Accessories for Circular Plastic Connectors (CPC)

Transcription

1 Accessores for Crcular Plastc Connectors (CPC) Instructon Sheet MAR 11 Sheld and Stran Relef Kt -- Straght Cable Clamp Receptacle Plug Extender Plug Back of Extender Stran Relef Clamp Self-Tappng Screw (2 Requred) Stran Relef Slot Contact Wre Bundle Sheld Matng Faces Back of Plug SHIELD AND STRAIN RELIEF KIT CLA,MP PART NUMBER TYPE QTY Standard Reversble 1 Standard Reversble 1 Large Reversble 2 Standard Reversble 2 Large Reversble 2 Standard Reversble 2 Large Reversble 2 Standard Reversble 2 Large Nonreversble 4 Large Reversble 2 Fgure 1 1. INTRODUCTION Ths nstructon sheet covers the nstallaton of CPC sheld and stran relef kts, extenders, flexble stran relef boots and grppers, jacketed cable sealng kts, sealng boots, perpheral seals, heat shrnk sealng boots, sealng caps, keyng plugs, couplng rngs, and plug flanges. Accessores are selected accordng to the connector sze. The connector sze s determned by measurng the dstance across the couplng threads - plug or receptacle - and convertng the dmenson to 16ths of an nch. For example, Sze 11 would measure 11/ 16ths of an nch across the couplng threads. Read these nstructons, and the materal packaged wth the connectors and crmp toolng, before nstallng any of the accessores. References to contacts, toolng, and nstructonal materal are ncluded n Instructon Sheet , packaged wth the connector. Dmensons are n metrc unts [wth U.S. customary unts n brackets], unless otherwse specfed. Reasons for ressue can be found n Secton 14, REVISION SUMMARY. 2. DESCRIPTION Sheld and stran relef kts, avalable n straght or rght-angle cable clamps, nclude a sheld, stran relef clamps/saddle nserts, and two self-tappng screws. These kts can be attached to the plug and/or 2011 Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company TOOLING ASSISTANCE CENTER All Rghts Reserved PRODUCT INFORMATION TE logo s a trademark. *Trademark. Other products, logos, and company names mght 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 9 LOC B

2 receptacle of free-hangng or panel-mounted connectors. Extenders are used wth sheld and stran relef (connector Sze 23 only) to put the clampng area farther away from the rear of the connector. Flexble stran relef boots and grppers are used wth jacketed cable (or frmly taped dscreet wres) to provde wre protecton and to prevent contact pullout when severe cable-angle applcatons are encountered. Jacketed cable sealng kts nclude a perpheral seal, boot-type cable seal, collar extender, and specal stran relef clamp. These kts are used wth the largesze sheld and stran relef kts Sze 23 only) on the plug and/or receptacle. Sealng boots are used to provde splashproof protecton at cable jacket and rear of plug and/or receptacle. They are NOT desgned to be used wth a sheld and stran relef kt. Perpheral seals provde splashproof protecton, serve as a buffer at the connector matng face, and can be used for hgh vbraton applcatons. The seal s recommended for use wth applcatons of other sealng accessores. Heat shrnk sealng boots are used to provde a splashproof stran relef for jacketed cable. The sealng boot contans an nner plastc shell that threads onto the rear of a plug or receptacle and an outer tubng (wth sealant) that shrnks around the cable jacket when heat s appled. Sealng caps are nstalled on the receptacle matng face to protect the receptacle from mosture and drt contamnaton when the plug s removed. Keyng plugs provde addtonal polarzaton for the connectors. The plugs are recommended for socket cavtes only. Plug flanges are used n applcatons that requre the plug half of a connector to be panel-mounted. The couplng rng, an ntegral part of the plug housng, s used to lock the connectors together. If the couplng rng should ever be damaged, t can be replaced. A specal four-lobe couplng rng s avalable (for plugs only, Sze 23) for use n applcatons where space s not crtcal, and when a more postve grp on the couplng s desred. 3. INSTALLING SHIELD AND STRAIN RELIEF KITS 3.1. Straght Cable Clamp Stran Relef Kts Refer to the table n Fgure 1 and select the approprate sheld and stran relef kt (standard or large) accordng to the connector sze and the cable (wre bundle) dameter. If the extender s to be used (connector Sze 23 only), refer to Secton 4, INSTALLING EXTENDER, and read that materal before contnung wth the followng procedures. If sealng kt s to be used, refer to Secton 6, INSTALLING JACKETED CABLE SEALING KITS, and nstall sheld and stran relef kt accordng to those procedures. For sheld and stran relef nstallaton (wthout sealng kt), proceed as follows: 1. Crmp contacts to wres accordng to nstructonal materal packaged wth crmp toolng. 2. Insert crmped contacts through BACK of sheld. Then, nsert contacts nto housng accordng to nstructons ( ) packaged wth connector. 3. Slde sheld forward and thread onto connector untl t bottoms. DO NOT overtghten. Matng the connectors before threadng sheld onto plug wll prevent rotaton of plug nsert. 4. Select an approprate sze of stran relef clamp (eg, large clamp for small bundle) from the carrer strp that holds the clamps. Clampng area s adjustable by nvertng or changng the stran relef clamps. The quantty and type of clamps suppled wth the kt are lsted n Fgure 1. Insert stran relef clamp nto stran relef slot untl t bottoms. Clamp should bottom on wre bundle and NOT on shoulder of sheld. Secure stran relef clamp wth two self-tappng screws. 5. Make sure the wre bundle s properly secured. If stran relef clamp has bottomed on shoulder, or f clamp has NOT entered slot far enough, remove t and select another clamp (See Fgure 3). After proper clamp has been nstalled, dscard remanng stran relef clamp(s). Stran Relef Kt for Sze 23 comes wth two clamps whch can be confgured as shown n Fgure 4. The clamps are self-centerng Rght-Angle Cable Clamp Stran Relef Kts Rght-angle cable clamp stran relef kts are used n tght areas where typcal straght cable clamp stran relef kts wll not ft. Refer to the table n Fgure 2 and select the approprate rght-angle sheld and stran relef kt accordng to the connector sze and the cable (wre bundle) dameter. 2 of 9

