.94D
[.125--.155]
0.97--1.07
18
20
[.038--.042]
3.56--4.32[
[.140--.170]
2.03--2.54
[.080--.100]
1.52--1.75
[.060--.069]
2.74--3
[.108--.118]
3.18--3.94D
[.125--.155]
ADJUSTABLE
(Barrel Should
Grip Insulation
Without Cutting
Into It)
0.81--0.91
[.032--.036]
3.56--4.32[
[.140--.170]
0.64--0.74
22
24
[.025--.029]
0.521--0.660
[.0205--.0260]
0.91--1.37
[.036--.054]
1.27--1.52
[.050--.060]
1.45--1.7
[.057--.067]
3.58--4.34U
[.141--.171]
0.51--0.61
[.020--.024]
26--28
DAutomatic Machine Crimp Dimensions, [Hand Tool Crimp Dimensions, UBoth Machine and Hand Tool Crimp Dimensions
Figure 3
3.5. Crimped Contact Requirements
Locate the contact to be crimped in the appropriate tooling according to the instructions packaged with that
tooling. Detailed instructions covering the placement of contacts in the tooling and the use of such tooling is
packaged with each tool.
Terminate the contact according to the directions shipped with the appropriate tooling. See Section 5,
TOOLING.
Wire insulation shall NOT be cut or broken during the crimping operation, nor shall the insulation be crimped into the
contact wire barrel. Reasonable care should be taken by tooling operators to provide undamaged wire terminations.
CAUTION
!
A typical receptacle contact as it should appear after crimping is shown in Figure 4. These requirements apply
equally to the pin contact.
A. Crimp Height
The crimp applied to the wire portion of the contact is the most compressed area and is most critical in
ensuring optimum electrical and mechanical performance of the crimped contact. The crimp height must
be within the dimensions provided in Figure 3.
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Rev C
114-10011
B. Crimp Length
For optimum crimp effectiveness, the crimp must be within the area shown in Figure 4. Effective crimp
length shall be defined as that portion of the wire barrel, excluding bellmouth(s), fully formed by the
crimping tool. Instructions for adjusting, repairing, and inspecting tools are packaged with the tools. See
Figure 10.
C. Bellmouths
Front and rear bellmouths shall be evident and conform to the dimensions given in Figure 4.
D. Cutoff Tab
The cutoff tab shall be cut to the dimensions shown in Figure 4.
E. Burrs
The cutoff burr shall not exceed the dimensions shown in Figure 4.
F. Wire Barrel Flash
The wire barrel flash shall not exceed the dimensions shown in Figure 4 in Section X--X.
G. Wire Location
After crimping, the wire conductor and insulation must be visible in the transition area between the wire
and insulation barrels.
H. Conductor Location
The conductor may extend beyond the wire barrel to the maximum shown in Figure 4.
I. Wire Barrel Seam
The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam.
Conductor Extension
0.51 [.020] Max
Wire Insulation and
Conductors Must Both
Be Visible in This Area
Wire Barrel Seam
Effective Crimp Length
Front Bellmouth
0.20 [.008] Max
Rear Bellmouth
0.18-0.30 [.007-.012]
X
X
No Damage or Distortion to the
Contact or the Locking Lance
Cutoff Tab Must Be
Visible - See View A
Wire
Barrel Flash
Wire Barrel
Crimp Width
Wire Barrel
Crimp Height
0.13 [.005]
Max. Burr
0.25 [.010] Max.
Wire Barrel
Flash
View A
Cutoff Tab 0.25
[.010] Max
Section X-X
Figure 4
Rev C
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114-10011
J. Twist and Roll
There shall be no twist, roll, deformation or other damage to the mating portion of the crimped contact that
will prevent proper mating. See Figure 5.
0_
Wire Barrel
Front of
Contact
(Pin or Socket)
Figure 5
K. Straightness
The force applied during crimping may cause some bending between the crimped wire barrel and the
mating portion of the contact. Such deformation is acceptable within the following limits.
1. Up and Down
The crimped contact, including cutoff tab and burr, shall not be bent above or below the datum line
more than the amount shown in Figure 6.
0.25 [.010] Max
Datum Line
0.25 [.010] Max
NOTE: Angles are drawn for clarification only and are not to scale.
Figure 6
2. Side to Side
The side--to--side bending of the contact may not exceed the limits provided in Figure 7.
Periodic inspections must be made to ensure crimped contact formation is consistent as shown.
NOTE
i
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Rev C
114-10011
0.25 [.010] Max
0.25 [.010] Max
Figure 7
3.6. Housings
Housings are available in 4, 5, or 6 circuit positions for your production requirements. Figure 8 shows the
housing configurations. The housings are made from black thermoplastic.
4 -Position
5 -Position
6 -Position
Locking Tab
Entry Slot
Mounting Fins
Numbered Cavities
Antirotation Key
Figure 8
Rev C
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114-10011
3.7. Assembly Procedures
Instruction Sheet 408--7819 provides specific assembly procedures. Figure 9 shows how the product fits
together. Insertion Tool 91002--[ ] may be used to help insert terminated wires and contacts into the housings if
needed. Refer to Instruction Sheet 408--7347.
