Instruction Sheet 408-3159 Strain Relief Hardware for CHAMP* Connectors (was IS 3159) 08 OCT 03 Rev A 2. Position the first half on the connector as shown in Figure 2. Receptacle Connector (Typ) 3. Hold the first half in position and align the second half with the connector. 4. Make sure the locking latches are aligned with the locking tabs, then press the second half onto the connector until the locks engage. Strain Relief Halves Plug Connector (Typ) Figure 1 1. INTRODUCTION (Figure 1) This instruction sheet covers the selection and installation of strain relief hardware for cable-to-cable and cable-to-panel CHAMP Connectors. Read this and all referenced material before starting assembly. NOTE Locking Tabs Locking Latch CONNECTOR POSITION STRAIN RELIEF PART NUMBER 24 1-552298-1 36 1-552297-1 50 1-552027-1 64 1-552296-1 Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Figures are for reference only and are not drawn to scale. Reasons for reissue are provided in Section 5, REVISION SUMMARY. Figure 2 2. DESCRIPTION Strain relief hardware can be selected from the tables in Figures 2 and 3. Determine what connector is to be used and what application is required. 3. SELECTING AND INSTALLING STRAIN RELIEF Strain reliefs are designed for cable and discrete wire applications where the stress is NOT placed on the conductors (e.g., when the cable bundle itself is secured and the connector is concealed - preventing inadvertent movement of the conductors). 1. Determine the number of positions in the connector. Refer to the table in Figure 2 and select the applicable strain relief. E2003 Tyco Electronics Corporation, Harrisburg, PA 4. SELECTING AND INSTALLING STRAIN RELIEF COVERS Five styles of strain relief covers are available: - 90 one-piece tapered - 90 one-piece straight - 90 two-piece standard profile - 90 two-piece low profile - 180 two-piece NOTE The degrees indicate the cable exit in relation to the mating face of the connector. Determine the number of contact positions, the degree of cable exit, and the cable diameter of your application. Refer to columns 4 and 5 of Figure 3 for the applicable paragraph in the following text for installation procedures. This controlled document is subject to change. For latest revision, call the FAX/PRODUCT INFO number. All International Rights Reserved AMP and Tyco are trademarks. *Trademark Other products, logos, and company names used are the property of their respective owners. TOOLING ASSISTANCE CENTER 1-800-722-1111 FAX/PRODUCT INFO 1-800-522-6752 For Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 4 LOC B 408-3159 Strain Relief Hardware for CHAMP Connectors CONNECTOR ASSEMBLY CONT POSN CABLE EXIT 900 14 180 0 CABLE DIA STRAIN RELIEF COVER DESCRIPTION PART NO. 4.70-5.84 [.185-.230] 90 Two-Piece Low Pf 552412-1 6.10-7.62 [.240-.300] 90 Two-Piece Low Pf 1-552412-1 4.44-5.59 [.175-.220] 180 Two-Piece 552079-1 5.59-6.73 [.220-.265] 180 Two-Piece 1-552079-1 6.73-7.87 [.265-.310] 180 Two-Piece CABLE DIA 90 0 12.7-13.97 2 [[.500-.550] 00 0] 90 Two-Piece Low Pf 1-552413-1 7.11-8.13 [.280-.320] 180 Two-Piece 1-552076-1 8.13-9.65 [.320-.380] 180 Two-Piece 90 7.87-9.14 [.310-.360] 90 Two-Piece Low Pf 552414-1 180 7.37-8.64 [.290-.340] 180 Two-Piece 552073-1 552413-1 90 0 64 180 2-552076-1 STRAIN RELIEF COVER DESCRIPTION PART NO. 90 Taper 229909-1 90 Straight 552617-1 Cable Clamp for All 4-229910-1 180 Two-Piece 3-552008-1 10.92-12.45 180 Two-Piece [.430-.490] 552008-1 12.45-13.97 180 Two-Piece [.490-.550] 4-552008-1 8.38-10.92 [.330-.430] 2-552079-1 7.87-9.14 [.310-360] 1800 CABLE EXIT 180 0 90 Two-Piece Low Pf 2 24 CONT POSN 500 6.10-7.62 [.240-.300] 900 CONNECTOR ASSEMBLY 10.41-12.06 90 Two-Piece Std Pf [.410-.475] 552496-1 12.06-13.72 90 Two-Piece Std Pf [.475-.540] 1-552496-1 13.72-15.37 90 Two-Piece Std Pf [.540-.605] 2-552496-1 12.19-13.72 180 Two-Piece [.480-.540] 552082-1 {A dash one (-1) suffix signifies black and a dash four (-4) signifies gray. 36 7.62-8.26 2 2 [[.300-.325] 00 2 ] 90 Taper 229909-1 90 Straight 552617-1 Cable Clamp for All 7.62-10.16 2 0 [ 00 00] [.300-.400] 8.26-9.40 2 0 [[.325-.370] 2 0] 500 90 0 8.64-10.16 0 [ 0 00] [.340-.400] 8.89-10.80 0 0 [ 0 2 ] [.350-.425] 90 Straight 10.80-12.7 0 0 2 [ 2 [.425-.500] 00] 90 Straight 229909-1 90 Straight 552617-1 Cable Clamp for All 3-229910-1 90 Two-Piece Std Pf 1-552011-1 90 Two-Piece Low Pf 552014-1 90 Taper 229909-1 90 Straight 552617-1 Cable Clamp for Str 229910-1 Kit for Taper 552560-1 229909-1 90 Straight 552617-1 Figure 3 (cont'd) 2 of 4 552011-1 90 Taper Kit for Taper Tapered - Designed for cable-to-cable applications within a cable diameter range of 7.62-12.7 [.300-.500]. Straight - Designed for multi-jack adapter and cable-to-cable applications within a cable diameter range of 7.62-12.7 [.300-.500]. 