Virginia Panel Corporation s 2100 Series/Gemini User s Manual Installations, Operations and General User s Guide Edition 2.1/April 2007
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 OBJECTIVE The following is a 2100 Series/Gemini Mass InterConnect System User s Manual. It has been written to educate the users of situations that have been cited from field experiences. Covered are the required set-up, operations and troubleshooting procedures of the Interface System. The objective of the User s Manual is to aide the user in the everyday operations of the Interface System(s) based on field and Life-Cycle Test observations. BACKGROUND Virginia Panel Corporation (VPC) has long been recognized for the design and manufacture of modular interface systems. Since developing the industry s first hybrid modular interface system in 1968, VPC has been dedicated to providing it s customers with the most effective, economical and dependable methods of interconnecting test devices. VPC possesses the experience to meet virtually all test interface product demands. A small but competitive company, VPC designs, manufactures and markets highly specialized interface test equipment. VPC products are used in conjunction with ATE by both military and commercial users. VPC s 2100 Series/Gemini Interface System provides high quality connections for all interface needs. The ability to intermix discrete wired terminations with a PCB in one system make Gemini a versatile system, giving the user flexibility to choose connections that best meet the test requirements. A variety of contacts are available in the 2100 Series including Signal, Power, Coaxial and High Frequency (up to 40 GHz). The 2100 Series/Gemini Interface System is comprised of a Receiver, Interchangeable Test Adapter (ITA), Connector Modules and/or PCB, Contacts and Patchcords. Gemini is the only system that can accommodate either discrete wired connections or a PCB, or a combination of both, in one system. WARRANTY VPC warrants that it s modular interface systems meet all design requirements. Any use of components in these systems manufactured by other suppliers will void this warranty. - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL TABLE OF CONTENTS Section 1 Module & Contact Installation/Removal Instructions 4 Section 2 Engagement of ITA with Receiver 15 Section 3 Care and Maintenance 16 Section 4 Mounting Gemini Receiver to Vertical Hinged Mounting Frames 20 Section 5 Assembly of Shelf/Horizontal Mounting Frame onto 19 Rack 21 Section 6 Edge Card Mounting Instructions 22 Section 7 Contact Assembly Instructions 24 Section 8 PWB Assembly Instructions 55 Section 9 Trouble Shooting 62 Section 10 Precautionary Notes 64 ADDENDUM-Keying Pin Kit Installation 65 ADDENDUM-ITA Protective Cover Installation 66 Section 11 2106 & 2110 User Instructions 67 Section 12 Product Cross Reference 79 Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd-
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Module Installation & Contact Removal Instructions Section 1 Pin & Socket Signal Contact Removal/Installation P/N 510 104 134 (Receiver) 64 positions P/N 510 108 101 (ITA) 64 positions P/N 510 104 136 (Receiver) 96 positions P/N 510 108 126 (ITA) 96 positions PARTS/TOOLS REQUIRED: 3/32 Allen Wrench 5/64 Allen Wrench 1/8 flat tipped screwdriver (for 510 104 149 only) Signal Contact Extraction Tool ( P/N 910 110 102) INSTRUCTIONS: Receiver 1. Remove the two Module retaining screws using a 3/32 Allen Wrench. 2. Remove the two cap securing screws using a 5/64 Allen Wrench. (or a 1/8 Flat Tipped screwdriver for P/N 510 104 149) 3. Remove the cap. 4. Place the Signal Contact Extraction Tool (P/N 910 110 (2) MODULE CAP SCREWS 102) over the Contact to be removed/replaced until the Tool touches the face of the Module - releasing the locking tab. DETAIL A. Use caution to keep the Tool perpendicular to the face of the Module to prevent damage to either the Tool or Contact. DETAIL A 5. Press downward on the Tool handle. The spring action of the Tool will extract the contact. 6. On the rear side of the Module, grasp the Contact with your fingers and hold it while removing the extration Tool. (This will avoid pulling the Contact back into the locked position.) 7. Replace the Contact, Module Cap and screws. NOTE: In order to maintain contact float, wires should CONTACTS be restrained a minimum of 2 inches from the back face of the Module by using a strain relief plate (recommended for both Receiver and ITA Modules). ITA 1. Place the Signal ITA Extraction Tool (VPC P/N 910 110 102) over the Contact to be removed/replaced until the Tool touches the face of the Module - releasing the locking tab. DETAIL A. Use caution to keep the Tool perpendicular to the face of the Module to prevent damage to either the Tool or Contact. 2. Press downward on the Tool handle. The spring action of the Tool will extract the Contact. 3. On the rear side of the Module, grasp the Contact with your fingers and hold it while removing the extration Tool. (This will avoid pulling the Contact back into the locked position.) (1) MODULE RETAINING SCREWS (3) MODULE CAP (4) EXTRACTION TOOL (5) PUSH TOOL DOWNWARD TO EXTRACT CONTACTS CAUTION: When replacing the upper portion of the two piece Module, torque both screws 3 to 4 inch pounds. Torque above 4 inch pounds can cause serious damage to Module lower portion. (3) ITA CONTACT - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation A (2) PUSH TOOL HANDLE TO EXTRACT CONTACT A CONTACT LOCKING TAB DETAIL A LOCKING TAB DETAIL A ITA MODULE Module (Receiver & ITA) Installation/Removal (1) EXTRACTION TOOL 1. Place the Module in the Receiver or ITA until the upper and lower module screws touch the mating holes in the inner frame (install modules such that Pin 1 is located at the top of the ITA/Receiver frame). 2. Using a 3/32 Allen wrench, tighten the top screw 1 to 2 full revolutions, while pushing lightly against the face of the module. 3. Maintain this pressure while tightening the bottom screw 1 to 2 full revolutions. 4. Repeat this sequence until the module is seated. Torque the screw until it is 8 to 10 inch pounds (clamping load 350 to 400 pounds). 5. To remove, loosen the top screw 1 to 2 full revolutions. Loosen bottom screw 1 to 2 full revolutions. 6. Repeat this sequence until the module is separated from the Receiver or ITA.
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Module Installation & Contact Removal Instructions Section 1 P/N 910 112 104 PARTS/TOOLS REQUIRED: Mini Coaxial/Mini Power Receiver/ITA Contact Extraction Tool (VPC P/N 910 112 104) INSTRUCTIONS: Receiver/ ITA 1. Insert the Mini Coaxial/Mini Power Receiver/ITA Contact Extraction Tool (VPC P/N 910 112 104) firmly over the contact by applying pressure with the shaft. Do not apply pressure with the handle area. 2. Apply pressure with the handle area only when the tool has slipped over the retaining ring and has collapsed the tabs (twisting the lower portion of the tool will ensure that the tabs have collapsed). See Detail A (2) PRESS DOWN TO EXTRACT CONTACT CONTACT EXTRACTION TOOL (1) PRESS DOWN UNTIL FULLY SEATED A RETAINING RING TAB DETAIL A 3. On the rear side of the module, grasp the contact with your fingers and hold it while removing the tool. This will avoid pulling the contact back into the locked position. (3) MINI POWER CONTACT (3) MINI POWER CONTACT A CONTACT RETAINING RING TAB (1) PRESS DOWN UNTIL FULLY SEATED (2) PRESS DOWN TO EXTRACT CONTACT DETAIL A Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd-
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Module Installation & Contact Removal Instructions Section 1 Mini Coaxial Module/Contact Removal Instructions P/N 510 104 120 (Receiver) 19 Positions P/N 510 108 111 (ITA) 19 Positions P/N 510 104 150 (Receiver) 76 Positions P/N 510 108 132 (ITA) 76 Positions PARTS/TOOLS REQUIRED: 0.050 Allen Wrench Mini Coaxial Contact Extraction Tool (P/N 910 112 104) 3/32 Allen Wrench INSTRUCTIONS: Receiver 1. Remove the three cap securing screws using a 0.050 Allen wrench (the module retaining screws also have to be removed). 2. Remove the cap. 3. Insert the Mini Coaxial Contact Extraction Tool (VPC P/N 910 112 104) firmly over the Contact by applying pressure with the shaft. Do not apply pressure with the handle area. 4. Apply pressure with the handle area only when the Tool has slipped over the retaining ring and has collapsed the tabs (see Detail A) (twisting the lower portion of the tool will ensure that the tabs have collapsed). 5. On the rear side of the Module, grasp the Contact with your fingers and hold it while removing the Tool. This will avoid pulling the Contact back into the locked position. *After replacing the contacts, align and re-install the cover using the three mounting screws. RETAINING RING TAB DETAIL A A (1) MODULE CAP SCREWS (4) PRESS DOWN TO EXTRACT CONTACT (2) MODULE CAP CONTACT EXTRACTION TOOL (3) PRESS DOWN UNTIL FULLY SEATED (5) MINI COAX CONTACT CAUTION: To align the cover to the receiver module, install 2 ITA mating contacts in positions 2 and 18 of the RCVR module (as shown to the right). Make sure the contacts are seated tightly into the mating contacts before tightening the screws. Use CAUTION when tightening the screws. Do not over-tighten screws. Screw torque limit is 13 +/- 1 in. oz. NOTE: In order to maintain contact float, wires should be restrained a minimum of 2 inches from the back face of the Module with a strain relief device (recommended for both Receiver and ITA Modules). ITA 1. Place the Mini Coax Extraction Tool (P/N 910 112 104) firmly over the contact to be removed/replaced by applying pressure to the shaft. (Do not apply pressure with the handle area). 2. Apply pressure with the handle area only when the tool has slipped over the retaining ring and has collapsed the tabs (twisting the lower portion of the tool will ensure that the tabs have collapsed). 3. On the rear side of the module, grasp the contact with your fingers and hold it while removing the tool. This will avoid pulling the contact back into the locked position. Module (Receiver & ITA) Installation/Removal 1. Place the Module in the Receiver or ITA until the upper and lower module screws touch the mating holes in the inner frame (install modules such that Pin 1 is located at the top of the ITA/Receiver frame). 2. Using a 3/32 Allen wrench, tighten the top screw 1 to 2 full revolutions, while pushing lightly against the face of the module. 3. Maintain this pressure while tightening the bottom screw 1 to 2 full revolutions. 4. Repeat this sequence until the module is seated. Torque the screw until it is 8 to 10 inch pounds (clamping load 350 to 400 pounds). 5. To remove, loosen the top screw 1 to 2 full revolutions. Loosen bottom screw 1 to 2 full revolutions. 6. Repeat this sequence until the module is separated from the Receiver or ITA. (2) ITA MINI COAX CONTACT RECEIVER MINI COAX CONTACT (3) MINI COAX CONTACT A (1) PRESS DOWN UNTIL FULLY SEATED (2) PRESS DOWN TO EXTRACT CONTACT (1) MODULE CAP DETAIL A CONTACT RETAINING RING TAB (3) MODULE CAP SCREWS - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Module Installation & Contact Removal Instructions Section 1 40 GHz Contact Module/Contact Removal/Installation Instructions P/N 510 104 224 (Receiver) 8 Positions P/N 510 108 169 (ITA) 8 Positions PARTS/TOOLS REQUIRED: 2.92, 3.5, or SMA connector 3/32 Allen Wrench 3/8 Wrench INSTRUCTIONS: (3) 40 GHZ CONNECTOR P/N 610102114 (2&4) BULKHEAD NUT RECEIVER MODULE Receiver and ITA 1. Attach cable to the rear of the Contact via a 2.92, 3.5, or SMA connector and torque per the connector manufacturer s recommendations. 2.92 - For applications up to 40 GHz 3.5 - For applications up to 34 GHz SMA - For applications up to 18 GHz (1) PATCHCORD 2. Remove the bulkhead nut from the front of the connector. 3. Install the connector into the module from the rear at the desired location. 4. Place the bulkhead nut back on the front of the connector and tighten to 20 in. lbs. using a 3/8 wrench. Module (Receiver & ITA) Installation/Removal 1. Place the Module in the Receiver or ITA until the upper and lower module screws touch the mating holes in the inner frame (install modules such that Pin 1 is located at the top of the ITA/Receiver frame). 2. Using a 3/32 Allen wrench, tighten the top screw 1 to 2 full revolutions, while pushing lightly against the face of the module. 3. Maintain this pressure while tightening the bottom screw 1 to 2 full revolutions. 4. Repeat this sequence until the module is seated. Torque the screw until it is 8 to 10 inch pounds (clamping load 350 to 400 pounds). 5. To remove, loosen the top screw 1 to 2 full revolutions. Loosen bottom screw 1 to 2 full revolutions. 6. Repeat this sequence until the module is separated from the Receiver or ITA. Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd-
