Instruction Sheet
CHAMP*
Cable–to–Cable and 408–7564
(was IS 7564)
LOC B
1 of 3
E
2003 T yco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
AMP and Tyco are trademarks. *T rademark
Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1–800–722–1 111
F AX/PRODUCT INFO 1–800–522–6752
For Regional Customer Service, visit our website at
www.tycoelectronics.com
This controlled document is subject to change.
For latest revision, call the FAX/PRODUCT INFO number.
08 OCT 03 Rev A
Cable–to–Panel Connectors
1. INTRODUCTION
This instruction sheet covers the CHAMP Connectors
listed in Figure 1. These connectors are designed for
cable–to–cable (two free–hanging connectors) and
cable–to–panel (one free–hanging and one
panel–mounted connector) applications. Read this
and all referenced material before starting assembly.
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 7,
REVISION SUMMARY.
Receptacle
Connector Plug
Connector
4–40 UNC–2B
(2 Holes)
(Typ)
Open End
(Ref)
Color Code
Letter Code
Flange Thickness
(Ref) Polarization
CHAMP–LOK*
Connector
Locking Latch
Mounting Hole
(Ref)
Color Code Dot
(Marked on Back)
WIRE
CONTACT CONNECTORS
WIRE
SIZE
D
,
LTR
COLOR
CONT
RECEPTACLE PLUG
SIZE
D
,
AWG
LTR
CODE
COLOR
DOT
CONT
POSN THREADED
HOLES THICK
FLANGE THIN FLANGE THREADED
HOLES OPEN ENDS
22
C
14 ––– ––– ––– 552300–1 –––
22
C
24 552305–1 ––– 2–552322–1 ––– 552317–1
22
Solid
22
C
Green 36 552306–1 ––– ––– ––– 552318–1
22
Strd 50 552064–1 ––– 2–552324–1 552173–1 552319–1
64 552307–1 ––– ––– 552303–1 552320–1
22
14 552312–1 ––– 2–552271–1 552282–1 552270–1
2
4 and
2
624 552313–1 552273–1 2–552273–1 552283–1 552272–1
2
4 and
2
6
Solid
2
B Blue 36 552314–1 2–552275–1 2–552275–1 552284–1 552274–1
2
4 Strd 50 229975–1 2–552001–1 2–552001–1 229974–1 552032–1
64 552315–1 ––– 2–552277–1 ––– 552276–1
Figure 1 (cont’d)
NOTE
408–7564
CHAMP Cable–to–Cable and Cable–to–Panel Connectors
Rev A2 of 3
WIRE
CONTACT CONNECTORS
WIRE
SIZE
D
,
LTR
COLOR
CONT
RECEPTACLE PLUG
SIZE
D
,
AWG
LTR
CODE
COLOR
DOT
CONT
POSN THREADED
HOLES THICK
FLANGE THIN FLANGE THREADED
HOLES OPEN ENDS
22
Y
14 ––– ––– ––– ––– –––
22
Y
24 ––– ––– 2–552474–1 552443–1 552469–1
2
6,
2
7,
or 28 E
Y
ellow 36 ––– ––– 2–552475–1 552444–1 552470–1
Strd 50 552391–1 ––– 2–552476–1 552390–1 552471–1
64 ––– ––– ––– 552488–1 –––
22
F
14 ––– ––– ––– ––– –––
22
F
24 ––– ––– ––– ––– –––
22
Solid
22
F
Brown 36 ––– ––– ––– 556040–1 –––
22
Strd 50 555227–1 ––– ––– 556039–1 –––
64 ––– ––– 555151–1 ––– –––
D
Wire insulation diameter of 1.14 [.045] max is acceptable for contacts with letter codes C, B, and E. Wire insulation diameter of 1.42 [.056] max is
acceptable for contacts with letter code F.
Figure 1 (end)
2. DESCRIPTION
Plug (male) and receptacle (female) connectors
consist of polarized housings which are preloaded
with contacts on 2.16 [.085] centers. They are
available with 14–, 24–, 36–, 50–, or 64–contact
positions that are arranged in two opposing rows.
