Instruction Sheet 408-10113 7-Pin Plug Kit (Potted Version) 06 MAR 08 Rev B Plug Kit 865594-1 Housing Boot Polyester Cap Brass Cap Plug Housing Contact Solder Cups Silicone Insert or Slug Plug Kit 865656-[ ] 7-PIN PLUG KITS PLUG KIT TYPE PART NUMBER DESCRIPTION Plastic Shell 865594-1 Standard Plug Kit 865656-1 Straight Shrinkable Boot 865656-2 Right-Angle Shrinkable Boot 865656-3 No Shrinkable Boot Metal Shell Figure 1 1. INTRODUCTION NOTE This instruction sheet covers the assembly procedures for the 7-Pin Plug Kit (Potted Version). This plug kit will accept a wire size range of 16-22 AWG and the insulation must be rated for at least 15kVDC with a maximum diameter of 4.70 mm [.185 in.]. Figure 1 provides connector features and terms used in this document. Use these terms when corresponding with Tyco Electronics Representatives to facilitate assistance. See the table in Figure 1 for related product part numbers and descriptions. E 2008 Tyco Electronics Corporation, Harrisburg, PA All International Rights Reserved Dimensions on this instruction sheet are in millimeters [with inches in brackets]. Figures and i illustrations are for identification only and are not drawn to scale. 2. WIRE SELECTION AND TERMINATION Select the correct wire size for your production requirements and refer to the following procedures. 1. Strip the wire insulation to a maximum of 3.56 mm [.140 in.]. TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. visit our website at www.tycoelectronics.com 1 of 2 LOC B 408-10113 7-Pin Plug Kit (Potted Version) CAUTION Be careful not to nick or cut the conductors. The straight potting shell has a positive stop so NOTE the cap will rotate freely. Allow the adhesive to i ! 2. Dress the leads through the holes in the plug housing towards the end with the keyways. cure before final potting. Kits without potting shells are filled to the top of NOTE the plug housing. i 3. Solder the leads to the contacts of the silicone insert. Clean soldered connector thoroughly. 6. POTTING 3. SILICONE APPLICATION NOTE Apply a thin coating of silicone adhesive (RTV-732 or equivalent) to only the shoulder of the silicone slug or insert. Insert the slug or insert into the plug housing until the interface of the silicone slug or insert is flush with the housing. The potting material selected must be compatible with the wire insulation and preparation i procedure used, the polyester housing, the operating voltage stress levels, and the environmental conditions in which the unit will be operated. 4. PREPARING THE HOUSING NOTE The surface of the plug housing and the potting shell should be prepared for potting in conjunction with the manufacturers recommended procedures for the appropriate potting material. Fill the potting area with the compound, taking proper precautions to avoid producing any voids. i Allow the compound to cure fully before finishing the assembly and applying the voltage. 7. SHIELD TERMINATION 5. ASSEMBLY Refer to Figure 2 for shield termination dimensions. Refer to the following steps for assembly procedures: 8. REVISION SUMMARY 1. Slip the cap over the back of the plug housing. 2. Apply epoxy adhesive to the threads of the potting shell, and attach to the plug housing. Polyolefin shrink tubing (located as shown below) and formed at 90 during heating and shrinking S Updated logo. S This document supercedes Instruction Sheet 866109-1 Right-Angle Version operation. Add metal braid, protective jacket and conductive shrink boot as shown below. 3.05 [.120] C L Ferrule 6.35 [.250] Metal Braid (Customer Supplied) Protective Jacket (Customer Supplied) 25.4 [1.000] Place Lip in Groove Cap Conductive Shrink Boot C L C L Polyolefin Shrink Tubing to Protect Wire Insulation (Optional) Straight Version Hook-Up Wire (Customer Supplied) Figure 2 2 of 2 Tyco Electronics Corporation Rev B