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Module Installation & Contact Removal Instructions Section 1 75 OHM & 20 GHz Contact Module/Contact Removal/Installation Instructions P/N 510 104 249 (Receiver) 75 OHM 32 Positions P/N 510 108 179 (ITA) 32 Positions P/N 510 104 251 (Receiver) 20 GHz 32 Positions P/N 510 108 179 (ITA) 32 Positions PARTS/TOOLS REQUIRED: 20 GHz/75 OHM Receiver and ITA Contact Extraction Tool (P/N 910 112 117) 5/64 Allen wrench 3/32 Allen Wrench (1) MODULE CAP SCREWS INSTRUCTIONS: Receiver 1. Remove the two module cap screws using a 5/64 Allen wrench. 2. Remove the module cap. 3. Use the 20 GHz/75 OHM Receiver/ITA Contact Extraction Tool (VPC P/N 910 112 117) and insert firmly over the contact by applying pressure with the shaft. Do not apply pressure with the handle area. Use caution to keep the tool perpendicular to the module face to prevent possible damage to either the tool or contacts. 4. Apply pressure with the handle area only when the tool has slipped over the retaining ring and has collapsed the tabs. (Twisting the lower portion of the tool will ensure that the tabs have collapsed.) 5. On the opposite side of the module from the extraction tool, grasp the contact with your fingers and hold it while removing the extraction tool. (This will avoid pulling the contact back into the locked position.) 6. Replace the contact, module cap, and screws. ITA 1. Use the 20 GHz/75 OHM Receiver and ITA Contact Extraction Tool (P/N 910 112 117 and insert firmly over the contact by applying pressure with the shaft. Do not apply pressure with the handle area. Use caution to keep the tool perpendicular to the module face to prevent possible damage to either the tool or contacts. 2. Apply pressure with the handle area only when the tool has slipped over the retaining ring (See Detail A) and has collapsed the ring. (Twisting the lower portion of the tool will ensure that the tabs have collapsed.) 3. On the opposite side of the module from the extraction tool, grasp the contact with your fingers and hold it while removing the extraction Tool. (This will avoid pulling the contact back into the locked position.) NOTE: In order to maintain contact float, wires should be restrained a minimum of 2 inches from the back face of the Module with a strain relief method (recommended for both Receiver and ITA Modules). (5) CONTACTS (2) MODULE CAP (4) PRESS DOWN TO EXTRACT CONTACT CONTACT EXTRACTION TOOL (3) PRESS TOOL DOWN UNTIL FULLY SEATED (3) CONTACTS A A (1) PRESS DOWN UNTIL FULLY SEATED CONTACT EXTRACTION TOOL (2) PRESS DOWN TO EXTRACT CONTACT RETAINING RING DETAIL A DETAIL A CONTACT RETAINING RING Module (Receiver & ITA) Installation/Removal 1. Place the Module in the Receiver or ITA until the upper and lower module screws touch the mating holes in the inner frame. (Install modules such that Pin 1 is located at the top of the ITA/Receiver frame.) 2. Using a 3/32 Allen wrench, tighten the top screw 1 to 2 full revolutions, while pushing lightly against the face of the module. 3. Maintain this pressure while tightening the bottom screw 1 to 2 full revolutions. 4. Repeat this sequence until the module is seated. Torque the screw until it is 8 to 10 inch pounds (clamping load 350 to 400 pounds). 5. To remove, loosen the top screw 1 to 2 full revolutions. Loosen bottom screw 1 to 2 full revolutions. 6. Repeat this sequence until the module is separated from the Receiver or ITA. - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Module Installation & Contact Removal Instructions Section 1 16/16 Signal/Coax and Signal/Power Module/Contact Removal Instructions P/N 510 104 206 (Receiver) 16/16 Positions P/N 510 108 178 (ITA) 16/16 Positions P/N 510 104 243 (Receiver) 16/16 Positions P/N 510 108 210 (ITA) 16/16 Positions PARTS/TOOLS REQUIRED: 1/8 Flat Tipped Screwdriver Mini Coaxial/Mini Power Receiver/ITA Contact Extraction Tool (P/N 910 112 104) Signal Receiver/ITA Contact Extraction Tool (P/N 910 110 102) 3/32 Allen Wrench (2) MODULE CAP INSTRUCTIONS: Receiver 1. Using the 1/8 flat tipped screwdriver, remove the two module cap screws. 2. Remove the module cap. 3. Place the appropriate Contact Extraction Tool (910112104 (Power & Coax) or 910110102 (Signal)) over the contact to be removed. Use caution to ensure that the tool is kept perpendicular to the module face to avoid damage to either the contact or tool. Press down until the tip of the tool has completely compressed the retaining ring tab(s) of the contact. (See Detail A and B.) 4. Apply pressure with the handle area and firmly press down on the tool until the contact is extracted. 5. On the opposite side of the module from the extraction tool, grasp the contact with your fingers and hold it while removing the extraction tool. (This will avoid pulling the contact back into the locked position.) 6. Replace the contact, module cap, and screws ITA 1. Place the appropriate Contact Extraction Tool (910112104 (Power & Coax) or 910110102 (Signal)) over the contact to be removed. Use caution to ensure that the tool is kept perpendicular to the module face to avoid damage to either the contact or tool. Press down until the tip of the tool has completely compressed the retaining ring tab(s) of the contact. (See Detail A and B.) 2. Apply pressure with the handle area and firmly press down on the tool until the contact is extracted. 3. On the opposite side of the module from the extraction tool, grasp the contact with your fingers and hold it while removing the extraction tool. (This will avoid pulling the contact back into the locked position.) (3) POWER/COAX CONTACT A (4) PRESS DOWN TO EXTRACT CONTACT (3) PRESS DOWN UNTIL FULLY SEATED (5) SIGNAL CONTACT (1) MODULE CAP SCREWS (5) POWER/COAX CONTACT Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- A B B (3) SIGNAL CONTACT (1) PRESS DOWN UNTIL FULLY SEATED RETAINING RING TAB DETAIL A RETAINING RING TAB DETAIL B RETAINING RING TAB DETAIL B RETAINING RING TAB (2) PRESS DOWN TO Module (Receiver & ITA) Installation/Removal EXTRACT CONTACT 1. Place the Module in the Receiver or ITA until the upper and lower module screws touch the mating holes in the inner frame. (Install modules such that Pin 1 is located at the top of the ITA/Receiver frame.) 2. Using a 3/32 Allen wrench, tighten the top screw 1 to 2 full revolutions, while pushing lightly against the face of the module. 3. Maintain this pressure while tightening the bottom screw 1 to 2 full revolutions. 4. Repeat this sequence until the module is seated. Torque the screw until it is 8 to 10 inch pounds (clamping load 350 to 400 pounds). 5. To remove, loosen the top screw 1 to 2 full revolutions. Loosen bottom screw 1 to 2 full revolutions. 6. Repeat this sequence until the module is separated from the Receiver or ITA. DETAIL A
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Module Installation & Contact Removal Instructions Section 1 Twin Access Contact (TAC) Receiver Twin Access Contacts (TAC) Module/Contact Removal Insructions P/N 510 133 101/102/103/104/105/106 (Receiver) Signal TAC P/N 510 133 103/104/107/108 (Receiver) Coaxial TAC, 50 OHM P/N 510 133 105/106 (Receiver) Coaxial TAC, 75 OHM P/N 510 133 103/104/107/108 (Receiver) Power TAC PARTS/TOOLS REQUIRED: 5/64 Allen Hex Wrench Phillips Head Screwdriver CAUTION DO NOT depress contacts with fingers. INSTRUCTIONS: Receiver 1. To insert Contact into Module, remove the contact retaining plate from the bottom of the module by unfastening the #2 Flat Head Phillips Screws. 2. Insert contacts into the rear of the module with the stop ring of the contact facing the back of the module. The contacts will automatically drop into alignment. 3. Replace the contact retaining plate and secure with two #2 Flat Head Phillips Screws. NOTE: The contact retaining plate must be removed prior to the extraction of the contacts. To remove the contact retaining plate, unfasten the #2 Flat Head Phillips Screws and remove the contact retaining plate. The contacts are then easily extracted by hand. RECEIVER (TAC MODULE) STOP RING OF PIN ALWAYS TOWARD RETAINING PLATE CONTACT RETAINING PLATE COMPLETED TAC MODULE TAC (Receiver) Module Installation/Removal 1. To install a module into the Receiver, place the supplied hardware (#4 socket head cap screws), in the TAC Receiver Module. 2. Place the Module in the front of the Receiver aligning the locating pins on the module with the appropriate holes in the Receiver Frame, so that the upper and lower module screws touch the mating holes on the Receiver Frame (install modules such that the numbers can be read from top to bottom, making them right side up). 3. Using a 5/64 Allen Hex Wrench, tighten the top screw 1 to 2 full revolutions, while lightly applying pressure against the face of the module. 4. Maintain this pressure while tightening the bottom screw 1 to 2 full revolutions. 5. Repeat this sequence, in order, until the module is seated. 6. As the module is being seated, watch to ensure that it does not become cocked at any time as a result of the guide pins not being properly aligned with the receiver or binding of the pins due to one screw being advanced ahead of the other more than 1 to 2 turns. If this should occur, back the screws off until the module is level, and repeat the tightening process. Torque the screw until it is 4 to 5 inch pounds. 7. To remove, unfasten using a 5/64 Allen Hex Wrench on the top and bottom screws. 10 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Module & Contact Installation/Removal Section 1 Twin Access Contact (TAC) Signal Module Contact Insertion/Removal Instructions P/N 510 133 109/110/111 (Signal Modules) P/N 510 134 101/102/103 (Signal Modules) PARTS/TOOLS REQUIRED: 5/64 Allen Hex Wrench Extraction Tool (Signal - P/N 910 110 110) INSTRUCTIONS: Contact Insertion 1. To insert Contact into Module, first terminate contact by crimping, soldering, wire-wrapping (see termination instructions in Section 7). 2. Insert terminal into module until front of contact is flush with module. 3. When installing Wiring Contacts in the Receiver Wiring Module (P/N 510 133 109/510 133 110/510 133 111), insert the contacts in from the screened side of the module. 4. When installing Wiring Contacts in the ITA Wiring Module (P/ N 510 134 101/510 134 102/510 134 103), insert the contacts from the screened side of the module as well. Contact Removal INSERTION ITA WIRING MODULE SHOWN EXTRACTION ITA WIRING MODULE SHOWN 1. To remove the Wiring Contacts, place the appropriate Extraction Tool (Signal - P/N 910 110 110), over the contact into the counter bore on the mating side of the module. 2. Press into the contact until the retaining ring is released and contact begins to emerge from the rear of the module. 3. Remove the contact by hand. NOTE: In order to maintain contact float, wires should be restrained a minimum of 2 inches from the back face of the Module by using a strain relief plate (recommended for both Receiver and ITA Modules). 910110110 910112112 CAUTION Twist Power/Coaxial and Signal Extraction Tools slightly to ensure that retaining clip ears have fully collapsed before applying pressure to handle. To avoid damage to contacts, always ensure that tool is perpendicular to Module face. Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 11
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Module & Contact Installation/Removal Section 1 Twin Access Contact (TAC) 75 OHM Coaxial Module/Contact Insertion/Removal Instructions P/N 510 133 111 (Coaxial Modules) P/N 510 133 117/118/119/120 (Coaxial Modules) P/N 510 134 103(Coaxial Modules) P/N 510 134 109/110/111/112 (Coaxial Modules) PARTS/TOOLS REQUIRED: 5/64 Allen Hex Wrench Extraction Tool (Coaxial/75 OHM - P/N 910 112 116) INSTRUCTIONS: Contact Insertion 1. To insert Contact into Module, first terminate contact by using a SMB connector. 2. Insert terminal into module until front of contact is flush with module. 3. When installing Wiring Contacts in the Receiver Wiring Module (P/N 510 133 111), insert the contacts in from the screened side of the module. 4. When installing Wiring Contacts in the ITA Wiring Module (P/N 510 134 103), insert the contacts from the screened side of the module as well. Contact Removal 1. To remove the Wiring Contacts, place the appropriate Extraction Tool (Coaxial/75 OHM - 910 112 116) over the contact into the counter bore on the mating side of the module. 2. Press into the contact until the retaining ring is released and contact begins to emerge from the rear of the module. 3. Remove the contact by hand. INSERTION ITA WIRING MODULE SHOWN EXTRACTION ITA WIRING MODULE SHOWN NOTE: In order to maintain contact float, wires should be restrained a minimum of 2 inches from the back face of the Module by using a strain relief plate (recommended for both Receiver and ITA Modules). 910112112 910110110 CAUTION Twist Power/Coaxial and Signal Extraction Tools slightly to ensure that retaining clip ears have fully collapsed before applying pressure to handle. To avoid damage to contacts, always ensure that tool is perpendicular to Module face. 12 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Module & Contact Installation/Removal Section 1 Twin Access Contact (TAC) P/N 910 112 112 PARTS/TOOLS REQUIRED: Extraction Tool (Coaxial/Power - 910 112 112) INSTRUCTIONS: Contact Removal 1. To remove the wiring contacts, place the appropriate extraction tool (Coaxial/Power - P/N 910 112 112) over the contact into the counter bore on the mating side of the module. 2. Press into the contact until the retaining ring is released and contact begins to emerge from the rear of the module. 3. Remove the contact by hand. EXTRACTION ITA WIRING MODULE SHOWN CAUTION Twist Power/Coaxial and Signal Extraction Tools slightly to ensure that retaining clip ears have fully collapsed before applying pressure to handle. To avoid damage to contacts, always ensure that tool is perpendicular to Module face. Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 13