552617-1, -4 552618-4 Cable Clamp for All 4.1. 90 Slide-On Covers (50-Position Only) 3-229910-1 Cable Clamp for Str 10.54-11.81 90 Two-Piece Std Pf [.415-.465] Figure 3 (end) 1-229910-1 552560-5 Straight (Ratchet Style) - Designed for cable-to-cable applications with a cable diameter up to 10.80 [.425] maximum. Strain relief snaps into cover by use of mating ratchet teeth on strain relief and cover. Recommended for use with CHAMP-LOK* Connector Locking Latch 552723-1. NOTE When installing 90 covers, the wires MUST be dressed to opposite ends of the plug and receptacle connectors. (Dress plug wires toward contacts numbered 1 and 26, and dress receptacle wires toward contacts numbered 25 and 50. Install as follows: 1. Grip the connector firmly with one hand, then draw the other hand over the wire and towards the proper end of the connector - forming the wires as indicated in Figure 4. Do NOT overwork the wires. 2. Align the terminated contacts with the contact groove in the cover. Rev A 408-3159 Strain Relief Hardware for CHAMP Connectors 90 Cable Exit Locking Tab Straight Captive Screw (Ref) Contacts Locking Latch Tapered Strain Relief Straight (Ratchet Style) Contact Groove Cable Clamp Cable Clamp Figure 4 3. While observing the wires, slide the cover onto the connector until bottomed. Do NOT pull wires. 4. Make sure the cable sheathing is located in the strain relief of the cover. 5. Install the strain relief clamp on the cover with your hand or a suitable pair of parallel pliers. Make sure the locking latches engage the locking tabs. 4.2. 90 Two-Piece Covers Standard - Designed for cable-to-cable and cable-to-panel applications. Low Profile - Designed for cable-to-cable and cable-to-panel applications where height is a concern. Install as follows: 1. Grip the connector firmly with one hand, then draw the other hand over the wires and toward the proper end of the connector - forming the wires as indicated in Figure 5. Do NOT overwork the wires. Rev A 2. Position the half with the locking latches on the terminated connector. Make sure the contacts enter the contact groove, and the wires will fit inside the cover. 3. Make sure the cable sheathing is located in the strain relief of the cover. 4. Align the second half of the cover with the first, then press it onto the connector until the locking latches engage the locking tabs (a pair of parallel pliers may be required to close the strain relief). 4.3. 180 Two-Piece Covers NOTE There are two methods of placing the wires inside the 180 cover. The one used will depend on the terminated cable bundle in relation to the connector. If the cable bundle is located at one end (standard tooling) use Method 1, if the cable bundle is located in the center (MI-1 tool with loose combs) use Method 2. 3 of 4 Strain Relief Hardware for CHAMP Connectors Cable Sheathing 408-3159 6. Make sure the wires will fit inside the cover, and the cable sheathing is in the strain relief. Locking Latch 7. Align the second half of the cover with the first half, then press it on to the connector until the locking latches engage the locking tabs (a pair of parallel pliers may be required to close the strain relief). Locking Tab B. Method 2 1. Gather the wires together at the center of the connector. Contact Groove Strain Relief 2. Place the cover half with the locking latches on one side of the connector, and make sure the contacts enter the contact groove. See Figure 6. Figure 5 A. Method 1 3. Fit the wires inside the cover, and the cable sheathing in the strain relief. 1. Gather the wires at the end of the connector that is nearest to the cable bundle. See Figure 6. 4. Align the second half of the cover with the first half, then press it onto the connector until the locking latches engage the locking tabs (a pair of parallel pliers may be required to close the strain relief). 2. Place the cover half with the locking latches on one side of the connector, and make sure the contacts enter the contact groove. 3. Press the wires (at connector end) into the cover and hold them there with your thumb. 5. REVISION SUMMARY 4. Fold the cable bundle to the other end of the connector and again press the wires into the cover with your thumb. Revisions to this instruction sheet per EC 0990-1240-03 include: S Updated document to corporate requirements S Updated document to current format S Deleted obsolete part numbers 5. Hold the wires in the cover half and fold the cable bundle to the middle of the cover and out through the strain relief. Method 1 Contact Groove Strain Relief Locking Latch Method 2 180 Cover Halves Strain Relief Locking Tab Figure 6 4 of 4 Rev A