3 When workng wth rght-angle cable clamps, the stran relef clamps are referred to as saddle nserts. If the extender s to be used (connector Sze 23 only), refer to Secton 4, INSTALLING EXTENDER, and read that materal before contnung wth the followng procedures. Sheld and Stran Relef Kt -- Rght-Angle Cable Clamp Couplng Rng Cable Clam Body Subassembly Saddle Insert 5. Select an approprate sze saddle nsert (eg, large nsert for small bundle) from the carrer strp that holds the nserts. Clampng area s adjustable by nvertng or changng the saddle nserts. The quantty and of nserts suppled wth the kt are lsted n Fgure 2. Insert saddle nsert nto stran relef slot untl t bottoms. Insert should bottom on wre bundle and NOT on shoulder of sheld. Secure saddle nsert wth two self-tappng screws. 6. Make sure the wre bundle s properly secured. If saddle nsert has bottomed on shoulder, or f nsert has NOT entered slot far enough, remove t and select another nsert (See Fgure 3). After proper clamp has been nstalled, dscard remanng stran relef clamp(s). Flat Rng Rm PART NO. Fgure 2 FLAT RING USED 5-20 Screws Rght-Angle Cable Clamp Body The cable clamp body subassembly conssts of the couplng rng ad the rght-angle cable clamp body. SADDLE INSERT QTY Yes No Yes Yes 2 For sheld and stran relef nstallaton (wthout sealng kt), proceed as follows: 1. Crmp contacts to wres accordng to nstructonal materal packaged wth crmp toolng. 2. Insert flat rng nto clamp subassembly, makng sure flat rng s not twsted and fully seated on rm. 3. Insert crmped contacts through BACK of sheld. Then, nsert contacts nto housng accordng to nstructons ( ) packaged wth connector. 4. Slde cable clamp body subassembly forward and rotate body nto poston cables are to be run. Hold n poston and thread couplng rng untl tght. DO NOT overtghten. Matng the connectors before threadng sheld onto plug wll prevent rotaton of plug nsert. Wrong Back of Sheld (Typ) Wrong Clamp s Too Large Number 2 Clamp (Ref) Shoulders Bottomed Clamp s Too Small Correct Fgure 3 Excessve Space Between Shoulders [ ] (Approx) : These Vews Represent Clamps wth Fully Tghtrened Screws. 4. INSTALLING EXTENDER (Fgure 1) Extender s used n conjuncton wth the sheld relef on connector Sze 23 only. After crmped contacts are passed through sheld, they are nserted through the BACK of the extender (external threaded end) and then nto the housng. The extender threads onto the BACK of the housng and the sheld threads onto the BACK of the extender. Ths moves the stran relef area farther back on the cable so that pullng on the contacts s avoded. The use of more than one extender s not recommended. 3 of 9