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Module & Contact Installation/Removal Section 1 Twin Access Contact (TAC) Receiver Wiring Module and ITA Module Installation/Removal Instructions P/N 510 133 109 (380 signal wiring contacts) P/N 510 134 101 (ITA 380 signal wiring contacts) P/N 510 133 110 (228 signal wiring contacts/12 coaxial or power wiring contacts) P/N 510 134 102 (ITA, 228 positions/12 coaxial/power wiring contacts) P/N 510 133 111 (180 signal wiring contacts/10 coaxial (75 OHM) wiring contacts) P/N 510 134 103 (ITA, 180 positions, 10 coaxial (75 OHM) P/N 510 133 112 (46 coaxial or power wiring contacts) P/N 510 134 104 (ITA, 46 positions, coaxial or power wiring contacts) PARTS/TOOLS REQUIRED: 5/64 Allen Hex Wrench 3/32 Allen Hex Wrench INSTRUCTIONS: Receiver 1. Place the module on the rear of the Receiver Module aligning the locating bosses on the modules with the appropriate holes in the Receiver Module. 2. Install the modules such that the numbers can be read from top to bottom, making them right side up. 3. Insert the #2 Socket Head Cap Screws,.50 length, in the module fastening holes. 4. Using a 5/64 Allen Hex Wrench, tighten the top screw 1 to 2 full revolutions, while lightly applying pressure against the face of the module. 5. Maintain this pressure while tightening the bottom screw 1 to 2 full revolutions. 6. Repeat this sequence until the module is seated. Torque the screw until it is 4 to 5 inch pounds. 7. To remove, loosen the top screw 1 to 2 full revolutions. Loosen bottom screw 1 to 2 full revolutions. Repeat this sequence until the module is separated from the Receiver. NOTE: It is important to alternate the tightening/loosening of module screws. Receiver Screened side of Receiver Wiring Module ITA 1. To install Module into ITA, place module in the ITA with the screening facing upward. Align top of the module with the designated top of the ITA and the locating bosses on the module with the appropriate holes in the ITA. 2. The modules should be installed such that the numbers can be read from top to bottom. 3. Insert the #4 Socket Head Cap Screws, 0.50 length, in the module fastening holes. 4. Using a 3/32 Allen Hex Wrench, tighten the top screw 1 to 2 full revolutions, while pushing lightly against the face of the module. 5. Maintain this pressure while tightening the bottom screw 1 t0 2 full revolutions. 6. Repeat this sequence until the module is seated. Torque the screw until it is 8 to 10 inch pounds. To remove, loosen the screws until the module is separated from the ITA. ITA Screened side of ITA Wiring Module 14 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Engagement of ITA with Receiver Section 2 CAUTION When engaging the ID with the Receiver, caution must be taken to ensure that the ID is parallel with the Receiver upon engagement and that the ID rollers are engaged at the same time! To prevent potential injury, care should be taken to avoid wrapping fingers around the engagement handle. All power supplies for the system should be properly disconnected prior to handling. Caution should always be used when engaging, making sure that all foreign objects are removed from the system. Listed below are the required steps to be taken prior to the engagment of the ITA and Receiver. Prior to engaging an ITA with the Receiver for the first time, the user may find it to be good practice to check to see if all the Modules (ITA and Receiver) have been installed properly. This would involve the inspection of the Module ends - ensuring the even height of all Module ends relative to one-another. While checking this, the user should verify the positioning of the Modules themselves. Pin 1 should always be at the top for both ITA and Receiver Modules. It is crucial for all modules to be installed properly. Improper installation will cause damage to the Modules, and possibly to the ITA and/or Receiver. All ITA Modules have to match the Receiver Modules. This means that upon engaging, an ITA Module will mate with its respective Receiver Module (Power ITA to mate with Power Receiver, etc.). The ITA, upon being inspected, is now ready for placement on to the Receiver. The Receiver should be checked one last time for any foreign objects that may hinder the engagement. The top rollers of the ITA may then be placed onto the Receiver s built-in hangers with the handle in the closed position. The ITA may be engaged with the Receiver only if properly lined up - meaning that the ITA must be placed onto the Receiver in the upright position. Care should be taken to have the alignment guide pin on the Receiver mate with the guide slot on the ITA to ensure proper left to right alignment. The handle may now be rotated to the lowered position. Due to additional equipment being added onto the ITA, the user may find that the ITA and Receiver will not line up as described above. One reason may be that the additional weight on the ITA will cause it to pull away from the Receiver at the top. The user should apply pressure to the top of the ITA to counter the weight that is pulling the top of the ITA away from the Receiver (with the Receiver handle in the open position). The user may then carefully engage the system by raising the handle until the handle makes contact with the Receiver. Always protect the TAC contacts when the system is not in use. The contacts are protected when either the ITA or Receiver Protective Cover is engaged to the Receiver. Upon completing use of the ITA, rotate the receiver handle to the open position, remove the ITA, reinstall the protective cover and rotate the handle to the closed position. In the event of complications, such as improper alignment of Modules or the ITA, a trained technician should be notified immediately to avoid any damage to the system. This should also apply to any difficulties that may be experienced during engagement. Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 15
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Care and Maintenance Section 3 CAUTION Serious damage can be caused due to mishandling or dropping the ITA or any system parts. The Gemini Interface System has been designed to be maintenance free, yet care does need to be taken when handling the ITA. Upon receiving Interchangeable Test Adapters from VPC, it is recommended that ITA squareness is noted using the steps below to verify future squareness (such as after being mishandled or dropped). Procedure For Checking ITA Squareness When Unit Has Been Damaged or Dropped (Use procedure 1 or 2) Parts Required ITA Frame being checked Precision Square (preferably 18 ) Feeler Gage Procedure 1 (using a Surface Plate) 1. Place ITA onto a Surface Plate with the ITA Frame s top on the Surface Plate and contact side facing you as illustrated in Fig.1. 2. Slide Precision Square up to left side (P1) of ITA. 3. Place Feeler Gage at point A and B (See Fig. 1). 4. The difference between point A and point B equals the squaring. This should be done upon receipt of the ITA from the VPC factory and recorded for referencing when the ITA is subject to an out of squareness condition. Fig. 1 Procedure 2 (for checking alignment in the field) 1. Place the side of the Precision Square on the top left (P1) of the ITA with contact side facing you as in Fig. 2. 2. Place Feeler Gage at point C and D (See Fig. 2). 3. The difference between point C and point D equals the squaring. This should be done upon receipt of the ITA from the VPC factory and recorded for referencing when the ITA is subject to an out of squareness condition. Fig. 2 16 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Care and Maintenance Section 3 Micro-Switch Removal & Installation A Microswitch is used in the Gemini Receiver to determine the presence (or absence) of an ITA engaged in the system. It is usually configured so that power to the interface is turned off when there is no ITA present. An integrated Microswitch is standard on the Gemini Receiver. The Gemini Interface System has been designed to be maintenance free; however, in the unlikely event that the Microswitch needs to be replaced, please use the following VPC part number to order a replacement Microswitch: P/N 310 113 200. For removal/installation of the Microswitch, please read the following steps. CAUTION As with all electrical systems - disconnect all electrical supplies to the system prior to removal of Microswitch. Microswitch Removal/Installation: 1. Disengage the ITA from the Receiver (remove the ITA completely). 2. The Microswitch mounting hardware can be accessed through the lower slot in right slide on Receiver when the Receiver Handle is in the open position (Handle is down). 3. Remove the necessary Modules so that the Microswitch retaining screws may be accessed. 4. Unscrew the retaining screws (using a Phillips screwdriver), removing each as they are loosened (caution should be used so that the screw(s) do not fall into the system). 5. Carefully remove the Microswitch for continuity testing. For Microswitch installation, repeat steps 1-5 in reverse order. Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 17
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Care and Maintenance Section 3 System Precautions In the event of complications, such as improper alignment of Modules or the ITA, a trained technician should be notified immediately to avoid any damage to the system. This should also apply to any difficulties that may be experienced during engagement. Gemini is designed to be maintenance free. However, there are a few precautions to take in order to prolong the life of the system. CAUTION Serious damage can be caused to the TAC contacts if they are not protected when the system is disengaged. It is recommended that either the ITA or the Receiver Protective Cover is engaged to the Receiver at all times. TAC Contact Cleaning Procedures TAC Contacts may require periodic cleaning during the life of the product due to the usage cycle imposed, as well as the environmental conditions to which it is subjected. If unacceptable resistance readings occur, the contacts should be cleaned using the following procedure: Spray contacts with filtered air or inert gas to remove any loose particle contamination. Clean contact mating surfaces using isopropyl alcohol and a soft bristle brush. (Do not pour alcohol directly onto contacts, apply to brush). Respray contacts with filtered air or inert gas to dry alcohol and remove any residual lint, dust, etc... By following this procedure for both the TAC contacts and the mating surface contacts or PCB pads, the user will avoid any perforamance problems that could arise due to contamination. CAUTION Virginia Panel Corporation PROHIBITS the use of any type of contact lubricant/cleaner to be used other than the procedure listed above. Contact cleaners that contain lubricants may leave residues that will degrade the electrical performance of the TAC Contacts. 18 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Care and Maintenance Section 3 Fiber Optic Module Care The cleanliness of the Fiber Optic termini is extremely critical to maintain high performance and extended life. Modules should be cleaned before initial usage and then after any extended storage period. The dust cover should be in place at any time the ITA is not mated with the Receiver. Also, the termini should be cleansed whenever questionable readings are encountered. CAUTION Make sure all laser light sources are turned off before cleaning. Laser light can do permanent damage to your eyes. Follow manufacturer s directions on pressurized cans. Do not tip or shake can during usage. Wear safety glasses and goggles when cleaning the modules. Particles and/or alcohol could be projected into your eyes by the pressurized cleaner. Cleaning Instructions for the ITA Fiber Optic Module for Installed Termini Recommended Kit: VPC P/N 910 121 170 1. Remove the dust cover from the ITA module. 2. Use a can of optical grade pressurized duster to clean the module by thoroughly spraying the inside of the casing containing the termini. 3. Saturate a clean foam tip with optical grade alcohol and wipe the end of an individual terminus. 4. Immediately dry the terminus with a dry foam tip. 5. Repeat the alcohol cleansing process for all existing termini. 6. Clean the inside of the module cover with an alcohol wipe and allow it to dry. 7. Reinstall the dust cover on the ITA module. Cleaning Instructions for the Receiver Fiber Optic Module for Installed Termini Recommended Kit: VPC P/N 910 121 170 1. Remove the dust cover from the Receiver module. 2. Use an alcohol wipe to clean the top and sides of the module. 3. Saturate a clean foam tip with optical grade alcohol and insert into an individual alignment sleeve, wipe the end of the termini. 4. Immediately dry the sleeve using a can of optical grade pressurized duster that has an extension tube ending with a small tip designed to fit inside the alignment sleeve. 5. Clean the inside of the module cover with an alcohol wipe and allow it to dry. 6. Reinstall the dust cover on the Receiver module. Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 19
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Mounting Gemini Receiver to Vertical HInged Mounting Frames Section 4 Virginia Panel has developed two Vertical Hinged Mounting Frames to be used with a standard rack or VXI chassis. It is recommended that only the 9U Vertical Hinged Mounting Frame be mounted to a VXI chassis. These mounting frames attach to flanges supplied by the chassis manufacturer*, allowing the Receiver to bolt directly on the mounting plate. Special alignment hardware is not required. *Flanges must be ordered from the manufacturer when ordering the chassis. 20 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Parts/Tools Required: P/N 310 113 331 #1 Phillips head screwdriver Instructions: Assembly of Shelf/Horizontal Mounting Frame onto 19 Rack Section 5 1. Attach the Top Mounting Bracket to the framework of the rack with the supplied hardware. This is best done from behind the rack, with the Top Adapter Panel in place. 2. Slide Top Support Bar through slots in Top Adapter Panel and into the grooves of the Top Mounting Bracket. 3. Tighten Top Mounting Bracket and Top Adapter Panel screws firmly into place. 4. Attach the Top Support Bar to the Shelf Frame. NOTE: 310 113 331 Dimension for A 17.62 Dimension for B 22.00 Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 21
