861753-1 - Tyco Electronics

Instruction Sheet

Commercial 408-10077

2006 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

Tyco is a trademark. *Trademark

Other products, logos, and company names used are the property of their respective owners. LOC B

of 2

TOOLING ASSISTANCE CENTER 1-800-722-1111

PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at

www.tycoelectronics.com

06 JUL 06 Rev A

Single-Line Connectors

10 KVDC

Connector

Assembly

30 KVDC

Connector

Assembly

20 KVDC

Connector

Assembly

Socket Contact

Pin Contact

Socket Contact

Plug Housing

Receptacle Housing

Plug Housing

Receptacle Housing

Cap

VOLTAGE CONNECTOR WIRE SIZE INSULATION

KIT

CONTACT

DIE SET

HAND EXT TOOL

RATING TYPE

{

mm2AWG DIA (MAX)

KIT

CONTACT

DIE SET

TOOL

(DOCUMENT)

Plug

02 06

20 24

2.66 [.105] 867157-1 203802-6 --- 91544-1

91038 3

10 KVDC

Plug

4.06 [.160] 867157-2 203802-6 --- 91544-1

91038

(408

7357)

Receptacle 0.2-0.6 20-24 4.06 [.160] 867156-1 203816-6 --- 91544-1

(408-7357)

0.3-0.6 22-20 4.7 [.185] 861610-1 66399-1 --- 91523-1

Plug

0.8-1.4 18-16 4.7 [.185] 861610-3 66101-2 --- 91505-1

Plug

0.3-0.6 22-20 7.67 [.302] 861610-4 66399-1 --- 91523-1

20 KVDC

0.8-1.4 18-16 7.67 [.302] 861610-2 66101-2 --- 91505-1 861751-1

20 KVDC

0.3-0.6 22-20 4.7 [.185] 861753-1 66400-1 --- 91523-1 (408-9567)

Receptacle

0.8-1.4 18-16 4.7 [.185] 861753-3 66099-2 --- 91505-1

Receptacle

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

Plug 2-3 14-12 12.7 [.50] 863103-2 66740-8 90145-1 69710-1

863558 1

30 KVDC 1.4 16 12.7 [.50] 863103-3 66740-8 90145-2 69710-1

863558

(N/A)

Receptacle

5-6 10 12.7 [.50] 863104-1 66259-1 90140-1 69710-1

(N/A)

Receptacle

1.4 16 12.7 [.50] 863104-3 66261-1 90145-2 69710-1

{

Bulkhead–mounted receptacle kits are also available.

Optional 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.

408-10077

Commercial Single-Line Connectors

Rev

of 2

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].

3. ASSEMBLY PROCEDURES

1. Determine which voltage requirement is needed

for your production requirements.

2. Select the specific connector kit based on your

voltage requirements according to wire size and

insulation diameter.

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

Insulation

Strip Length Conductors

VOLTAGE CONNECTOR STRIP LENGTH

RATING KIT JACKET INSULATION

10 KVDC

867157-1

867157-2 --- 15.49-16.00

[.610-.630]

10 KVDC

867156-1 --- 4.83-5.08

[.190-.200]

861610-1

861610-3 22.86-24.13

[.900-.950] 3.56-4.32

[.140-.170]

20 KVDC

861610-2

861610-4 --- 22.86-25.4

[.900-1.000]

861753-1

861753-2

861753-3

861753-4

6.60-7.37

[.260-.290] 3.56-4.32

[.140-.170]

30 KVDC

863103-1

863103-2

863103-3

863104-1

863104-3

--- 20.32-22.86

[.800-.900]

Figure 2

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.

Extraction

Tool (Typ)

Receptacle

Connector

(Typ)

Plug Connector

(Typ)

VOLTAGE DISTANCE FROM END OF CONNECTOR

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]

Figure 3

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.

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.

6. REVISION SUMMARY

Initial release of document

NOTE