4 Intermedate 1. Install boot and grpper on cable before removng cable jacket. Slde boot onto cable - flexble end frst. Slde grpper onto cable - slotted end frst. Stran Relef Clamps Self-Centerng Stran Relef Clampng Area Clampng Area Clampng Area 2. Crmp contacts to wres accordng to nstructonal materal packaged wth crmp toolng. 3. Insert contacts nto housng accordng to nstructons ( ) packaged wth connector. 4. Thread grpper onto connector. Thread boot onto grpper untl wre s tght. Do NOT overtghten. CAUTION Overtghtenng of grpper on flexble boot can fracture boot.! Mnmum Fgure 4 5. INSTALLING FLEXIBLE STRAIN RELIEF BOOTS AND GRIPPERS (Fgure 5) Refer to Fgure 5 and select the approprate boot and grpper accordng to the connector sze and the cable jacket dameter. Back of Connector Cable Jacket Grpper (Slotted End) CABLE JACKET OUTSIDE DIE 6.35 Max. [.250 Max.] [ [ ] Fgure 5 GRIPPER PART NO. BOOT PART NO Maxmum Boot (Flexble End) Some threads on grpper may be exposed on larger dameter wre. Matng the connectors before threadng grpper and boot onto plug wll prevent rotaton of plug nsert. 6. INSTALLING JACKETED CABLE SEALING KITS The jacketed cable sealng kt s used wth the large, Sze 23 sheld and stran relef kt only. Refer to Fgure 6 and select the approprate jacketed cable sealng kt accordng to the cable sze and the cable jacket dameter. Install sealng kt - wth sheld and stran relef kt - as follows: 1. Install followng tems before removng cable jacket. Thread sheld onto extender and slde unt onto cable, sheld porton frst. Assemble collar on seal, just behnd flange. Slde seal onto cable wth flange toward cable end. 2. Crmp contacts to wres accordng to nstructonal materal packaged wth crmp toolng. 3. Insert contacts nto housng accordng to nstructons ( ) packaged wth connector. 4. Poston seal (flange porton) aganst BACK of housng. Slde extender/sheld over seal and thread unt onto housng untl t s fnger tght. Then tghten unt an addtonal half-turn. Matng the connectors before threadng adapter/ sheld unt onto plug wll prevent rotaton of plug nsert. 5. Insert stran relef clamp - the one ncluded wth the sealng kt - nto stran relef slot untl t bottoms on cable. Secure clamp wth two self-tappng screws. Dscard clamps ncluded wth stran relef kt. 4 of 9

5 Receptacle Perpheral Seal Back of Housng Stran Relef Clamp (IInclu wth Sealng Kt Seal Back of Connector Sealng Rng Edge Sealng Boot Plug Cable Jacket Flange CABLE JACKET OUTSIDE DIA. Collar Extender Sheld JACKED CABLE SEALING KIT Threaded Porton Shoulder Boot Collar (Rolled Back) Outer Insulaton (Jacket) [ ] [ ] [ ] Shoulder Rng Seated on Shoulder Boot Collar Cable Jacket Fgure 6 6. Insert perpheral seal nto receptacle matng face untl seal bottoms. 7. INSTALLING SEALING BOOTS A sealng boot s used on jacketed cable only. Refer to Fgure 7 and select the approprate sealng boot accordng to the connector sze. Do NOT use sealng boot when usng sheld and stran relef kt. 1. Slde sealng boot onto cable before removng cable jacket. Make sure boot collar s toward cable end. 2. Strp jacket (outer nsulaton) to approxmately two-thrds the length of the sealng boot - a suffcent length of outer nsulaton must reman on the cable to ensure sealng when boot s nstalled. 3. Crmp contacts to wres accordng to nstructonal materal packaged wth crmp toolng. 4. Insert crmped contacts nto housng accordng to , packaged wth connector. 5. Roll boot collar back over tself - turnng collar nsde out, and slde boot over cable untl t butts aganst BACK of connector. 6. Roll collar forward and onto threaded porton of connector. Seat sealng rng edge on shoulder of connector. Fgure 7 7. A perpheral seal s recommended for splashproof protecton at the connector matng face. Refer to Secton 8, SELECTING AND INSTALLING PERIPHERAL SEAL. 8. SELECTING AND INSTALLING PERIPHERAL SEAL The perpheral seal s recommended for sealng for boot and heat shrnk sealng boot applcatons. The seal also serves as a buffer between mated connectors (sealed and unsealed applcatons). 1. Refer to Fgure 8 and select the approprate perpheral seal accordng to the connector sze. 2. Apply a bondng materal, such as Loctte Super Bonder 416, to seal to avod loss of the seal durng unmatng; then nsert seal nto receptacle matng face untl seal bottoms. 9. INSTALLING HEAT SHRINK SEALING BOOTS Refer to Fgure 9 the and select the approprate heat shrnk sealng boot accordng to the connector sze. Loctte s a trademark. 5 of 9