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 NOTE: Versamount Edge Card Mounting Instructions Section 6 The Versamount Edge Card Adapter features snap-in Unitrack card guides. Parts/Tools Required: Versamount Edge Card Adapter Kit (P/N 111 107 140) Phillips screwdriver Instructions: 1. To mount the brackets to an enclosure, drill two holes for each bracket, one for the antirotation pin and the other for a #4 machine screw, see dimensions below. 2. Assemble the ADJUST-A-LOCK, using the hardware furnished, to the Versamount with the snap-in card guide in place. 3. Slide the p.c. card and seat it in its connector. Lower the ADJUST-A-LOCK units onto the pc card and lock in position by tightening the screws. (Locks p.c. card 8.95 maximum length) 4. Remove the card by springing back the card locking members, or by loosening the screws. Slide out the p.c. card. 22 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Universal Edge Card Mounting Instructions Section 6 NOTE: The Universal Edge Card Adapter features a Support Block that is tapped allowing for two #10 screws to attach to the Support Block from under the mounting surface. Parts/Tools Required: Universal Edge Card Adapter Kit (P/N 111 107 138) #1 Phillips screwdriver Instructions: 1. Using the dimensions provided below, calculate the distance that the card guides will need to be apart and the location of the holes that will need to be drilled to attach the Support Blocks. 2. Determine optimum placement of the card guides, making sure that there are no obstructions that may prevent the card guides from folding for storage (the Edge Card Adapter will permit itself to be folded by pulling the release pin found on the side of the Support Block). 3. Cut surface at desired location to allow for the installation of the card edge connector (not supplied). 7.140.586 REF..078 REF..125 REF..214 REF..67.190-32UNF-2B x.35 DP TYP. 2 PLCS. 1.250 REF. Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 23
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 Virginia Panel Corporation has been providing the ATE market with quality parts and accessories for several years. It is VPC s goal to continue to provide high performance and quality parts. To ensure that the same level of quality is maintained, VPC expects from its Interface System users that all components used in operating, servicing and adjusting meet certain guidelines. These guidelines are available from VPC directly and are supplied with the Interface Systems. VPC, in its attempt to perfect its product lines, takes field studies seriously. Observations have revealed that some users are not following VPC s procedures and are not using VPC tools for the proper assembly of the VPC Contacts. The user must strictly adhere to/follow the Assembly Instruction Sheets that are available from and provided by VPC. Assembly Instruction Sheets are available for the following contacts: Description Cable Type VPC P/N Page Signal Signal, Receiver 22 AWG (max.) 610 110 101 25 Signal, Receiver 22 AWG (max.) 610 110 125 25 Signal, Receiver 14 AWG (max.) 610 110 128 25, 27 Signal, ITA 22 AWG (max.) 610 110 108 25 Signal, ITA 22 AWG (max.) 610 110 146 25 Signal, ITA 14 AWG (max.) 610 110 129 26 Mini Coaxial Mini Coaxial, RCVR RG316 610 104 114 28-31 Mini Coaxial, RCVR RG178 610 104 141 32-35 Mini Coaxial, ITA RG316 610 103 115 36-39 Mini Coaxial, ITA RG178 610 103 130 40-43 Mini Coaxial ITA 24 AWG 610 103 136/166 44 Mini Coaxial ITA 24 AWG 610 103 161 45 Solder Sleeve Coaxial Solder Sleeve Mini Coaxial, RCVR RG316 610 104 142 48 Solder Sleeve Mini Coaxial, RCVR RG178 610 104 142 49 Solder Sleeve Mini Coaxial, ITA RG316 610 103 140 46 Solder Sleeve Mini Coaxial, ITA RG178 610 103 140 47 High Frequency Coaxial 20 GHz Coaxial, RCVR Stripflex 142B, M17/60-RG 142 610 102 109 51 20 GHz Coaxial, RCVR M17/84-RG 223 610 102 116 51 20 GHz Coaxial, ITA Stripflex 142B, M17/60-RG 142 610 102 110 50 20 GHz Coaxial, ITA 142B, M17/84-RG 223 610 102 117 50 TAC Wiring Contacts Signal Wiring Contact, RCVR/ITA 20 AWG (max.) 610 127 110 52 Coaxial Wiring Contact, RCVR/ITA RG316 610 134 101/107 53 Coaxial Wiring Contact, RCVR/ITA RG178 610 134 101/107 54 24 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instructions Section 7 Signal Terminal Assembly P/N 610 110 101 (Receiver) P/N 610 110 108 (ITA) P/N 610 110 125 (Receiver) P/N 610 110 146 (ITA) Set up crimp tool P/N 910 101 103 (Fig. A) by loosening the latch locking screw (counter-clockwise, until turning stops). Remove any previously used crimp contact locator. Insert the open end of crimp contact locator P/N 910 104 107 into crimp tool contact locator retainer. Locator P/N 910 104 127 is optional for Receiver contacts using wires smaller than 20 AWG - locator has a wire stop incorporated into it. Slide the retaining latch toward contact locator until contact locator is securely locked into place. The contact locator may have to be twisted to allow latch to retain contact locator. Tighten latch locking screw. MICROCRIMP ADJUSTING KNOB MICROCRIMP INDICATOR LATCH ASSEMBLY AND LOCKING SCREW CONTACT LOCATOR DIE INDENTER OPENING Using the table below, adjust the crimp tool setting by pulling adjusting knob and turning it at the same time (clockwise increases, counter-clockwise decreases setting) until the desired setting is achieved on the microcrimp indicator. Wire Gauge Strip Length +.05 0.0 Crimp Max. Crimp Min. Pullout Force (lb.) 18 (Acceptable Stranding: 1 x 18).25.043.041 10 20.25.037.033 10 22.25.033.029 10 24.25.029.025 8 26.25.024.021 4 2-24.25.041.037 8 2-26.25.036.033 4 Fig. B Fig. C Using the table above, determine the strip length according to wire gauge. Strip wire. Fully insert stripped wire into contact P/N 610 110 108/610 110 146 (Fig. B). With the crimp tool in the open position, insert the prepared contact and wire through the indenter opening. While keeping the wire fully inserted into the contact, squeeze the handles of the crimp tool until a positive stop is reached. Tool will release and return into fully open position. Remove crimped contact wire. For P/N 610 110 101/610 110 125 (Fig.C), always drop female contact (without wire attached) into contact locator, allowing it to orient/seat itself properly - squeeze handles of crimp tool slightly to hold contact in position while inserting wire. NOTE: Observe precision ratchet action by opening and closing tool fully several times. Note that tool cannot be opened without completing cycle. Never attempt to disassemble tool. Never tighten or loosen stop nuts on back of tool. Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 25
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 9 Signal ITA Terminal Assembly P/N 610 110 129 Set up crimp tool P/N 910 101 102 (Fig. A) by loosening the latch locking screw (counter-clockwise, until turning stops). Remove any previously used crimp contact locator. Insert the open end of crimp contact locator P/N 910 104 118 into crimp tool contact locator retainer. Slide the retaining latch toward contact locator until contact locator is securely locked into place. The contact locator may have to be twisted to allow latch to retain contact locator. Tighten latch locking screw. MICROCRIMP ADJUSTING KNOB MICROCRIMP INDICATOR LATCH ASSEMBLY AND LOCKING SCREW CONTACT LOCATOR DIE INDENTER OPENING Using the table below, adjust the crimp tool setting by pulling adjusting knob and turning it at the same time (clockwise increases, counter-clockwise decreases setting) until the desired setting is achieved on the microcrimp indicator. Using the table above, determine the strip length according to wire gauge. Strip wire. Fully insert stripped wire into contact P/N 610 110 129 (Fig. B). With the crimp tool in the open position, insert the prepared contact and wire through the indenter opening. While keeping the wire fully inserted into the contact, squeeze the handles of the crimp tool until a positive stop is reached. Tool will release and return into fully open position. Remove crimped contact and wire. Wire Gauge Strip Length +.05-0.0 Crimp Max. Crimp Min. Pullout Force (lb.) 14 (Acceptable Stranding: 1 x14; 19 x 27).20.063.059 10 16.20.059.055 10 Fig. B NOTE: Observe precision ratchet action by opening and closing tool fully several times. Note that tool cannot be opened without completing cycle. Never attempt to disassemble tool. Never tighten or loosen stop nuts on back of tool. 26 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instructions Section 9 Signal Receiver Terminal Assembly P/N 610 110 128 Set up crimp tool P/N 910 101 102 (Fig. A) by loosening the latch locking screw (counter-clockwise, until turning stops). Remove any previously used crimp contact locator. Insert the open end of crimp contact locator P/N 910 104 116 into crimp tool contact locator retainer. Slide the retaining latch toward contact locator until contact locator is securely locked into place. The contact locator may have to be twisted to allow latch to retain contact locator. Tighten latch locking screw. MICROCRIMP ADJUSTING KNOB MICROCRIMP INDICATOR LATCH ASSEMBLY AND LOCKING SCREW CONTACT LOCATOR DIE INDENTER OPENING Using the table below, adjust the crimp tool setting by pulling adjusting knob and turning it at the same time (clockwise increases, counter-clockwise decreases setting) until the desired setting is achieved on the microcrimp indicator. Wire Gauge Strip Length +.05-0.0 Crimp Max. Crimp Min. Pullout Force (lb.) 14 (Acceptable Stranding: 1 x 14; 19 x 27).20.063.059 10 16.20.059.055 10 18.20.055.050 10 Fig. B Using the table above, determine the strip length according to wire gauge. Strip wire. Fully insert stripped wire into contact P/N 610 110 128 (Fig. B). With the crimp tool in the open position, insert the prepared contact and wire through the indenter opening. While keeping the wire fully inserted into the contact, squeeze the handles of the crimp tool until a positive stop is reached. Tool will release and return into fully open position. Remove crimped contact and wire. NOTE: Observe precision ratchet action by opening and closing tool fully several times. Note that tool cannot be opened without completing cycle. Never attempt to disassemble tool. Never tighten or loosen stop nuts on back of tool. Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 27
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 Mini Coaxial Receiver (50 OHM) Assembly P/N 610 104 114 for RG 316 For the assembly of the Mini-Coaxial Contact (VPC P/N 610 104 114), VPC requires the following parts be used: Tools: P/N Description 910 121 143 Center conductor enlargement tool for female mini coax contact 910 121 119 Center conductor forming tool for mini coax contact 910 101 115 Hex crimp tool for mini coax contact Gages & Weights: P/N Description 910 121 156 Inspection gage to verify depth setting of center conductor on female mini coax contact 910 121 131 Weight gage kit for female mini coax contact 432 026 000 4.0 oz. weight - part of kit P/N 910 121 131 432 025 000 0.5 oz. weight - part of kit P/N 910 121 131 28 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instruction Section 7 Mini Coaxial Receiver (50 OHM) Assembly P/N 610 104 114 for RG 316 1. Strip the outer insulation, cut braid, and expose the conductor wire as shown (Fig. A). DIELECTRIC BRAID CONDUCTOR WIRE OUTER INSULATION 2. Slide the crimp ring onto the wire (Fig. B)..33/.25 FIGURE A.17/.14.49 ±.02 CRIMP RING 3. Turn braid back over outer insulation (Fig. C). FIGURE B FIGURE C BRAID 4. Solder wire into center conductor and clean (Fig. D). Note: Center conductor and dielectric must touch. SOLDER FIGURE D NO GAP PERMISSABLE CENTER CONDUCTOR 5. Slide shield conductor over center conductor until the center conductor stops in the teflon shield (Fig. E). Note: Shield Conductor and teflon insulator are supplied as an assembly. SMALL GAP TO ENSURE THAT COAX CABLE HAS BEEN FULLY INSERTED SHIELD CONDUCTOR CENTER CONDUCTOR FIGURE E Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 29
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Mini Coaxial Receiver (50 OHM) Assembly P/N 610 104 114 for RG316 (continued) 6. Calibrate gage P/N 910 121 156 (Fig. F) by loosening the dial face retaining screw until the dial face allows itself to be turned. Insert the calibration plug (P/N 414 854 104) into base of gage. While keeping constant pressure on the plug, adjust the dial by rotating it such that the pointer points to 0. Re-tighten retaining screw. Adjust locating markers to 80 and 40. 7. Check.06 ±.02 dimensions (Fig. G) with P/N 910 121 156 (Fig. F). Push the contact onto the pressure plunger of the gage (Fig. F). After attaining positive stop and while holding firm pressure, push plunger on top of dial (to push collar over teflon), read the dial on the gage. Go to step 8 if the indicator is between the two marker bands ( 80 & 40 ). Repeat steps 1-6 Fig. G should the range of dimensions not meet the criterion. Fig. F 8. Check minimum extraction force of 1/2 ounce with 432 025 000 (Fig. H). Slide female center conductor over approximately 3/4 of the length of the tip in the weight gage (Fig. I). The weight gage should remain mated with the center conductor as the center conductor is slowly lifted and suspended in the air. If weight gage remains mated, move to step 9. If weight gage falls off, the extraction force is too low and the center conductor needs to be closed with the center conductor forming tool (P/N 910 121 119) (Fig. J). Recheck 1/2 ounce retention force. Fig. H Fig. J Fig. I 30 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instructions Section 7 Mini Coaxial Receiver (50 OHM) Assembly P/N 610 104 114 for RG 316 (continued) 9. Check maximum extraction force of 4 ounces with 432 026 000. Slide female center conductor over approximately 3/4 of the length of the tip in the weight gage (Fig. K). The weight gage should fall off the contact as the contact is slowly lifted and suspended in the air. If weight gage falls off move to step 10. If weight gage remains mated with the contact, the extraction force is too high and the center conductor needs to be opened with the center conductor enlarging tool (P/N 910 121 143) (Fig. L). Fig. L Exercise caution when using this tool. Insert and remove tool in-line with contact to avoid breaking tip of tool or contact. To enlarge the center conductor, gently insert the enlarging tool into the center conductor. Pivot the enlarging tool to increase the diameter. Recheck 1/2 and 4 ounce retention force - go to step 8. BRAID SHOULDER Fig. K Fig. M 10. Turn braid back toward the front of the shield conductor (Fig. M). 11. If braid extends beyond shoulder, trim braid back to face of shoulder. 12. Slide crimp ring into position over the braid. 13. Crimp using the Hex Crimp Tool (P/N 910 101 115) (Fig. N) - in Hex position A for the larger end first and in Hex position B for the small section of the crimp ring (Fig. O). To ensure proper crimp position, slide shield conductor over pin on locator (Fig. P). Wire must not be allowed to pull on center conductor during crimping (for example, long wire hanging down to floor). Fig. N CRIMP RING A POSITION B POSITION Fig. O.06 ±.02 REF 14. Repeat step 7 to verify.06 ±.02 dimension with P/N 910 121 156. Fig. P 15. During installation of contact into module, listen for retaining clip ears to spring out, then push on front of contact to ensure that it is locked into position. Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 31