Each housing has a color–code dot which indicates
the wire size to be terminated in the connector. The
flanges on the plug housing have either 4–40
UNC–2B threads for screw mounting, or open ends
for bail mounting. The flanges on the receptacle
housing have either 4–40 UNC–2B threads for screw
mounting, or mounting holes (which accept screw or
bail mounting hardware – depending on type of plug
flanges). Note that receptacles have thick 4.75 [.187]
flanges for free–hanging applications and thin 1.98
[.078] flanges for panel–mounted applications.
Contacts have been designed for discrete wire with
solid conductors and for laminated cable with seven
stranded conductors (see Figure 1). A letter code,
designating the wire size, has been stamped on each
contact to assist in selecting replacement contacts.
Cables are manufactured to various
specifications (material, tolerances, etc.). All are
NOT compatible with CHAMP Connectors.
Before making production assemblies, it is
suggested that samples of your cable be
submitted to Tyco Electronics Engineering for
evaluation.
A full complement of strain–relief covers, strain
reliefs, and attaching hardware is available for each
connector. Refer to Instruction Sheet 408–3159 for
the selection and installation procedures of
strain–relief hardware. Refer to Instruction Sheet
408–3160 for the selection and installation
procedures of mounting hardware.
3. TERMINATION TOOLING
There are five basic terminating tools, each designed
for a specific purpose. The tool designator, part
number, function, and referenced instruction material
are provided in the following text.
CHAMPOMATOR* Machine
– Control Module and
Applicator Module. The semi–automatic power tool
is intended for production line terminations of
discrete wires to CHAMP Connectors. See
Customer Manual 409–5411 for operating
instructions.
Frame Assembly and Tooling Assembly
– Tooling
Assembly 231593–2 is designed for mass
termination of discrete wire, see Instruction Sheet
408–3133 for operating instructions. Tooling
Assembly 231592–2 is designed for laminated
cable, see Instruction Sheet 408–3137. Tooling
Assembly 230506 is designed for back–to–back
connectors, see Instruction Sheet 408–6503.
MI–1 –
The portable Hand Operated Tool 229378
is intended for production line and field
terminations of all connectors. See Instruction
Sheet 408–7559 for operating instructions.
Palm Grip
– The single wire Insertion Tool
229451–1 is intended for field service and repair
terminations of all connectors. See Instruction
Sheet 408–7642 for operating instructions.
T–Handle
– The single wire Insertion Tool
229384–1 is intended for repair terminations of all
connectors. See Instruction Sheet 408–7558 for
operating instructions.
CAUTION
408–7564
CHAMP Cable–to–Cable and Cable–to–Panel Connectors
3 of 3Rev A
4. CONTACT REPLACEMENT TOOL
Damaged contacts should not be used and can be
removed and replaced with the use of
Extraction/Insertion Tool 230238–1. Refer to
Instruction Sheet 408–7787, packaged with the tool,
for contact selection, removal, and replacement.
5. CONNECTOR SELECTION
1. Determine the size of the wire, and the number
of contacts that are to be terminated.
2. Determine the type of application that is to be
used (cable–to–cable or cable–to–panel).
3. Determine the hardware to be used (captive
screw for semi–permanent assembly, and bail
mounts for quick disconnect assembly).
4. Using the information established in Steps 1, 2,
and 3, refer to the table in Figure 1 and select the
applicable connectors.
6. INSTALLING DUST COVER
Dust covers should be used to protect the mating
face of connectors that are NOT mated. Determine
the size and style of the connector requiring
protection, then refer to the table in Figure 2 and
select the applicable cover. To install the cover, simply
align it with the mating face of the connector and
press it into position.
Connector
Dust Cover
NO. OF
POSITIONS PLUG
(BLUE) RECEPTACLE
(RED)
14 229968–5 229969–5
24 229968–4 229969–4
36 229968–3 229969–3
50 229968–1 229969–1
64 229968–2 229969–2
Figure 2
7. REVISION SUMMARY
Revisions to this instruction sheet per
EC 0990–1242–03 include:
S
Updated document to corporate requirements
S
Updated document to current format
S
Deleted obsolete part numbers in Figure 1