6 Matng Face Fgure 8 1. Before removng cable jacket, slde heat shrnk sealng boot onto cable, sealant end frst. 2. Crmp contacts to wres accordng to nstructonal materal packaged wth crmp toolng. Back of Connector Threaded Porton HEAT SHRINK BOOT Receptacle Connector Inner Plastc Shell Heat Shrnk Sealng Boot Work Toward Sealant End Fgure 9 Perpheral Seal Heat Source Sealant End HEAT SHRINK BOOT Insert contacts nto housng accordng to nstructons ( ) packaged wth connector. Cable jacket should be roughened wth sandpaper n area where sealng boot wll be appled. 4. Thread sealng boot onto BACK of connector. Matng the connectors before threadng boot onto plug wll prevent rotaton of plug nsert. 5. Use a heat source capable of delverng at least 121 C [250 F] - electrcal heat gun, propane or butane torch, oven, or heat lamp. 6. Start close to BACK of connector and work toward sealant end of boot. Apply heat evenly around crcumference of boot. CAUTION Keep heat source n moton to avod over-heatng and possbly damagng cable jacket and plastc! parts. 7. Shrnk process s complete when sealant extrudes from end of boot. 8. A perpheral seal s recommended for splashproof protecton at the connector matng face. Refer to Secton 8, SELECTING AND INSTALLING PERIPHERAL SEAL. 10. INSTALLING SEALING CAPS Refer to Fgure 10 and select the approprate sealng cap accordng to the connector sze and seres. The sealng cap s threaded onto the receptacle matng face untl the postve lock snaps nto poston. The free end of the strap can be secured to one of the mountng screws under the receptacle flange. 11. INSTALLING KEYING PLUGS Keyng plugs vary n confguraton, and the nstallaton procedures for each connector seres are dfferent. Identfy the connector seres to be keyed and proceed wth A, B, or C as follows: All keyng plugs are nserted nto connectors that are recommended for socket contacts (connectors wth flush matng face) Keyng Seres 1 Connectors (Fgure 11) Select Keyng Plug and proceed as follows: 6 of 9