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 Mini Coaxial Receiver (50 OHM) Assembly P/N 610 104 141 for RG 178 For the assembly of the Mini-Coaxial Contact (VPC P/N 610 104 141), VPC requires the following parts be used: Tools: P/N Description 910 121 143 Center conductor enlargement tool for female mini coax contact 910 121 119 Center conductor forming tool for mini coax contact 910 101 115 Hex crimp tool for mini coax contact Gages & Weights: P/N Description 910 121 156 Inspection gage to verify depth setting of center conductor on female mini coax contact 910 121 131 Weight gage kit for female mini coax contact 432 026 000 4.0 oz weight - part of kit P/N 910 121 131 432 025 000 0.5 oz. weight - part of kit P/N 910 121 131 32 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instructions Section 7 Mini Coaxial Receiver (50 OHM) Assembly P/N 610 104 141 for RG 178 1. Strip the outer insulation, cut braid, and expose the conductor wire as shown (Fig. A). BRAID DIELECTRIC CONDUCTOR WIRE OUTER INSULATION 2. Slide the crimp ring onto the wire (Fig. B)..33/.25 Fig A.17/.14.49 ±.02 CRIMP RING 3. Turn braid back over outer insulation (Fig. C). Fig B 4. Slide the spacer tube over dielectric to edge of the braid (Fig. D). Heat spacer tube with a heat gun until it has shrunk to hold on to dielectric. HEAT FLUSH WITH EDGE AFTER SHRINKING TUBE CENTER CONDUCTOR 5. Solder wire into center conductor and clean (Fig. SOLDER C). Note: Fig CCenter conductor and dielectric must touch. SOLDER Fig D NO GAP PERMISSABLE CENTER CONDUCTOR 6. Slide shield conductor over center conductor until the center conductor stops in the teflon shield. To ensure that coaxial cable has been fully inserted into contact, ensure that a gap is between shielding and contact when achieving positive stop (Fig. E). Note: Shield Conductor and teflon insulator are supplied as an assembly. SMALL GAP TO ENSURE THAT COAX CABLE HAS BEEN FULLY INSERTED SHIELD CONDUCTOR CENTER CONDUCTOR Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 33 Fig. E
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 Mini Coaxial Receiver (50 OHM) Assembly P/N 610 104 141 for RG 178 (continued) 7. Calibrate gage P/N 910 121 156 (Fig. F) by loosening the dial face retaining screw until the dial face allows itself to be turned. Insert the calibration plug (P/N 414 854 104) into base of gage. While keeping constant pressure on the plug, adjust the dial by rotating it such that the pointer points to 0. Re-tighten retaining screw. Adjust locating markers to 80 and 40. 8. Check.06 ±.02 dimensions (Fig. G). Push the contact onto the pressure plunger of the gage (Fig. F). After positive stop is attained and while holding firm pressure, push plunger on top of dial (to push collar over teflon), read the dial on the gage. Go to step 9 if the indicator is between the two marker bands 80 and 40. Repeat steps 1-6 should the range of dimensions not meet the criterion. Fig. F Fig. G Fig. H 9. Check minimum extraction force of 1/2 ounce with 432 025 000 (Fig. H). Slide female center conductor over approximately 3/4 of the length of the tip in the weight gage (Fig. I). The weight gage should remain mated with the center conductor as the center conductor is slowly lifted and suspended in the air. If weight gage remains mated, move to step 10. If weight gage falls off, the extraction force is too low and the center conductor needs to be closed with the center conductor forming tool (P/N 910 121 119) (Fig. J). Recheck 1/2 ounce retention force. Fig. J Fig. I 34 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instructions Section 7 Mini Coaxial Receiver (50 OHM) Assembly P/N 610 104 141 for RG 178 (continued) 10. Check maximum extraction force of 4 ounces with 432 026 000. Slide female center conductor over approximately 3/4 of the length of the tip in the weight gage (Fig. K). The weight gage should fall off the contact as the contact is slowly lifted and suspended in the air. If weight gage falls off move to step 11. If weight gage remains mated with contact, the extraction force is too high and the center conductor needs to be opened with the center conductor enlarging tool (P/N 910 121 143) (Fig. L). Fig. L Exercise caution when using this tool. Insert and remove tool in-line with contact to avoid breaking tip of tool or contact. To enlarge the center conductor, remove it from Fig. M shield assembly and gently insert the Enlarging Tool into the Center Conductor. Insert Enlarging Tool until Center Conductor stops on shoulder. Be careful not to break or fracture Center Conductor. Recheck 1/2 and 4 ounce retention force - go to step 9. Fig. K 11. Turn braid back toward the front of the shield conductor (Fig. M). 12. If braid extends beyond shoulder, trim braid back to face of shoulder. 13. Slide crimp ring into position over the braid. 14. Crimp using the Hex Crimp Tool (P/N 910 101 115) (Fig. N) - in Hex position A for the larger end first and in Hex position C for the smaller section of the crimp ring (Fig. O). To ensure proper crimp position, slide shield conductor over pin on locator (Fig. P). Wire must not be allowed to pull on center conductor during crimping (for example, long wire hanging down to floor). Fig. N 15. Repeat step 8 to verify.06 +.02 dimension with P/N 910 121 156. 16. During installation of contact into module listen for retaining clip ears to spring out, then push on front of contact to ensure that it is locked into position. Fig. O Fig. P Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 35
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 Mini Coaxial ITA (50 OHM) Assembly P/N 610 103 115 for RG 316 For the assembly of the Mini-Coaxial Contact (VPC P/N 610 103 115), VPC requires the following parts be used: Tools: P/N Description 910 121 142 Outer shield conductor expanding tool for male mini coax contact 910 121 126 Outer shield conductor forming tool for male mini coax contact 910 101 115 Hex crimp tool for mini coax contact Gages & Weights: P/N Description 910 121 157 Inspection gage to verify depth setting of conductor on male mini coax contact 910 121 155 Weight gage kit for male mini coax contact 414 852 000 3 oz. weight - part of kit P/N 910 121 155 414 853 000 20 oz. weight - part of kit P/N 910 121 155 36 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instructions Section 7 Mini Coaxial ITA (50 OHM) Assembly P/N 610 103 115 for RG 316 1. Strip the outer insulation, cut braid, and expose the conductor wire as shown (Fig. A). Fig. A 2. Slide the crimp ring onto the wire (Fig. B). Fig. B 3. Turn braid back over outer insulation (Fig. C). Fig. C 4. Solder wire into center conductor and clean (Fig. D). Note: Center conductor and dielectric must touch. 5. Slide shield conductor over center conductor until the center conductor stops in the teflon shield (Fig. E). Note: Shield Conductor and teflon insulator are supplied as an assembly. Fig. D 6. Turn braid back toward the front of the shield conductor (Fig. F). If braid extends beyond shoulder, trim back to face of shoulder. Fig. E Fig. F Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 37
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 Mini Coaxial ITA (50 OHM) Assembly P/N 610 103 115 for RG 316 7. Calibrate gage P/N 910 121 157 (Fig. G) by loosening the dial face retaining screw until the dial face allows itself to be turned. Insert the calibration plug (P/N 414 855 103) into base of gage. While keeping constant pressure on the plug, adjust the dial by rotating it such that the pointer points to 0. Re-tighten retaining screw. Adjust locating markers to 90 and 20. Fig. G Fig. H 8. Check the.01 +.01 -.02 dimension (Fig. H) by using P/N 910 121 157 (Fig. G). Insert contact into gage until contact stops. If pointer is between the two markers ( 90 & 20 ), go to step 9. If the pointer is out of the range of the two markers, check dimensions and/or repeat steps 1-7. Fig. I 9. Slide crimp ring into position over the braid (Fig. I). 10. Crimp using the Hex Crimp Tool (VPC P/N 910 101 115) (Fig. J) - in Hex position A for the larger end first, and in Hex position B for the smaller section of the crimp ring for P/N 610 103 115 (Fig. I). To ensure proper crimp position, slide shield conductor over pin on the locator (Fig. K). Wire must not be allowed to pull on the center conductor during crimping (for example, long wire hanging down to floor). Fig. K Fig. J 38 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instructions Section 7 Mini Coaxial ITA (50 OHM) Assembly P/N 610 103 115 for RG 316 11. Check minimum extraction force of 3 ounces with P/N 414 852 000 (Fig. L). Slide contact into tip of weight gage. Insert approximately 0.15 into tip - be careful not to insert chamfer of contact into tip of weight gage (Fig. M). The weight gage should remain mated with the contact as the contact is slowly lifted and suspended in the air. If weight gage remains mated move to step 12. Fig. N If weight gage falls off, the extraction force is too low and the shield conductor needs to be opened up with the outer shield conductor enlarging tool P/N 910 121 142 (Fig. N). Fig. L To enlarge the shield conductor, gently insert the enlarging tool into the contact. Be careful not to bend the contact center conductor. Once inserted into the contact, pivot the enlarging tool to increase the shield diameter. Repeat until 3 ounce weight gage can be held by contact. Fig. M 12. Check maximum extraction force of 20 ounces with P/N 414 853 000 (Fig. O). Slide contact into tip of weight gage. Insert approximately 0.15 into tip - be careful not to insert chamfer of contact into tip of weight gage (Fig. P). The weight gage should fall off the contact as the contact is slowly lifted and suspended in the air. If weight gage falls off move to step 13. If weight gage remains mated with contact, the extraction force is too high and the shield conductor needs to be closed with the outer shield conductor forming tool P/N 910 121 126 (Fig. Q). Squeezing the tool handles will reposition the contact legs. This procedure should be done in three different locations (approximately 120 apart) on the same shield to obtain proper sizing. Repeat steps 11 and 12. Fig. Q 13. Use P/N 910 121 157 to check.010 +.01 -.02 dimension (See step 8). Fig. O 14. During installation of contact into module listen for the retaining clip ears to spring out, then push on front of contact to ensure that it is locked into position. Fig. P Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 39
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 Mini Coaxial ITA (50 OHM) Assembly P/N 610 103 130 for RG 178 For the assembly of the Mini-Coaxial Contact (VPC P/N 610 103 130), VPC requires the following parts be used: Tools: P/N Description 910 121 142 Outer shield conductor expanding tool for male mini coax contact 910 121 126 Outer shield conductor forming tool for male mini coax contact 910 101 115 Hex crimp tool for mini coax contact Gages & Weights: P/N Description 910 121 157 Inspection gage to verify depth setting of conductor on male mini coax contact 910 121 155 Weight gage kit for male mini coax contact 414 852 000 3 oz. weight - part of kit P/N 910 121 155 414 853 000 20 oz. weight - part of kit P/N 910 121 155 40 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instructions Section 7 Mini Coaxial ITA (50 OHM) Assembly P/N 610 103 130 for RG 178 1. Strip the outer insulation, cut braid, and expose the conductor wire as shown (Fig. A). BRAID DIELECTRIC CONDUCTOR WIR OUTER INSULATION.38/.30.17/.14 FIGURE A.52 ±.02 2. Slide the crimp ring onto the wire (Fig. B). CRIMP RING 3. Turn braid back over outer insulation (Fig. C). 4. Slide the spacer tube over dielectric to edge of the braid (Fig. D). Heat spacer tube until spacer shrinks to hold onto dielectric. FIGURE B SOLDER FIGURE C NO GAP PERMISSABLE CENTER CONDUCTOR 5. Solder wire into center conductor and clean (Fig. C). Note: Center conductor and dielectric must touch. HEAT SOLDER FIGURE D NO GAP PERMISSABLE CENTER CONDUCTOR 6. Slide shield conductor over center conductor until the center conductor stops in the teflon shield. To ensure that coaxial cable has been fully inserted into contact, ensure that a gap is between shielding and contact when achieving positive stop (Fig. E). Note: Shield Conductor and teflon insulator are supplied as an assembly. 7. Turn braid back toward the front of the shield conductor (Fig. F). If braid extends beyond shoulder, trim back to face of shoulder. SMALL GAP TO ENSURE THAT COAX CABLE HAS BEEN FULLY INSERTED INTO CONTACT SHIELD CONDUCTOR CENTER CONDUCTOR FIGURE E BRAID SHOULDER FIGURE F Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 41
