AMP THREADED COUPLING AMP* LGH* Circular High Voltage Connector with 2, 3, 4, 6, or 7 Contacts HEX NUT instruction Sheet 408-9169 29 JUN 94 RevB RECEPTACLE TYPICAL, 6-CONTACT CONNECTOR SHOWN NUMBER PLUG KIT PLUG KIT AND | PLUG (with strain OF WIRE SIZE | RECEPTACLE PLUG WITH RECEPTACLE | relief) AND CONTACTS (AWG) KIT STRAIN RELIEF KIT RECEPTACLE KIT 2 24 through 14 859529 | 860261-{ ] 863020-{ | 860288 | 863015-{ } 3 859526] 860263- | 863021-| ] 860287-| } 863016-{ } 4 859526 | 860265-{ | 863022 ] 860286-{ } 863017- | 859527-| | 860267-{ | 863023-{ ] 860229-{ | 863018-{ ] 863031-{ ] 7. 861647- | 861648 | 863024 ] 860825-| | 863019-{ ] Figure 7 85-118 1. INFRODUCTION size, a retaining ring or strain relief (plug kits only), This instruction sheet covers the assembly procedure for the AMP circular connectors listed in Figure 1. Notice that only base numbers are shown; for more specific information about a particular connector, contact AMP Product Information Center at 1-800-522-6752, or order AMP Catalog 82024. Read this sheet, and applicable referenced material, before assembling connectors or installing hardware. See Paragraph 7, REVISION SUMMARY, for revision information. All dimensions on this document are in metric units [with U. S. customary units in brackets]. 2, DESCRIPTION Each connector kit features a plug or receptacie shell, TYPE Il Pin or Socket Contacts of a specified wire and a hex nut {receptacle kits only). The connectors are equipped with threaded caps for quick connect/disconnect capability and can be panel or bulkheadmounted, or used for free hanging applications. When crimping the contacts and assembling the connectors, the connectors must be sealed with a Suitable potting material. Refer to Section 4, ASSEMBLY AND POTTING, for specific instructions. 3. WIRE PREPARATION (Figure 2} Refer to Figure 2 for proper stripping dimensions, and proceed as follows: 1. Strip the insulation according to the dimensions shown in Figure 2. 2. Crimp the contact to the wire using the appropriate tooling. Refer to Figure 3 and to the instruction sheet packaged with the tool. AMP Incorporated, Harrisburg, PA 17105 TECHNICAL ASSISTANCE GENTER 1-800-722-1111 AMP FAX/PRODUCT INFO 1-800-522-6752 1of5 This AMP controlled document is subject tc change. For latest revision call the AMP FAX number. Copyright 1994 by AMP incorporated. All Rights Reserved. *Trademark LOC BLGH Circular High Voltage Connectors 408-9169 LOCKING SOCKET CONTACT LANCE (Typ) CLEAN < AREA ARMSTRONG (Typ) A12-To Ori =~ (Typ) Ve <= WIRE STRIP LENGTH = 6.40 mm + .51 mm PIN CONTACT [.250 IN. + .02IN.] INSULATION - BUTTED AGAINST CONTACTS 10-1A Figure 2 2. Insert contacts into cavities of housings, making sure locking lances of contacts are fully seated in the housing. Pull back lightly on each contact to make sure itis seated properly. 3. After crimping the contact, thoroughly clean the surface of the wire and contact with alcohol, as shown in Figure 2. if silicone insulated wire is fo be used (with silicone rubber potting material), clean the insulation with alcohol. If PTFE insulated wire is used(with silicone rubber, epoxy, or polyure- thane potting material), abrade, etch, and prime the insulation according to the recommenda- tions of the manufacturer for the appropriate potting material. his Extraction cannot be accomplished after the assembly has been fully assembled and potted: it is possible to remove contacts before poiting by using AMP Extraction Too! 861751-1; see Paragraph 6, CONTACT EXTRACTION; refer to instruction sheet packaged with the tool. 3. If strain relief is used, attach it to the shell by applying Armstrong A12-T epoxy to the lip of the Strain relief where it makes contact. Allow to cure. Install cap on shell before attaching strain relief. 