7 Locate contact cavty to be keyed on FRONT (matng face) of connector. Postve Lock Mountng Screw Receptacle Keyng Seres 2 Connectors (Fgure 12) Select Keyng Plug and proceed as follows: 1..Locate contact cavty to be keyed on FRONT (matng face) of connector. 2. Algn ponted end of plug wth contact cavty. Insert plug straght nto cavty untl head of plug bottoms on connector matng face. 3. To remove keyng plug, nsert a flat-bladed tool under head of plug and pry outward. Strap Sealng Cap Front of Connector Matng Face) SERIES Fgure 10 PLASTIC STRAP SEALING CAP METAL CHAIN 11 1 & , 2, & & Head Ponted End Keyng Plug ( ) Installed Keyng Plug 9. Algn tapered end of plug wth contact cavty. Insert plug straght nto cavty untl t snaps nto poston. When properly nstalled, plug should protrude from connector matng face approxmately 0.79 [.031] 10. To remove keyng plug, nsert a sutable tool (3.18 [.125]-da max drll rod) nto BACK of keyed cavty and push plug out FRONT of connector. Front of Connector Matng Face) Keyng Plug ( ) Tapered End Fgure 11 Installed Keyng Plug (Protrudes Appox 0.79mm[.031 In.} Fgure Keyng Seres 3 Connectors (Fgure 13) 1. Locate contact cavty to be keyed on BACK (wre sde) of connector. 2. Algn cross-tp end of plug wth contact cavty. Algn lockng lances wth wder porton of cavty. Insert plug straght nto cavty untl t bottoms. Pull back lghtly to be sure plug s locked n place. It s possble to nstall plug n wrong drecton. Ths wll NOT damage connector or keyng plug. However, plug wll NOT lock n poston... and wll pull back out easly. 3. When properly nstalled, front of plug should be flush wth connector matng face, and back of plug should protrude out BACK of connector approxmately 3.2 [.125]. 4. To remove keyng plug, depress lockng lances (through FRONT of connector) and push plug out BACK of cavty. Extracton Tool can be used to extract these keyng plugs. Instructons for extracton tool use are packaged wth the tool. 7 of 9

8 Back of Connector (Wre Sde) Cross-Tp End Pry Upward Thn-Bladed Screwdrver Keyng Plug Lockng Lance Installed Keyng Plug (Protrudes Appox ]) Splnes Removng Damaged Couplng Rng Fgure Keyng Seres 4 Connectors (Fgures 13 and 11) Follow procedures for Type XII Contacts (Paragraph 11.3) and Multmate Contacts (Paragraph 11.1.) 12. REPLACING COUPLING RING The couplng rng s an ntegral part of the plug housng. In the event that t becomes damaged, or f the specal couplng rng s to be nstalled (plug only Sze 23), t can be replaced n the followng manner. It s NOT necessary to extract contacts from the plug when replacng the couplng rng Removng Couplng Rng (Fgure 14) The couplng rng can be removed ether by cuttng the rng collar or by removng 3 or 4 splnes and then sldng the rng off the FRONT of the connector. The latter method s accomplshed by nsertng a thnbladed screwdrver between splnes and pryng outward. CAUTION Use care not to damage connector threads and keys.! Installng Couplng Rng (Fgure 15) A couplng rng s nstalled by applyng even force to the outer permeter of both the connector and the couplng rng. A small wheel puller wth a recessed or open spndle s deal for ths applcaton. A properly nstalled couplng rng wll recede approxmately 3.2 [.125] beyond the matng face of the connector. Therefore, t s necessary for the spndle to be recessed or open. Fgure 14 Refer to Fgure 15 and select the approprate couplng rng accordng to the connector sze. 1. Orent couplng rng so splnes are facng connector. Slde rng over FRONT of connector as far as t wll go wthout usng force. 2. Poston tool grppers on BACK (wre sde) of connector, beng careful NOT to damage wres or threads. Poston spndle on couplng rng. 3. Take up on spndle untl components are snug, and check algnment of connector to spndle. Clearance must be avalable for connector matng face to enter spndle. 4. Tghten spndle untl couplng rng splnes spread and enter splne groove n connector. Remove tool and check that couplng rng s secure and that t rotates freely. 13. INSTALLING PLUG FLANGES (Fgure 16) Refer to Fgure 16 and select the approprate plug flange accordng to the connector sze. 1. Make cutout n panel accordng to the dmensons provded n Fgure Install the flange and plug as shown n ether Vew A or B, dependng on your applcaton. Secure flange wth four commercally avalable screws and nuts. 14. REVISION SUMMARY Snce the prevous release of these nstructons, the TE Connectvty logo has been appled. 8 of 9

9 Spndle (Must Have Recess or Openng) Tool Grpper Back of Connector Plug Flange Panel Nut (4 Reqd) Splne Groove Screw (4 Reqd) Couplng Rng Wheel Puller (Ref) Plug Installed Couplng Rng Installng Couplng Rng Fgure 15 Panel Cutout 3.05 [.12] Panel Thckness PLUG FLANGE PANEL CUTOUT DIMESNSION A B C [.844] [.969] [1.125] [1.438] Fgure [.840] [.979] [1.210] 40.9 [1.610] 3.16 [.125] 3.18 [.125] 3.81 [.150] 3.81 [.150] 9 of 9