AMPLIMITE* .050 Series Connectors (Round-to-Flat Cable} instruction Sheet 408-9427 (was IS 9427) 29SEP93 Revd BACKSHELL COMPONENTS STRAIGHT EXIT STYLE METAL BACKSHELL ANGLED EXIT STYLE METAL BACKSHELL METAL STRAIN RELIEF STAPLE SHIELDED PLASTIC BACKSHELL JACKSCREW a SPRING CONNECTOR COMPONENTS LATCHING BLOCK INSULATION (Optional) DISPLACEMENT cP TERMINATION COVER _ CONTACTS va x KEYING INSERT METAL : SHELL HOUSING (Optional) Figur e 7 88-256, 88-257, 88-258, 88-259 1. INTRODUCTION This instruction sheet provides basic information regarding the termination and assembly of AMP* AMPLIMITE .050 Series Connectors. The connectors are terminated onto shielded, round, jacketed cable with multiple wire or twisted pair conductors. Wire sizes range from 28 to 30 AWG, solid or seven-strand with a 0.74-0.91 [.029-.036] insulation diameter. Wire must be approved by AMP Engineering. The connectors are available in both plug and receptacle configuration, in various sizes ranging fram 20 to 120 positions. Measurements are in millimeters [followed by inches in brackets]. Figures and illustrations are for identification only and are not drawn to scale. Reasons for reissue are provided in Section 5, REVISION SUMMARY. 2. DESCRIPTION (Figure 1) The front of each connector assembly features a keystone-shaped shell with a housing having a dual row of pin or receptacle contacts on 1.27x2.54 [-050x.100] centerlines. The back of each connector features insulation displacement contacts which are staggered to achieve the 1.27 [.050] centerline spacing on each side. A pair of termination covers, which are ribbed on the inner surface, assist in locating the wires over the insulation displacement contacts. A pair of metal backshells, or plastic backshells with metal hermaphroditic shields, is designed to secure the terminated connector assembly and provide EMI/RFI shielding for the finished connector assembly. The lower backshell features two slots for either of the following applications: (1) installation of keying inserts when keying of connector assemblies is desired, or AMP Incorporated, Harrisburg, PA 17105 TOOLING ASSISTANCE CENTER 1-800-722-1111 AMP FAX/PRODUCT iNFO 1-800-522-6752 This AMP controlled document is subject to change. For latest revision call the AMP FAX number. Copyright 1993 by AMP Incorporated. All Rights Reserved. Trademark 1of7 Revised Per EC 0990-0252-99, EC 0020-0426-53, EC BD6235AMPLIMITE .050 Series Connectors 408-9427 (2) installation of latching blocks for free~hanging, cable-to-cable applications. A metal strain relief staple, which is press-fit over the cable and into a corresponding slot in the cable exit of the lower backsheil, provides strain relief for the cable as well as grounding continuity for the cable braid to the backshells or shields. A pair of slots is provided in the lower metal backshell for installation of spring latches. The upper metal backshell is secured to the lower backshell with machine screws. These screws are not required with the plastic backshell. Backshells designed to correspond to the various connector sizes are available in two cable exit configurations; one type has the cable exit straight out of the back and the other has the cable exit at an angle from the finished assembly. 3. TERMINATION TOOLING (Figure 2} Termination of the connector, when using roundtoflat cable, requires AMP Cover Closing Kit 543508-1. AMP Staple Insertion Kit 543515-1 is used to insert metal strain relief staples into the backshells of the connector assemblies. Both kits must be mounted on an AMP Manual Miniature Applicator Frame Assembly 91295-1. A semi-automatic machine, AMP CHAMPOMATOR* 2.5 Bench Terminating Machine 354786-1 is available for higher-volume operations when terminating individual conductors in connectors prior to backshel! installation. The staple insertion kit is required to install metal strain relief staples in backshells