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 Mini Coaxial ITA (50 OHM) Assembly P/N 610 103 130 for RG 178 CRIMP RING A POSITION C POSITION FIGURE G 8. Calibrate gage P/N 910 121 157 (Fig. G) by loosening the dial face retaining screw until the dial face allows itself to be turned. Insert the calibration plug (P/N 414 855 103) into base of gage. While keeping constant pressure on the plug, adjust the dial by rotating it such that the pointer points to 0. Re-tighten retaining screw. Adjust locating markers to 90 and 20. 9. Check the.01 +.01 -.02 dimension (Fig. H) by using P/N 910 121 157. Insert contact into gage and push contact into collar until contact stops. If pointer is between the two markers, go to step 10. If the pointer is out of the range of the two markers, check dimensions and/or repeat steps 1-8. 10. Slide crimp ring into position over the braid (Fig. I). FIGURE H -.020 +.010.010 ±.010 -.020 11. Crimp using the Hex Crimp Tool (VPC P/N 910 101 115) FIGURE I (Fig. J) - in Hex position A for the larger end first, and in Hex position C for the smaller section of the crimp ring for P/N 610 103 130 (Fig. I). To ensure proper crimp position, slide shield conductor over pin on the locator (Fig. K). Wire must not be allowed to pull on the center conductor during crimping (for example, long wire hanging down to floor). FIGURE J FIGURE K 42 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instructions Section 7 Mini Coaxial ITA (50 OHM) Assembly P/N 610 103 130 for RG 178 12. Check minimum extraction force of 3 ounces with P/N 414 852 000 (Fig. L). Slide contact into tip of weight gage. Insert approximately 0.15 into tip - be careful not to insert chamfer of contact into tip of weight gage (Fig. M). The weight gage should remain mated with the contact as the contact is slowly lifted and suspended in the air. If weight gage remains mated move to step 13. If weight gage falls off, the extraction force is too low and the shield conductor needs to be opened up with the outer shield conductor enlarging tool P/N 910 121 142 (Fig. N). Fig. L Fig. M Fig. N To enlarge the shield conductor, gently insert the enlarging tool into the contact. Be careful not to bend the contact center conductor. Once inserted into the contact, pivot the enlarging tool to increase the shield diameter. Repeat until 3 ounce weight gage can be held by contact. 13. Check maximum extraction force of 20 ounces with P/N 414 853 000 (Fig. O). Slide contact into tip of weight gage. Insert approximately 0.15 into tip - be careful not to insert chamfer of contact into tip of weight gage (Fig. P). The weight gage should fall off the contact as the contact is slowly lifted and suspended in the air. If weight gage falls off move to step 14. If weight gage remains mated with contact, the extraction force is too high and the shield conductor needs to be closed with the outer shield conductor forming tool P/N 910 121 126 (Fig. Q). Squeezing the tool handles will reposition the contact legs. This procedure should be done in three different locations (approximately 120 apart) on the same shield to obtain proper sizing. Repeat steps 12 and 13. Fig. P Fig. Q 14. Use P/N 910 121 157 to check.010 +.01 -.02 dimension (See step 9). Fig. O 15. During installation of contact into module listen for the retaining clip ears to spring out, then push on front of contact to ensure that it is locked into position. Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 43
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 Mini Coaxial ITA (50 OHM) Assembly P/N 610 103 136 and 610 103 166 for 24 AWG PARTS REQUIRED: Crimp Tool (P/N 910 101 118) Crimp Locator (P/N 910 104 128) INSTRUCTIONS: 1. Set up Crimp Locator (Fig. A) in Crimp Tool (Fig. B). Fig. A 2. Select correct crimp setting for gauge of wire and contact to be used (See Table below). While in closed position, check diameter of crimp tool with plug gauge to be sure setting is correct. (This should be done periodically during use to compensate for wear). Strip wire to length shown below (Fig. C). 3. Slide tubing onto wire. 4. Insert contact with wire in place to the depth allowed by die (Fig. D). 5. Close crimp tool completely until it automatically releases. 6. Contact should be crimped in correct position with no fractures or loose crimp. Fig. B 7. Gently pull wire to check crimp. 8. Slide tubing into position and shrink (Fig. E). CRIMP SETTINGS: Wire Gauge Strip Max. Min. Pullout Force 24.160.039.035 2 lbs. 22*.160.044.039 2 lbs. 26.160.034.031 2 lbs. *Acceptable Stranding: 1 x 22; 7 x 30 Fig. C Fig. D Fig. E 44 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instructions Section 7 Mini Coaxial (ITA) Terminal 50 OHM Assembly P/N 610 103 161 PARTS REQUIRED: Crimp Tool (P/N 910 101 118) Crimp Tool (P/N 910 101 115) Crimp Die/Locator (P/N 910 104 128) INSTRUCTIONS: 1. Set up Locator in Crimp Tool. 2. Select correct crimp setting for gauge wire to be used (see table below). While in closed position, check diameter of crimp tool with plug gauge to be sure setting is correct (this should be done periodically during use to compensate for wear). 3. Unravel about 2 inches of twisted wire. Cut 0.5 off white wire and strip white wire 0.160 (Fig. A). SHRINK TUBING CRIMP POSITION WHITE CENTER CONDUCTOR WIRE FIGURE A.160 4. Slide 1/16 shrink tubing (1/4 long) over white wire. Slide crimp ring over both wires (smaller end first). FIGURE B 5. Insert wire with terminal in place at depth allowed by die into Crimp Tool (P/N 910 101 118) and close Crimp Tool handles completely until handles release. Remove crimped terminal and wire. Gently pull on wire to ensure proper crimp (Fig. B). 6. Slide shrink tubing over crimped area so that it covers all exposed areas of center conductor and touches dielectric. Heat to shrink (Fig. C). SLIDE SHRINK TUBING TO EDGE OF DIELECTRIC AND HEAT FIGURE C UNRAVEL STRANDS TO FLARE AROUND SHIELD CUT BLACK WIRE HERE AND TRIM RE-TWIST BLACK WIRE STRANDS TO HERE AFTER UNRAVELING 7. Re-twist black wire around white center conductor. Cut off excess length above crimp area of shield (see Fig. D). Strip black wire such that insulation still covers shrink tubing but not crimp area on shield. Unravel and flare strands around shield (Fig. D). FIGURE D SLIDE CRIMP RING OVER UNRAVELED/FLARED STRANDS OF BLACK WIRE 8. Slide crimp ring over rear of terminal (Fig. E). 9. Using Crimp Tool (P/N 910 101 115) crimp areas A and B A for the larger portion of crimp ring and B for the smaller end (Fig. F). CRIMP SETTINGS: Wire Gauge Max. Min. Pull-out Force 24.039.035 2 lbs. 22*.044.039 2 lbs. *Acceptable Stranding: 1 x 22; 7 x 30 FIGURE E CRIMP AREA FOR SETTING "B" CRIMP AREA FOR SETTING "A" FIGURE F Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 45
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 Solder Sleeve Mini Coaxial (ITA) Assembly P/N 610 103 140 for RG316 PARTS REQUIRED: Solder Kit for Mini Coax includes holding fixture and adapter (P/N 910 121 144) Adapter (for those who already own a holding fixture) (P/N 910 121 149) Steinel Heat Gun with nozzle (P/N 910 121 160-110V or P/N 910 121 167-220V) Mini Coax Contact (ITA) Solder Sleeve (P/N 610 103 140) INSTRUCTIONS: 1. Prepare the coaxial cable to the dimensions shown (Fig. A). 2. Straighten the center conductor making sure the stranded center conductor is twisted into its original lay. 3. Pretin stranded center conductor with Sn63 solder per QQ-S-571. Use RMA flux per MIL-F-14256 (Alpha #611 or equivalent). 4. Make sure the shield braid is trimmed evenly and no loose strands are extending out across the exposed dielectric or cable jacket. 5. Smooth the braid ends flat against the cable dielectric. 6. Slip the contact over the end of the prepared cable, and carefully push the contact onto the cable until it stops. Rotating the contact slightly during cable insertion will help prevent the braid from catching. 7. Inspect for proper insertion (Fig. B). The center conductor must be visible through one of the forward inspection windows. The distance from the rear of the contact outer body to the cable jacket insulation should be.065 +.015. 8. Install the adapter onto the holding fixture (Fig. C). Insert a contact in the adapter side marked P for pin, and set up the dimensions as shown in Figure C. 9. Insert the contact/cable assembly into the adapter. Clamp the cable in the holding fixture. The cable must remain fully inserted in the contact and the contact must be fully inserted in the adapter (for adapter to act as a heat sink). The cable must be straight between the contact and the cable clamp. 10. Attach the appropriate reflector to the heating tool (See instruction sheet accompanying heat gun for instructions and safety precautions). 11. Using the holding fixture, position the contact in the heating tool reflector, with the forward inspection window centered in the reflector. Continue heating until the small solder preform in the forward inspection window has melted and flowed. The large solder preform in the rear inspection window should have melted and flowed by this time; if it has not, direct hot air at the rear inspection window until it does. 12. If contact is UNDERHEATED, there will be visible remnants of the original shapes of the solder preforms. An underheated contact must be re-heated. If contact is OVERHEATED, solder will wick away from the joint areas, leaving no solder fillets. An overheated contact must be removed and a new contact installed. 13. After the contact has cooled for at least 10 seconds, remove the contact and cable from the holding fixture. 14. Inspect the completed termination for correct assembly. The cable shield must extend into the contact at least as far as the front edge of the rear inspection windows. The center conductor must be visible through one of the forward inspection windows..170 ±.015.190 ±.015.05/.07 INCH FORWARD INSPECTION WINDOW FORWARD INSPECTION WINDOW FIGURE A.065 ±.015 FIGURE B FIGURE C.115 ±.015 CENTER CONDUCTOR CONTACT SIDE MARKED "P" HOLDING FIXTURE ADAPTER 46 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Solder Sleeve Mini Coaxial (ITA) Assembly P/N 610 103 140 for RG178 PARTS REQUIRED: Solder Kit for Mini Coax includes holding fixture and adapter (P/N 910 121 144) Adapter (for those who already own a holding fixture) (P/N 910 121 149) Steinel Heat Gun with nozzle (P/N 910 121 160-110V or P/N 910 121 167-220V) Mini Coax Contact (ITA) Solder Sleeve (P/N 610 103 140) INSTRUCTIONS: 1. Strip the coaxial cable to the dimensions shown (Fig. A). 2. Straighten the center conductor making sure the stranded center conductor is twisted into its original lay. 3. Pretin stranded center conductor with Sn63 solder per QQ-S-571. Use RMA flux per MIL-F-14256 (Alpha #611 or equivalent). 4. Fold the center conductor back on itself as shown (Fig. B). 5. Make sure the shield braid is trimmed evenly and no loose strands are extending out across the exposed dielectric or cable jacket. 6. Smooth the braid ends flat against the cable jacket. 7. Slip the contact over the end of the prepared cable, and carefully push the contact onto the cable until it stops. Rotating the contact slightly during cable insertion will help prevent the braid from catching. 8. Inspect for proper insertion (Fig. C). The center conductor must be visible through one of the forward inspection windows. The distance from the rear of the contact outer body to the edge of the braid should be.015 +.015. 9. Install the adapter onto the holding fixture (Fig. D). Insert a contact in the adapter side marked P for pin, and set up the dimensions as shown in Figure D. 10. Insert the contact/cable assembly into the adapter. Clamp the cable in the holding fixture. The cable must remain fully inserted in the contact and the contact must be fully inserted in the adapter (for adapter to act as a heat sink). The cable must be straight between the contact and the cable clamp. 11. Attach the appropriate reflector to the heating tool (See instruction sheet accompanying heat gun for instructions and safety precautions). 12. Using the holding fixture, position the contact in the heating tool reflector, with the forward inspection window centered in the reflector. Continue heating until the small solder preform in the forward inspection window has melted and flowed. The large solder preform in the rear inspection window should have melted and flowed by this time; if it has not, direct hot air at the rear inspection window until it does. 13. If contact is UNDERHEATED, there will be visible remnants of the original shapes of the solder preforms. An underheated contact must be re-heated. If contact is OVERHEATED, solder will wick away from the joint areas, leaving no solder fillets. An overheated contact must be removed and a new contact installed. 14. After the contact has cooled for at least 10 seconds, remove the contact and cable from the holding fixture. 15. Inspect the completed termination for correct assembly. The cable shield must extend into the contact at least as far as the front edge of the rearinspection windows. The center conductor must be visible through one of the forward inspection windows..150±.015.290±.015 BRAID FOLDED BACK.05/.07 INCH FIGURE A.115±.015 FIGURE B.015±.015 FORWARD INSPECTION WINDOW FIGURE C FORWARD INSPECTION WINDOW FIGURE D.215±.015.029 MAX. CENTER CONDUCTOR CONTACT SIDE MARKED "P" HOLDING FIXTURE ADAPTER Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 47
