Instruction Sheet 408-10077 Commercial Single-Line Connectors 06 JUL 06 Pin Contact Rev A Receptacle Housing 20 KVDC Connector Assembly Cap 30 KVDC Connector Assembly Plug Housing Receptacle Housing Pin Contact Cap 10 KVDC Connector Assembly Socket Contact Socket Contact Plug Housing VOLTAGE CONNECTOR RATING TYPE { Plug 10 KVDC Receptacle WIRE SIZE 2 mm 0 2 0 6 0.2-0.6 INSULATION AWG HAND D KIT CONTACT DIE SET 2.66 [.105] 867157-1 203802-6 --- 91544-1 4.06 [.160] 867157-2 203802-6 --- 91544-1 DIA (MAX) TOOL EXT TOOL (DOCUMENT) 20 24 20-24 91038 3 91038-3 (408-7357) 0.2-0.6 20-24 4.06 [.160] 867156-1 203816-6 --- 91544-1 0.3-0.6 22-20 4.7 [.185] 861610-1 66399-1 --- 91523-1 0.8-1.4 18-16 4.7 [.185] 861610-3 66101-2 --- 91505-1 0.3-0.6 22-20 7.67 [.302] 861610-4 66399-1 --- 91523-1 0.8-1.4 18-16 7.67 [.302] 861610-2 66101-2 --- 91505-1 861751-1 0.3-0.6 22-20 4.7 [.185] 861753-1 66400-1 --- 91523-1 (408-9567) 0.8-1.4 18-16 4.7 [.185] 861753-3 66099-2 --- 91505-1 0.3-0.6 22-20 7.67 [.302] 861753-4 66400-1 --- 91523-1 0.8-1.4 18-16 7.67 [.302] 861753-2 66099-2 --- 91505-1 5-6 10 12.7 [.50] 863103-1 66741-8 90140-1 69710-1 2-3 14-12 12.7 [.50] 863103-2 66740-8 90145-1 69710-1 1.4 16 12.7 [.50] 863103-3 66740-8 90145-2 69710-1 5-6 10 12.7 [.50] 863104-1 66259-1 90140-1 69710-1 1.4 16 12.7 [.50] 863104-3 66261-1 90145-2 69710-1 Plug 20 KVDC Receptacle Plug 30 KVDC 863558 1 863558-1 (N/A) Receptacle {Bulkhead-mounted receptacle kits are also available. DOptional 626 Pneumatic Tool System is also available. Figure 1 1. INTRODUCTION This instruction sheet provides assembly information for the Commercial Single-Line Connectors listed in Figure 1. This document supercedes drawing Instruction Sheets 862749-1, 862755-1, 863668-1, and 867443-1. E2006 Tyco Electronics Corporation, Harrisburg, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. All International Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, Tyco is a trademark. *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 408-10077 Commercial Single-Line Connectors NOTE All dimensions are in metric units [with U.S. customary units in brackets]. Figures and illustrations are for reference only and are not drawn to scale. 2. DESCRIPTION All connector kits (excluding contacts) are made from UL Recognized self extinguishing plastic material (94V-0 rated). These connectors are designed for commercial application in industrial environments and have an operating temperature range of 15 to 85 C [59 to 185 F]. 4. Tin lead between the contact and insulation to provide mechanical strength required for lead insertion. 5. Terminate the contact onto the wire using the referenced tooling listed in the table in Figure 1. Instruction sheets for application requirements for the referenced tooling are available from Tyco Electronics. 6. Insert leads into the housing until the contacts latch in the cavity. The pin and socket contacts should be located the proper distance from the end of the respective plug and receptacle housings according to the dimensions provided in Figure 3. 3. ASSEMBLY PROCEDURES Receptacle 1. Determine which voltage requirement is needed for your production requirements. Connector (Typ) 2. Select the specific connector kit based on your voltage requirements according to wire size and insulation diameter. Extraction Tool (Typ) 3. Refer to the table in Figure 2 for the specific connector kit, and strip the jacket (if required), and insulation to the proper strip length. Jacket Strip Length Plug Connector (Typ) Insulation Strip Length VOLTAGE RATING Conductors CONNECTOR KIT STRIP LENGTH JACKET 867157-1 --- 867157-2 INSULATION 15.49-16.00 [.610-.630] VOLTAGE RATING PLUG RECEPTACLE 10 KVDC 0.0-0.76 [.000-.030] 9.14-9.65 [.360-.380] 20 KVDC 0.76-1.52 [.030-.060] 18.03-18.80 [.710-.740] 30 KVDC 2.03-2.54 [.080-.100] 18.03-18.54 [.710-.730] 10 KVDC --- 861610-1 22.86-24.13 3.56-4.32 861610-3 [.900-.950] [.140-.170] 861610-2 20 KVDC --- 861610-4 Figure 3 4.83-5.08 867156-1 [.190-.200] 22.86-25.4 [.900-1.000] DISTANCE FROM END OF CONNECTOR 4. REMOVAL Use Extraction Tools listed in the table in Figure 1 for removing the contacts from the connector housings. Refer to the instruction sheets provided with the extraction tool for proper use and procedures. 861753-1 861753-2 6.60-7.37 3.56-4.32 861753-3 [.260-.290] [.140-.170] 861753-4 863103-1 863103-2 30 KVDC 863103-3 863104-1 863104-3 Figure 2 2 of 2 --- 20.32-22.86 5. CONNECTOR MATING Keys and keyways designed in the plug and receptacle housings will align the contacts for positive mating and sealing for recommended operation. [.800-.900] 6. REVISION SUMMARY S Initial release of document Rev A