after termination of connectors in the machine. The following AMP documentation is available for AMPLIMITE .050 Series Connector termination tooling and machines: 408-9820 AMP Cover Closing Kits 543508-1, 543526-1 and Staple Insertion Kit 543515-1 for AMPLIMITE .050 Series Connector Assembly 409-5839 AMP CHAMPOMATOR 2.5 Bench Terminating Machine 354786-1 Catalog 82068 AMPLIMITE and AMPLIMITE .050 Series Connectors and Terminals (Subminiature D) installation of latching blocks, rather than keying inserts, in the slots of the lower backsheil requires an arbor frame-type tooling. The AMP Manual! Arbor Frame Assembly 58024-1 may be used for this function, provided the ram and base plate surfaces are not fitted with any tooling. 3.1. Cable Preparation and Termination Procedure 1. Gable preparation requires conductors to be laminated on 1.27 [.050] centerlines for the AMP Cover Closing Tool 543508-1. The AMP CHAMPOMATOR 2.5 Machine 354786-1 does not require lamination since it is designed for discrete wire termination. See Figure 3 for appropriate cable breakout lengths. COVER CLOSING KIT 543508-1 (Ref) \ ADAPTER STAPLE INSERTION KIT 543515-1 Figure 2 RAM TOOLING MANUAL MINIATURE APPLICATOR FRAME ASSEMBLY 91295~1 cad 9820, cad 9817 2o0f7 Rev DAMPLIMITE .050 Series Connectors 408-9427 STRAIGHT EXIT BACKSHELL LAMINATION BRAID LENGTHe ANGLED EXIT BACKSHELL 6.35 [.250] REQUIRED LENGTH FOR - CONDUCTOR ALIGNMENT CABLE OUTER BRAID BREAKOUT BREAKOUT CONDUCTORS LENGTH JACKET LENGTH ON 1.27050] (MAX.) . See Table (See Table) CENTERLINES ( ) @ Braid length will vary according to backshell style. Refer to Paragraph 3.2, Backshell Assembly. CONNECTOR CABLE BREAKOUT LENGTH (MAX) SIZE STRAIGHT EXIT BACKSHELL ANGLED EXIT BACKSHELL 20 26 22,86 [.900] 22.86[.900] 28 40 22.86 [.900] 27.94/1.100] 50 . 27.94 [1.100] 27.94[1.100] 80 100 120 27.94 [1.100] 38.10[1.500] Figure 3 88-2638 Correct cable breakout lengths are critical to successful termination and placement of back- Shells. Excessive cable breakout lengths will result in too much bulk for backshel! mounting. 2. On cable requiring lamination, you need to determine the placement of conductors in relation to the contact pin assignments for both rows of contacts in the connector. This may be done by color code or continuity check, per customer requirements. See Figure 4. 3. Fully insert prepared cabie conductor ends, with the laminated sides facing termination covers, into rear of connector assembly. Simultaneously press termination covers firmly by hand to captivate conductors between insulation displacement contacts and termination covers. PIN ASSIGNMENT oppose ppoocon Pin No. 1 is ALWAYS indicated 1 on the .050 Series plug and ERA , receptacle connectors. Pin BEARanGpaqanna assignment for plug connectors is from LEFT TO RIGHT. 7 a5 Pin assignment for receptacle 3s pomapoegseaaons connectors is a mirror image of ARAL > the plug connector, therefore PFonnoadboooco RIGHT TO LEFT. An example of 26 50 a 50-position pin assignment of = gy each is shown. Figure 4 88-262, 88-2624 Rev DB 3of7AMPLIMITE .050 Series Connectors 408-9427 ALL CONDUCTORS CORRECTLY PLACED OVER INSULATION DISPLACEMENT CONTACTS PRIOR TO TERMINATION / kes LAMINATED CONDUCTORS ON 1.27 |.050} CENTERLINES { Oo CONDUCTORS VISIBLE iN GAP BETWEEN TERMINATION COVER AND CONNECTOR SHELL 8E-2914 5. Insert the connector to be terminated into the termination tooling assembly. 6. Terminate the connector by rotating the lever of the manual applicator until termination covers bottem on connector housing, and then return the lever to the original position. 7. Remove the terminated connector from the tooling. 