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 Solder Sleeve Mini Coaxial (RCVR) Assembly P/N 610 104 142 for RG316 PARTS REQUIRED: Solder Kit for Mini Coax includes holding fixture and adapter (P/N 910 121 144) Adapter (for those who already own a holding fixture) (P/N 910 121 149) Steinel Heat Gun with nozzle (P/N 910 121 160-110V or P/N 910 121 167-220V) Mini Coax Contact (Receiver) Solder Sleeve (P/N 610 104 142) INSTRUCTIONS: 1. Prepare the coaxial cable to the dimensions shown (Fig. A). 2. Straighten the center conductor making sure the stranded center conductor is twisted into its original lay. 3. Pretin stranded center conductor with Sn63 solder per QQ-S-571. Use RMA flux per MIL-F-14256 (Alpha #611 or equivalent). 4. Make sure the shield braid is trimmed evenly and no loose strands are extending out across the exposed dielectric or cable jacket. 5. Smooth the braid ends flat against the cable dielectric. 6. Slip the contact over the end of the prepared cable, and carefully push the contact onto the cable until it stops. Rotating the contact slightly during cable insertion will help prevent the braid from catching. 7. Inspect for proper insertion (Fig. B). The center conductor must be visible through one of the forward inspection windows. The distance from the rear of the contact outer body to the cable jacket insulation should be.065 +.015. 8. Install the adapter onto the holding fixture (Fig. C). Insert a contact in the adapter side marked S for socket, and set up the dimensions as shown in Figure C. 9. Insert the contact/cable assembly into the adapter. Clamp the cable in the holding fixture. The cable must remain fully inserted in the contact and the contact must be fully inserted in the adapter (for adapter to act as a heat sink). The cable must be straight between the contact and the cable clamp. 10. Attach the appropriate reflector to the heating tool (See instruction sheet accompanying heat gun for instructions and safety precautions). 11. Using the holding fixture, position the contact in the heating tool reflector, with the forward inspection window centered in the reflector. Continue heating until the small solder preform in the forward inspection window has melted and flowed. The large solder preform in the rear inspection window should have melted and flowed by this time; if it has not, direct hot air at the rear inspection window until it does. 12. If contact is UNDERHEATED, there will be visible remnants of the original shapes of the solder preforms. An underheated contact must be re-heated. If contact is OVERHEATED, solder will wick away from the joint areas, leaving no solder fillets. An overheated contact must be removed and a new contact installed. 13. After the contact has cooled for at least 10 seconds, remove the contact and cable from the holding fixture. 14. Inspect the completed termination for correct assembly. The cable shield must extend into the contact at least as far as the front edge of the rear inspection windows. The center conductor must be visible through one of the forward inspection windows. 0.5-0.7 INCH.170 ±.015.190 ±.015 FORWARD INSPECTION WINDOW FORWARD INSPECTION WINDOW FIGURE A.065±.015 FIGURE B.115 ±.015 CENTER CONDUCTOR CONTACT SIDE MARKED "S" HOLDING FIXTURE FIGURE C ADAPTER 48 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instructions Section 7 Solder Sleeve Mini Coaxial (RCVR) Assembly P/N 610 104 142 for RG178 PARTS REQUIRED: Solder Kit for Mini Coax includes holding fixture and adapter (P/N 910 121 144) Adapter (for those who already own a holding fixture) (P/N 910 121 149) Steinel Heat Gun with nozzle (P/N 910 121 160-110V or P/N 910 121 167-220V) Mini Coax Contact (Receiver) Solder Sleeve (P/N 610 104 142) INSTRUCTIONS: 1. Strip the coaxial cable to the dimensions shown (Fig. A). 2. Straighten the center conductor making sure the stranded center conductor is twisted into its original lay. 3. Pretin stranded center conductor with Sn63 solder per QQ-S-571. Use RMA flux per MIL-F-14256 (Alpha #611 or equivalent). 4. Fold the center conductor back on itself as shown (Fig. B). 5. Make sure the shield braid is trimmed evenly and no loose strands are extending out across the exposed dielectric or cable jacket. 6. Smooth the braid ends flat against the cable jacket. 7. Slip the contact over the end of the prepared cable, and carefully push the contact onto the cable until it stops. Rotating the contact slightly during cable insertion will help prevent the braid from catching. 8. Inspect for proper insertion (Fig. C). The center conductor must be visible through one of the forward inspection windows. The distance from the rear of the contact outer body to the edge of the braid should be.015 +.015. 9. Install the adapter onto the holding fixture (Fig. D). Insert a contact in the adapter side marked S for socket, and set up the dimensions as shown in Figure D. 10. Insert the contact/cable assembly into the adapter. Clamp the cable in the holding fixture. The cable must remain fully inserted in the contact and the contact must be fully inserted in the adapter (for adapter to act as a heat sink). The cable must be straight between the contact and the cable clamp. 11. Attach the appropriate reflector to the heating tool (See instruction sheet accompanying heat gun for instructions and safety precautions). 12. Using the holding fixture, position the contact in the heating tool reflector, with the forward inspection window centered in the reflector. Continue heating until the small solder preform in the forward inspection window has melted and flowed. The large solder preform in the rear inspection window should have melted and flowed by this time; if it has not, direct hot air at the rear inspection window until it does. 13. If contact is UNDERHEATED, there will be visible remnants of the original shapes of the solder preforms. An underheated contact must be re-heated. If contact is OVERHEATED, solder will wick away from the joint areas, leaving no solder fillets. An overheated contact must be removed and a new contact installed..150±.015 BRAID FOLDED BACK.015 ±.015 0.5-0.7 INCH 14. After the contact has cooled for at least 10 seconds, remove the contact and cable from the holding fixture. 15. Inspect the completed termination for correct assembly. The cable shield must extend into the contact at least as far as the front edge of the rear inspection windows. The center conductor must be visible through one of the forward inspection windows. FORWARD INSPECTION WINDOW FORWARD INSPECTION WINDOW FIGURE A.115±.015 FIGURE B FIGURE C CONTACT.290±.015.215±.015 HOLDING FIXTURE FIGURE D.029 MAX CENTER CONDUCTOR SIDE MARKED "S" ADAPTER Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 49
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 20 GHz Terminal (ITA) P/N 610 102 110 for Stripflex 142B or M17/60-RG142 610 102 117 for M17/84-RG223 PARTS REQUIRED: Crimp Tool P/N 910 101 124 INSTRUCTIONS: 1. Strip cable to dimensions shown (Fig. A) 2. Slide crimp ferrule over the cable. Insert cable into back end of crimp nut. The tubular nut extension will slide under the braid. Fig. A 3. Slide crimp ferrule up over braid and crimp with P/N 910 101 124, using cavity A. Trim insulator flush as shown. (Fig. B) 4. Insert assembly into back end of the body and tighten wrench nut with a torque of 7 inch pounds. (Fig. C) Fig. B *It is recommended to use the following cables to achieve certain frequencies: Stripflex TM 142B 20 GHz M17/84 -RG223 12.4 GHz M17/60 -RG142 8 GHz Fig. C updated 3/29/02 50 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instructions Section 7 20 GHz Terminal (Receiver) P/N 610 102 109 for Stripflex 142B, or M17/60-RG142 610 102 116 for M17/84 RG-223 PARTS REQUIRED: Crimp Tool P/N 910 101 124 INSTRUCTIONS: 1. Strip cable to dimensions shown. (Fig. A) 2. Slide crimp ferrule over the cable. Insert cable into back end of crimp nut. The tubular nut extension will slide under the braid. Fig. A 3. Slide crimp ferrule up over braid and crimp with P/N 910 101 124, using cavity A. Trim insulator flush as shown. (Fig. B) 4. Insert assembly into back end of the body and tighten wrenchnut with a torque of 7 inch pounds. (Fig. C) Fig. B Fig. C It is recommended to use the following cables to achieve certain frequencies: Stripflex TM 142B 20 GHz M17/84 -RG223 12.4 GHz M17/60 -RG142 8 GHz updated 3/29/02 Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 51
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 Signal Terminal Assembly (RCVR/ITA) P/N 610 127 110 Set up crimp tool P/N 910 101 103 (Fig. A) by loosening the latch locking screw (counter-clockwise, until turning stops). Remove any previously used crimp contact locator. Insert the open end of crimp contact locator P/N 910 104 133 into crimp tool contact locator retainer. Slide the retaining latch toward contact locator until contact is securely locked into place. The contact locator may have to be twisted to allow latch to retain contact locator. Tighten latch locking screw. Using the table below, adjust the crimp tool setting by pulling adjusting knob and turning it at the same time (clockwise increases, counter-clockwise decreases setting) until the desired setting is achieved on the microcrimp indicator. Fig. A Wire Gauge Strip Length +.05/-0.0 Crimp Max. Crimp Min. Pullout Force (lb.) 20.25.037.033 10 22.19.033.029 10 24.19.029.025 8 26.19.024.021 4 2-24.25.043.041 8 2-26.25.041.037 4 Using the table above, determine the strip length according to wire gauge. Strip wire. Fully insert stripped wire into contact P/N 610 127 110 (Fig. B). With the crimp tool in the open position, insert the prepared contact and wire through the indenter opening. While keeping the wire fully inserted into the contact, squeeze the handles of the crimp tool until a positive stop is reached. Tool will release and return into fully open position. Remove crimped contact and wire. Fig. B NOTE: Observe precision ratchet action by opening and closing tool fully several times. Note that tool cannot be opened without completing cycle. Never attempt to disassemble tool. Never tighten or loosen stop nuts on back of tool. 52 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Contact Assembly Instructions Section 7 Coaxial Terminal Assembly P/N 610 134 101 RG316 P/N 610 134 107 RG316 PARTS REQUIRED: Solder Kit for Mini Coax includes holding fixture and adapter (P/N 910 121 162) or Adapter (for those who already own a holding fixture) (P/N 910 121 163) Steinel Heat Gun with Reflector (P/N 910 121 160-110V or P/N 910 121 167-220V) INSTRUCTIONS: 1. Prepare the coaxial cable to the dimensions shown (Fig. A). 2. Straighten the center conductor making sure the stranded center conductor is twisted into its original lay. 3. Pretin stranded center conductor with Sn63 solder per QQ-S-571. Use RMA flux per MIL-F-14256 (Alpha #611 or equivalent). 4. Make sure the shield braid is trimmed evenly and no loose strands are extending out across the exposed dielectric or cable jacket. 5. Smooth the braid ends flat against the cable dielectric. 6. Slip the contact over the end of the prepared cable, and carefully push the contact onto the cable until it stops. Rotating the contact slightly during cable insertion will help prevent the braid from catching. 7. Inspect for proper insertion (Fig. B). The center conductor must be visible through one of the forward inspection windows. The distance from the rear of the contact outer body to the cable jacket insulation should be.065±.015 8. Install the adapter onto the holding fixture (Fig. C). Insert a contact in the adapter and set up the dimensions as shown in Figure C. 9. Insert the contact/cable assembly into the adapter. Clamp the cable in the holding fixture. The cable must remain fully inserted in the contact and the contact must be fully inserted in the adapter (for the adapter to act as a heat sink). The cable must be straight between the contact and the cable clamp. 10. Attach the appropriate reflector to the heating tool (see separate Heat Gun instruction sheet included with tool for tool operation and precaution). 11. Using the holding fixture, position the contact in the heating tool reflector, with the forward inspection window centered in the reflector. Continue heating until the small solder preform in the forward inspection window has melted and flowed. The large solder preform in the rear inspection window should have melted and flowed by this time; if it has not, direct hot air at the rear inspection window until it does. 12. If contact is UNDERHEATED, there will be visible remnants of the original shapes of the solder preforms. An underheated contact must be reheated. If contact is OVERHEATED, solder will wick away from the joint areas, leaving no solder fillets. An overheated contact must be removed and a new contact installed. 13. After the contact has cooled for at least 10 seconds, remove the contact and cable from the holding fixture. 14. Inspect the completed termination for correct assembly. The cable shield must extend into the contact at least as far as the front edge of the rear inspection windows. The center conductor must be visible through one of the forward inspection windows. Fig. A Fig. B Fig. C Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 53