Locking Tab
Entire Length of Collets
Must Grip Cable Jacket
Cable
Plug
Insert
Detent
Contacts Inserted Into
Back of Plug Insert
Alignment Groove
Polarizing Rib
Mounting
Fins
After Mating,
Turn Clockwise
to Tighten
Locking Tab Slot
Panel
Discrete Wires
Figure 9
3.8. Repair/Replacement
If a damaged contact is apparent before the contacts are inserted into the housing, cut the wire in back of the contact
and reterminate the wire end. If contacts or housing are damaged after insertion, the wire must be cut directly in back
of the housing and reterminated with new contacts and housing. See Section 5, TOOLING.
CAUTION
!
Contacts are not repairable once a termination has been made. Any defective contact should be removed and
replaced with a new one. Damaged contacts can be removed from the housing by using Extraction Tool
91136--1. Refer to Instruction Sheet 408--7859 for extraction procedures.
4. QUALIFICATION
Audio/Microphone Connectors are not required to be agency approved.
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Rev C
114-10011
5. TOOLING
Figure 10 provides tool part numbers and instructional material related to wire size.
TE Tool Engineers have designed machines for a variety of application requirements. For assistance in setting up
prototype and production line equipment, contact TE Tool Engineering through your local TE Representative or call the
Tooling Assistance Center number at the bottom of page 1.
NOTE
i
S Hand Crimping Tool
Hand crimping tools that accommodate the full wire size range are designed for prototype and
low--volume applications such as repair of damaged contacts.
S Applicator
Applicators are designed for the full wire size range of strip--fed, precision formed contacts, and provide
for high volume, heavy duty, production requirements. The applicators can be used in bench or floor
model power units.
Each applicator is shipped with a metal identification tag attached. DO NOT remove this tag or disregard the
information on it. Also, a packet of associated paperwork is included in each applicator shipment. This information
should be read before using the applicator; then it should be stored in a clean, dry area near the applicator for future
reference. Some changes may have to be made to the applicators to run in all related power units. Contact the Tooling
Assistance Center number located at the bottom of page 1 for specific changes.
NOTE
i
S Power Units
A power unit is an automatic or semi--automatic device used to assist in the application of a product.
Power unit includes the power source used to supply the force or power to an applicator.
The Model “K” AMP -O -LECTRIC Terminating Machine PN 565435 -5 has been superseded by the Model “G”
Terminating Machine PN 354500 -1 (409 -5842) for new applications. For existing applications, the Model “K” is still
recommended because of the large number of installed machines.
NOTE
i
S Insertion Tools
Insertion Tools are designed for contacts crimped to small fragile wire. They are designed to stabilize the
contact during insertion.
S Extraction Tools
Extraction Tools are designed to release the locking lance inside the connector housing without
damaging the housing or contacts.
INSULATION
DIAMETER
WIRE SIZE,
AWG
APPLICATOR
(DOCUMENT)
POWER UNIT
(DOCUMENT)
HAND TOOL
(DOCUMENT)
680402--1 (408--8040)
680402--2 (408--8040)
680402--3 (408--8040)
466644--3 (408--8040)
217500--[ ] (409--5866)
565435--5 (409--5128)
354500--1 (409--5842)
354500--[ ] (409--5842)
565435--5 (409--5128)
354500--1 (409--5842)
354500--[ ] (409--5842)
854040--3 (409--5855)
2.03--2.54
90715--1
18--20
22--28
[.080--.100]
(408--4392)
0.91--1.37
[.036--.054]
90363--1
(408--7901)
466644--4 (408--8040)
466966--1 (409--5855)
Figure 10 (cont’d)
Rev C
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114-10011
Insertion Tool
91002 -1 and -2
(408 -7347)
Hand Crimping Tool
90715 -1 (408 -4392) or
90363 -1 (408 -7901)
Extraction Tool
91136 -1 (408 -7859)
Typical Heavy Duty
Mini -Applicator
(408 -8040)
AMPOMATOR CLS IV
Lead -Making Machine
217500 -[ ] (409 -5866)
AMP -O -LECTRIC Model “G”
Terminating Machine 354500 -1
(409 -5842)
AMP -O -LECTRIC Model “K”
Terminating Machine 565435 -5
(409 -5128)
AMP -O -MATIC
Stripper -Crimper Machine
854040 -3 (409 -5855)
Figure 10 (end)
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Rev C
114-10011
6. VISUAL AID
Figure 11 shows a typical application of an Audio/Microphone Connector. 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.
MATING END MUST
NOT BE DAMAGED
WIRE CONDUCTORS AND
INSULATION BOTH VISIBLE
IN THIS AREA
PLUG AND RECEPTACLE
CONNECTOR MUST NOT
BE DAMAGED
CONDUCTOR ENDS
MUST BE VISIBLE
BELLMOUTHS MUST
BE VISIBLE
NO CONDUCTOR
WIRES SHOWING IN
WIRE BARREL SEAM
MAKE SURE BOTH CONNECTORS
CONTAIN SAME NUMBER OF
POSITIONS
PULL LIGHTLY ON
MAKE SURE RECEPTACLE
HOUSING IS SECURE ON PANEL
WIRE TO MAKE
SURE CONTACTS
ARE SEATED
FIGURE 11. VISUAL AID
Rev C
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