3.2, Backshell Assembly Backshell assembly requires the correct placement of the connector within the backshell relative to your application. See Figures 6A and 6B for the two styles of cable exits. Assembly also requires placement of the metal strain relief staple, installation of jackscrews or latches, and insertion of keying inserts (if used). When using the angled exit style backshell, Figure 5 NOTE . : placement of the connector in the backshell is 4. Visually examine the connector for correct more critical due to cable exit direction in placement of conductors over insulation component packaging. Not only must the D of displacement contacts by looking at the gap the connector correspond to the mating connec- between each termination cover and the connector tor, but the cable exit of the backshell must be housing flange. Gonductors should be visible in the predetermined if the cable is to be routed in a gap. See Figure 5. specific direction for packaging. See Figure 6A. A ANGLED EXIT STYLE METAL BACKSHELL STRAIGHT EXIT STYLE METAL BACKSHELL B MACHINE SCREWS METAL STRAIN REUEF STAPLE UPPER TERMINATED BACKSHELL CONNECTOR SPRING LATGH LOWER BACKSHELL MACHINE SCREWS UPPER BACKSHELL TERMINATED LATCH CONNECTOR LOWER KEYING INSERTS BACKSHELL (Optional) Figure 6 (continued) 88-264, 88-265 4of7 Rev DANF AMPLIMITE .050 Series Connectors 408-9427 SHIELDED PLASTIC BACKSHELL b. Lay the upper backshell over the lower back- (Available in Straight Exit Style Only) shell with the legs of the upper backshell positioned over the latching block inserts as SY 5 Sd , shown in Figure 7. c. Place the backshell assembly on the plate of the arbor frame assembly and under the ram. Lower the ram slowly and seat the latching blocks by applying pressure to the upper back- SS OA CRSHELL HALF shell with the ram. STRAIN-RELIEF 4. Insert the connector in the lower backshell until STAPLE HERMAPHRODITIC bottomed. See Figure 8. NR SHELD 5, After ensuring that the cable braid is folded back smoothly over the cable jacket and trimmed, place CONNECTOR cable in the cable exit of the lower backshell. Make (Sold certain that braid and cable jacket extend beyond Separately) the front edge of the staple slot area and behind (Covers Shown the recessed pocket of the lower backshell. Refer Assembled} to Figure 8. 6. When using the plastic backshell kit, insert lower hermaphroditic shield in lower backshell. See Figure 6C. Place one hermaphroditic shield over the assembly, and insert it until it latches with the other shieid. Place the metal strain relief staple in the slot and over the cable braid (and upper shield, when used). Braid should not extend out of cable exit of backshell. See Figure 8. CAUTION it is extremely important to ensure that all con- ductors extending from the strain relief area to the connector assembly are positioned within the sides of the lower backshell. Any conductors extending over the sides will be pinched, and consequently shorted, when the upper backshell PLASTIC LOWER is assembled to the lower backshell SHIELD BACKSHELL HALF - , 7. Position the metal strain relief stapte into the backshell slot, and over the cable. Then using the Figure 6 (end) AMP Staple Insertion Kit 543515-1, press firmly into place. This will secure the cable in the cable Assembly is as follows: exit of the backshell. See Figure 9. For more information on the setup and use of Staple 1. Lay the lower backshell on a flat surface and Insertion Kit 543515-1, refer to instruction sheet ensure the proper orientation of the connector D 408-9820. in relation to the cable exit. See Figure 6A and 6B. 8. Install the spring latches (or jackscrews for 2. If using keying inserts, install in the slots shielded plastic backshell) in the slots provided. provided, making sure that placement is in a See inset of Figure 8 for detail. mating configuration consistent with the mating 9. When using metal backshells, place the upper connector. backshell over the lower backshell and, after ; . . ensuring that no conductors are in a pesitton to be 3. If using latching blocks, install as follows: ninched between the mating halves She ; backshell, insert the machine