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Contact Assembly Instructions Section 7 Coaxial Terminal Assembly P/N 610 134 101 RG178 P/N 610 134 107 RG178 PARTS REQUIRED: Solder Kit for Mini Coax includes holding fixture and adapter (P/N 910 121 162) or Adapter (for those who already own a holding fixture) (P/N 910 121 163) Steinel Heat Gun with Reflector (P/N 910 121 160-110V or P/N 910 121 167-220V) INSTRUCTIONS: 1. Prepare the coaxial cable to the dimensions shown (Fig. A). 2. Straighten the center conductor making sure the stranded center conductor is twisted into its original lay. 3. Pretin stranded center conductor with Sn63 solder per QQ-S-571. Use RMA flux per MIL-F-14256 (Alpha #611 or equivalent). Fig. A 4. Fold the center conductor back on itself as shown (Fig. B). 5. Make sure the shield braid is trimmed evenly and no loose strands are extending out across the exposed dielectric or cable jacket. 6. Smooth the braid ends flat against the cable jacket. 7. Slip the contact over the end of the prepared cable, and carefully push the contact onto the cable until it stops. Rotating the contact slightly during cable insertion will help prevent the braid from catching. 8. Inspect for proper insertion (Fig. C). The center conductor must be Fig. B visible through one of the forward inspection windows. The distance from the rear of the contact outer body to the cable jacket insulation should be.015±.015. 9. Install the adapter onto the holding fixture (Fig. D). Insert a contact in the adapter and set up the dimensions as shown in Figure D. 10. Insert the contact/cable assembly into the adapter. Clamp the cable in the holding fixture. The cable must remain fully inserted in the contact and the contact must be fully inserted in the adapter (for the adapter to act as a heat sink). The cable must be straight between the contact and Fig. C the cable clamp. 11. Attach the appropriate reflector to the heating tool (see separate Heat Gun instruction sheet included with tool for tool operation and precaution). 12. Using the holding fixture, position the contact in the heating tool reflector, with the forward inspection window centered in the reflector. Continue heating until the small solder preform in the forward inspection window has melted and flowed. The large solder preform in the rear inspection window should have melted and flowed by this time; if it has not, direct hot air at the rear inspection window until it does. 13. If contact is UNDERHEATED, there will be visible remnants of the original shapes of the solder preforms. An underheated contact must be reheated. If contact is OVERHEATED, solder will wick away from the joint areas, leaving no solder fillets. An overheated contact must be removed and a new contact installed. 14. After the contact has cooled for at least 10 seconds, remove the contact and cable from the holding fixture. 15. Inspect the completed termination for correct assembly. The cable shield must Fig. D extend into the contact at least as far as the front edge of the rear inspection windows. The center conductor must be visible through one of the forward inspection windows. 54 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL PCB Specifications Section 8 PCB SPECIFICATIONS The following drawings show PCB mechanical design specifications for the Receiver and ITA sides of the interface. VPC recommends that we review your final PCB design to ensure all dimensions are correct. For additional PCB information, please visit our web-site: www.vpc.com/pcb2100.htm. Receiver PCB Mechanical Design Specifications: Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 55
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Receiver PCB Mechanical Design Specifications: Section 8 56 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Receiver PCB Mechanical Design Specifications: Section 8 Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 57
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 ITA PCB Mechanical Design Specifications: Section 8 58 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL ITA PCB Mechanical Design Specifications: Section 8 Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 59
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 ITA PCB Mechanical Design Specifications: Section 8 60 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL PWB Assembly/Pad Recommendations Section 8 Pad Recommendations for PWB Development All contact pads are to be gold plated per MIL-G-45204, Type 1, Grade C,.000120 Min. thick over Nickel plating per QQ- N-290, Class 2,.000150 Min. thick. Board material is left to the user as the material used will depend upon variables such as anticipated environmental conditions (temperature, humidity, chemical resistance, etc.) and electrical parameters (voltage breakdown, dielectric constant and others). Specific circuitry may also limit the desired flexing. VPC supplies the force per contact exerted upon the board and the contact array dimensions. Once the operational contact array is determined, we recommend that the complete environmental, electrical and mechanical requirements be given to a professional board designer for design review. Contact Forces Signal TAC Contact Coaxial TAC Contact (50 OHM) Coaxial TAC Contact (75 OHM) Power TAC Contact 2 ounces maximum 7 ounces maximum 7 ounces maximum 20 ounces maximum Deflection at no time should exceed.020 Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 61
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Trouble Shooting Section 9 ITA Engagement Bearings/Studs are not lining up with the Engagement Slots of the Receiver Check the alignment of the ITA Frame. There is a possibility that the ITA Frame could have misaligned itself if it was dropped (See Procedure for Checking ITA Squareness on page 6, Section 3). Contact Virginia Panel Corporation - user adjustments to System, unless authorized, will void the warranty. Forceful engagement of the Receiver and the ITA will result in serious damage to multiple parts of the system (Modules, Receiver, ITA and Contacts)! ITA Frame is not lined up when in the process of engagement with the Receiver This may indicate that the ITA was dropped and is out of alignment or that a Module is not mating with its intended Module. Remove and inspect the ITA for alignment (See Procedure for Checking ITA Squareness on page 6, Section 3). Contact Virginia Panel Corporation - user adjustments to System, unless authorized, will void the warranty. Check for foreign objects/tools. Verify the orientation of the Receiver and ITA Modules (See Section 2). Inspect the matching of Modules - Power ITA Module to mate with Power Receiver Module, etc. (See Section 2). Forceful engagement of the Receiver and the ITA will result in serious damage to multiple parts of the system (Modules, Receiver, ITA and Contacts)! Excessive force is needed upon engaging the Handle This may indicate that the ITA was dropped and is out of alignment or that a Module is not mating with its intended Module. Remove and inspect the ITA for alignment (See Procedure for Checking ITA Squareness on page 6, Section 3). Contact Virginia Panel Corporation - user adjustments to System, unless authorized, will void the warranty. Check for foreign objects/tools. A damaged Contact(s) may provide enough resistance to notice. Upon replacing a Contact in the ITA, the mating Contact on the Receiver side should also be inspected and replaced if necessary (See Section 2). Verify the orientation of the Receiver and ITA Modules (See Section 2). Inspect the matching Modules - Power ITA Module to mate with Power Receiver Module, etc. (See Section 2). Forceful engagement of the Receiver and the ITA will result in serious damage to multiple parts of the system (Modules, Receiver, ITA and Contacts)! ITA will not engage with the Receiver after diagnosing the above problems Contact Virginia Panel Corporation - user adjustments to the System, unless authorized, will void the warranty. 62 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Trouble Shooting Section 9 No continuity upon engagement Upon replacing a Contact in the ITA, the mating Contact on the Receiver side should also be inspected and replaced if necessary (See Section 2). Check wiring - replace if necessary. Contact not secured in module. The ITA and Receiver Wiring Modules (TAC) may be interchanged, resulting in miswiring because of the reversed screening. TAC contacts have been inserted backwards which will prevent the Receiver Wiring Module from being attached to the back of the Receiver frame. A contact may have been damaged. Visually check all TAC and Wiring Contacts for damage to potentially isolate damaged pin prior to checking for continuity with a multimeter. A short in the wiring upon engagement A damaged Contact(s) may provide enough resistance to notice. Upon replacing a Contact in the ITA, the mating Contact on the Receiver side should also be inspected and replaced if necessary (See Section 2). Check wiring - replace if necessary. Receiver and ITA will not disengage This may indicate that the Engagement Mechanism within the Receiver is faulty - contact Virginia Panel Corporation immediately-user adjustments to System, unless authorized, will void the warranty. Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 63
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Precautionary Notes Section 10 The following is a listing of precautionary notes found within this Manual and otherwise. They should be noted and followed for the equipment to operate at an optimum state. Never probe a contact without using a mating patchcord as a test lead. Never forcefully engage a system if there is an excessive amount of resistance on the handle. Never allow an ITA to drop as this may cause misaligned engagement and/or irreparable damage. Always insert and extract a contact insertion/extraction tool inline with the contact. Never apply pressure to the side as this may break either contact or tool. This also applies to forming and enlarging tools. When engaging the ITA with the Receiver, caution must be taken to ensure that the ITA is parallel with the Receiver upon engagement and that the ITA rollers are engaged at the same time! It is advisable that power to the Interface System be disconnected prior to handling and maintenance. Caution should always be used when engaging, making sure that all foreign objects are removed from the system. To prevent potential injury, care should be taken to avoid wrapping fingers around the engagement handle. Use care when hinging Receiver down. Always maintain hand contact to prevent Receiver from dropping suddenly, resulting in damage to the system. The foremost precautionary step that needs to be taken is to protect the Interface System from damage caused by people (bumping into the Receiver/ITA assembly with a box, chair or electronic equipment for example). To prevent this, VPC recommends engaging either the ITA or the Receiver Protective Cover to the Receiver at all times. 64 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL Keying Pin Kit Usage Instructions The Keying Pin Kit (P/N 310 118 112) uses pins and screws to provide a way to isolate your connectors to prevent operational mismatch. By design, the pins are to be used in the receiver, and the screws are to be used in the ITA. If the pins are used in the ITA, other accessories such as the protective cover (P/N 410 112 541) will not function properly. PINS USED IN RECEIVER SIDE SCREWS USED IN ITA SIDE Use this table as a guide for keying pin locations. PATTERN 1 PATTERN 4 RECEIVER ITA RECEIVER ITA PIN A INSTALLED PIN C INSTALLED SCREW A OPEN SCREW C OPEN PIN A OPEN PIN C OPEN SCREW A INSTALLED SCREW C INSTALLED PIN B OPEN PIN D OPEN SCREW B INSTALLED SCREW D INSTALLED PIN B INSTALLED PIN D INSTALLED SCREW B OPEN SCREW D OPEN PATTERN 2 PATTERN 5 RECEIVER ITA RECEIVER ITA PIN A INSTALLED PIN C OPEN SCREW A OPEN SCREW C INSTALLED PIN A OPEN PIN C INSTALLED SCREW A INSTALLED SCREW C OPEN PIN B INSTALLED PIN D OPEN SCREW B OPEN SCREW D INSTALLED PIN B INSTALLED PIN D OPEN SCREW B OPEN SCREW D INSTALLED PATTERN 3 PATTERN 6 RECEIVER ITA RECEIVER ITA PIN A OPEN PIN C INSTALLED SCREW A INSTALLED SCREW C OPEN PIN A INSTALLED PIN C OPEN SCREW A OPEN SCREW C INSTALLED PIN B OPEN PIN D INSTALLED SCREW B INSTALLED SCREW D OPEN PIN B OPEN PIN D INSTALLED SCREW B INSTALLED SCREW D OPEN Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 65
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 Installation of ITA Protective Cover P/N 410 112 541 Interchangeable Test Adapter (ITA - shown with wiring side up) Top of ITA Top Roller Bearing ITA Protective Cover Bottom Roller Bearing Latch (dimples) Lay the ITA (P/N 410 120101) flat with the contact side facing upward. Slide the ITA Protective Cover (P/N 410 112 541) over the bottom roller bearings on the ITA. Continue to slide the cover up over the top roller bearings until you hear the cover snap in place. If the Keying Pin Kit (P/N 310 118 112) is being used, make sure the screw is used on the ITA and the pin is used on the receiver. 66 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation
VER. 2.1 2100 SERIES/GEMINI USER S MANUAL 2106 & 2110 Instructions - Section 11 Cable Bundle Wire Information A formula to calculate the maximum number of wires recommended for a cable bundle is shown below. Using this formula, the table below shows a sampling of the maximum number of wires that will fit in the oblong bushing; for example the oblong bushing will hold a maximum of 683 Signal (20 AWG) wires OR 202 Coaxial (RG316) wires. Formula to calculate approximate number of wires in a cable bundle: N={D/d - 1) 2 (.907) N=Number of Wires D=*Inside Diameter of Converted Oblong Bushing d=outside Diameter of Wire NOTE: If the wiring bundle is too small to secure with the adjustable bushing, remove the clamp assembly within the bushing by removing the two adjustment screws. Reverse the direction of the clamp assembly and secure with the two screws. This provides a reduced diameter within the bushing and allows smaller wire bundles to be held securely. Oblong Bushing Opening Size = 1.59 * diameter - 3.927=C General Guidelines Wire Type Outside Diameter Number of Wires 20 AWG Signal - Teflon.056 683 10 AWG Power - PVF.160 72 RG316 Coaxial _ 50 OHM.100 202 NOTE: Addition of shrink tubing or braid will reduce maximum number of wires through bushing. * Oblong Opening Circumference Converted to Simple Diameter 1.25.54 Virginia Panel Corporation www.vpc.com VM2100_V2.1.indd- 67
2100 SERIES/GEMINI USER S MANUAL VER. 2.1 2106 & 2110 Instructions - Section 11 Cable Bundle Wire Information The ITA for both the Gemini 2106 and 2110 is equipped with a removable EMI-shielded cover. The cover slides up to provide access to wires and connectors. The 10 module cover is secured by two screws, the 6 module by one. Please note: covers must be secured with screws for EMI shielding to take effect. Diagrams of ITA cover w/ dimensions 10 Module Interchangeable Test Adapter (ITA) with Sliding, Removable Cover - P/N 410 104 272 10 Module Interchangeable Test Adapter (ITA) with Sliding, Removable Cover and PCB capability - P/N 410 104 270 6 Module Interchangeable Test Adapter (ITA) with Sliding, Removable Cover - P/N 410 104 273 68 - VM2100_V2.1.indd www.vpc.com Virginia Panel Corporation