4, ASSEMBLY AND POTTING (Figures 4, 5, and 6) Proceed as follows: 1, Roughen the inner surface of the potting area of the receptacle, plug, and strain relief (if used), by abrasive blasting. Clean abraded area thoroughly 4. Fill the housing and strain relief (if used}, with HYSOL 4215 when wire insulation is TEFLONT; use GE RTV-511 or RTV-214 when wire with alcohoi and allow to dry. insulation is silicone. Do NOT introduce voids. WIRE CONTACT CRIMP SIZE (AWG) INSULATION DIAMETER PIN SOCKET TOOLING 24 to 20 1.35-2.08 200673-1 201328-1 45089 [.055 - .085] 1810 16 200681-1 200333-4 45098 14 201645-1 201568-1 45098 24 to 20 2.03-2.54 663991 90067-5 [.080 100} 18 to 16 2.03-2.54 66101-2 90067-5 [.080 100] 14 2.032.54 86360-2 90310-3 [.080 -.100] @ Manutactured by Armsirong Products Co., Warsaw, IN Manutactured by HYSOL Industrial Products T Trademark of E. 1. DuPont de Nemours & Co. 4 Manufactured by General Electric Company Neen a mana 20f5 RevB Figure 3AMF LGH Circular High Voltage Connectors 408-9169 1.52mm MIN. +- [0.061N.] i CUSTOMER BULKHEAD ! ta MOUNTING SURFACE POTTING POTTING ! HEX CAP AREA SHELL NUT = O-RING POTTING AREA RECEPTACLE PLUG Figure 4 a5-118D 1.52 mm MIN. [0.061N.] | CUSTOMER BULKHEAD MOUNTING SURFACE . POTTING POTTING HEX GAP AREA SHELL NUT O-RING POTTING AREA RECEPTACLE PLUG Figure 5 BS-118E CUSTOMER BULKHEAD MOUNTING SURFACE ~ 1.62 mm MIN. | h CAP [0.06 IN} 1 | HEX O-RING NUT = L __ POTTING POTTING AREA AREA a RETAINING RING RECEPTACLE PLUG Figure 6 85-1184 eee renee ee re ee eee errr ce eee Rev B ; 30t5AMP LGH Circular High Voltage Connectors 408-9169 5. When potting with HYSOL 4215, contact and wire sub-assemblies must be bonded with Armstrong A12-T epoxy to seal cavities. Apply adhesive to area designated in Figure 2, and insert per Paragraph 4, step 3 above. Allow epoxy to cure thoroughly, 6. After filling the housings, allow the compound to cure FULLY before applying voltage. 7, Mount appropriate O-rings, retaining rings, threaded caps, and hex nuts as shown in Figure 4. AMP recommends using HYSOL 4215 or GE RTV-511 potting material and Armstrong At2-T epoxy adhesive. If these materials are NOT used, obtain materials which are compatible with the wire insulation, housings, wire preparation used, operating voltage, stress levels, and the environmental conditions in which the unit will be operated. 5. PANEL MOUNTING Using the dimensions shown in Figures 7 or 8, make the panel cutout for the proper receptacle connector. Attach the connector to the panel using the hex nut supplied with the connector. Tighten the nut to a maximum torque of 2.26 Newton (N) [20 inch- pounds]. 6. CONTACT EXTRACTION Contacts can be extracted from the connector before potting by using AMP Extraction Tool 861751~1. Proceed as follows: 1. Hold the connector with the mating face toward you (see Figure 9). 2. Align the sleeve of the extraction tool with the contact to be removed. 3. Holding the handle, insert the sleeve straight into the contact cavity until the sleeve bottoms. Aliow the push rod button to back out of the handle as shown in Figure 9. 4. Rotate handle in either direction to assure that contact locking lance has released. 9. Keep the sleeve firmly bottomed in the cavity, and depress the push rod button. The contact will eject as the button is depressed. 6. Remove the tool from the contact cavity. 4of5 RECOMMENDED PANEL CUTOUT FOR 2, 3, AND 4 CONTACTS 3.96 mm [-1561N.] sai r SF 25.80-26.19 mm [1.015-1.031 IN.] Figure 7 RECOMMENDED PANEL CUTOUT FOR 6 AND 7 CONTACTS 3.96 mm [.1561N] aap ps ST 32.00-32.31 mm [1.260-1.2701N.] Figure 8 7, REVISION SUMMARY Since the previous release, the following change was made to this document: Per EC 0600-1886-94: e Changed part number of the 7-contact plug kit in Figure 1 RevBANF LGH Circular High Voltage Connectors 408-9169 CONTACT EXTRACTION CONNECTOR SLEEVE PIN CONTACT (Ref) ROTATE HANDLE DEPRESS PUSH ROD BUTTON NOTE: EXTRACTION CANNOT BE ACCOMPLISHED AFTER THE ASSEMBLY HAS BEEN FULLY ASSEMBLED AND POTTED. Figure 9 85-1186 Rev B o0f5