screws and tighten a. Place latching block inserts in lower backshell slots, maki tain that they are oriented out- them uth the packshel haives are secured. See ward as shown in Figure 7. igure Oo and oe. When using plastic backshells, place the upper. if incorrectly oriented, the latching blocks will backshell over the lower backsheil, inserting the be sheared off with the application of tooling post of the upper backshell in the holes of the pressure and the backshell will be rendered iower backshell untit the backshell halves are unusable. secured. See Figure 6C. Rev D 5of7ANF AMPLIMITE .050 Series Connectors 408-427 \ ~~ AES ~ Tt UPPER | BACKSHELL LEGS OF UPPER BACKSHELL MUST BE POSITIONED OVER LATCHING BLOCKS oa >) y Ao 2 _-> LATCHING Oe BLOCKS a MRRNTED AS OO SHOWN NN C SS oS A LOWER BACKSHELL BASE PLATE yo Figure 7 68-258 METAL STRAIN RELIEF STAPLE SLOT CABLE EXIT SPRING LATCH RECESSED POCKET NOTE: Braid and cable jacket must extend beyond the front edge of strain relief KEYING staple slot and behind recessed pocket INSERT of lower backshell. {Optional) STAPLE TERMINATED CONNECTOR INSTALLED IN LOWER BACKSHELL Figure 8 89-292A, 88-258 Bot? Rev DAMPLIMITE .050 Series Connectors 408-9427 METAL STRAIN RELIEF STAPLE Fy STAPLE INSERTION KIT 5435151 TYPICAL LOWER 7 a BACKSHELL - ~ | TERMINATION Se COVERS (Ref) MANUAL APPLICATOR FRAME ASSEMBLY 91295~1 (Ref} Figure 9 4. STAPLE INSERTION DEPTH Refer to Figure 10 for the recommended staple insertion depth. For most cables, this depth is sufficient to provide adequate strain relief. Some smaller diameter cables might require the staple to be inserted deeper in order to obtain the desired strain relief. Inserting the staple too deeply will cause breakage of the cable conductors. Not inserting the stapie deeply enough will result in inadequate strain relief for the cable. STAPLE INSERTION DEPTH CABLE CONDUCTORS 1271,005) BRAID 264{.010} (0 CABLE STAPLE JACKET \ FLOOR OF LOWER BACKSHELL CROSS-SECTION VIEW OF METAL STRAIN RELIEF STAPLE AFTER INSTALLATION IN LOWER METAL BACKSHELL Figure 10 SLOT cad 9820 Staple Inspection Check for proper depth by grasping the cable behind the staple and moving the cable around, gently. Note whether the wires within the backshell remain Stationary. If the wires within the backshell move, it will be necessary to press the staple deeper. 5, REVISION SUMMARY Revisions to this document include: Per EC 0990-0252-93: - New format - Metric measurements added Per EC BD6235: ~ Removed latches on shielded plastic upper backshell in figures that apply Per EC 0020-0426-93: - Changed Termination Tooling Assembly 852859-1 to AMP Cover Closing Tool 43508-1, Manual Applicator 91085-2 to Manual Miniature Applicator Frame Assembly 91295-1, Strain Relief Staple Tooling 764088-1 to Staple Insertion Kit 543515-1 ~ Changed 75 angle exit to angled exit - Removed any information pertaining to the termination bar and holder assembly part for connectors Changed AMP CHAMPOMATOR 2.5 (762734-1) TO AMP CHAMPOMATCR 2.5 Bench Terminating Machine 354786-1 - Changed AMP staple tooling assembly (764088-1) to AMP Staple Insertion Kit 43515-1 - Corrected reference documentation - Replaced tooling in Figure 2 with appropriate tooling - Added illustration for angled exit backshell and corrected information in Figure 3 Changed Figure 4 to show only D shape of connectors and corrected positions of pin assignment - Changed conductor lengths to cable breakout lengths and pertaining information - Removed Figure 6 and renumbered figures thereafter - Removed reference of specific connector sizes in backshell assembly procedure - Replaced Figure 9 with appropriate frame, fooling, and backshell - Removed formuta for staple height calculation tables and pertaining information - Changed Staple Height Calculation to Staple Insertion Depth and pertaining information Added staple insertion depth dimension to Figure 10 Rev D Tof?