5748678-2 - Tyco Electronics

Instruction Sheet

AMPLIMITE* Connector

HD- 20 Shielded 408--6609

LOC B

1of 8

E2009 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

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

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

09 SEP 09 Rev GCable Clamp Kits

Figure 1

Cable Clamp Strain--Relief Bar Cable

Captive Screw

Nut

Fillister

Head Screw

Inner Ferrule

Conductors

Flange Gripper

Outer Ferrule

Cable with Inner and Outer Crimp Ferrules

1. INTRODUCTION

This instruction sheet covers the use of AMPLIMITE

Connector HD--20 Shielded Cable Clamp Kits with

available ferrules listed in Figures 2 and 8, and

grommets listed in Figure 14.

Dimensions are in millimeters [with inch

equivalents in brackets]. Figures and illustrations

are for identification only and are not drawn to

scale.

Read these instructions carefully before using cable

clamp kits and ferrules.

Reasons for reissue of this sheet are provided in

Section 9, REVISION SUMMARY.

2. DESCRIPTION (Figure 1)

Each shielded cable clamp kit consists of two

symmetrical cable clamps which contain strain--relief

bars. Each kit also includes two captive screws, two

fillister head screws, and two nuts.

The shielded cable clamps are designed to provide

electromagnetic shielding and strain--relief for braid--

and/or foil--type (with drain wire) shielded cables. The

shielded cable clamps may be used on cables fitted

with split--ring or crimp ferrules, on cables without

ferrules, or on cables fitted with grommets.

Unshielded cable clamp with grommet kits are also

available to provide strain relief only.

Refer to Paragraph 3 when using cable without

ferrules, to Paragraphs 5 and 6 for installation of

cable clamps on cable with ferrules, and to

Paragraph 7 for installation of cable clamps on cable

with grommets.

Cable clamps are available in five sizes for

AMPLIMITE connectors with corresponding contact

positions (9, 15, 25, 37, and 50 for HD--20, and 15,

26, 44, 62 and 78 for HD--22).

Refer to Figures 2 and 8 to determine appropriate

cable clamp kit relative to cable diameter,

AMPLIMITE connector size, and type of ferrule (if

used) for the cable.

Refer to Figure 14 to determine appropriate grommet

set and cable clamp kit relative to cable diameter.

If cable diameter is too small to fit properly into

strain--relief, apply heat--shrinkable tubing before

working braid over cable jacket to build up the

outside diameter of the cable. The inside

diameter of the heat--shrinkable tubing should be

no more than twice the outside diameter of the

cable. See Figure 3.

NOTE

CAUTION

408- 6609

AMPLIMITE Connector HD- 20 Shielded Cable Clamp Kits

Rev G2 of 8 Tyco Electronics Corporation

FERRULES STRAIN--RELIEF

INNER OUTER ZINC DIE

CAST

PLATED

PLASTIC

745129--[ ] 745130--[ ]

5745171--[ ]

5745172--[ ]

5745173--[ ]

5745174--[ ]

5745175--[ ]

5745833--[ ]

5745854--[ ]

5747098--[ ]

5747099--[ ]

5747100--[ ]

Figure 2

3. ATTACHING CABLE CLAMP ASSEMBLY (Figure 3)

3.1. Braided Shield Cable (Without Ferrule)

1. Strip cable jacket from end of conductors. Refer

tothetableinFigure7forthecablejacketstrip

length for HD--20 and HD--22 connectors.

2. Push braided shield away from conductors to

form a bulge at base of outer cable jacket. Work

braided shield back over outer jacket. It may be

necessary to unweave shield and place strands

over outer jacket (strands should be spread evenly

over outer jacket).

3. Install tape or heat--shrinkable tubing without

sealant to secure loose strand ends to cable until

cable clamps are installed. The braid should be

exposed 14.27 mm [.562 in.] between tape or

tubing and conductors. See Figure 3. Use an

electric heat gun as the heat source.

4. Terminate conductors with contacts and insert

contacts into rear of connector or terminate to

connector per the appropriate document listed in

Figure 4.

5. Position one half of cable clamp on cable and

connector. Ensure that flange of connector is

behind flange gripper of clamp and that braided

shield of cable is in strain--relief grooves of clamp.

6. Position the other half of clamp on top of cable

and start the two fillister head screws and nuts on

the clamps.

7. Insert captive screws into mounting holes.

Alternately tighten the fillister head screws until the

two clamp halves bottom on each other.

Excess braided shield may be left secured or

may be trimmed off directly behind clamps with a

sharp shield trimming tool. Take care not to nick

or cut conductors. If heat--shrinkable tubing was

used to secure braid, do NOT trim the tubing.

3.2. Foil Shield Cable (Without Ferrule)

1. Strip the cable jacket from end of conductors.

Refer to the table in Figure 7 for the cable jacket

strip length for HD--20 connectors.

2. Unwrap foil shield from cable and wrap it around

outer jacket. Wrap drain wire around foil. Ensure

that conductive side of foil is facing outward.

3. Secure ends of foil and drain wire with tape or

heat--shrinkable tubing until clamps are installed.

Leave 14.27 mm [.562 in.] of foil exposed between

tape or tubing and conductors.

4. Terminate conductors with contacts and insert

contacts into rear of connector or terminate to

connector per the appropriate document listed in

Figure 4.

5. Position one half of cable clamp on cable and

connector. Ensure that flange of connector is

behind flange gripper of clamp and that foil shield

of cable and the drain wire are in strain--relief

grooves of clamp.

6. Position the other half of the clamp on top of

cable and start the two fillister head screws and

nuts on the clamps.

Figure 3

Cable

Tubing or Tape

Braid (Typ)

Conductors

Strain--Relief

Grooves

Cable Clamp

Built--Up

Tubing

Foil (Typ -- Conductive

Side Faces Out)

Cable Without Ferrules

14.27 [.562]

CAUTION

408- 6609

AMPLIMITE Connector HD- 20 Shielded Cable Clamp Kits

3of 8Rev GTyco Electronics Corporation

CONNECTOR TYPE DOCUMENT

HDP--20 Crimp Snap Instruction Sheet 408--7514

HDP--20 Solder Cup Instruction Sheet 408--9193

HDE--20 All Plastic Instruction Sheet 408--6621

HDE--20 Metal Shell Instruction Sheet 408--6645

HDP--22 Application Specification 114--10001

Figure 4

7. Insert captive screws into mounting holes.

8. Alternately tighten the fillister head screws until

the cable clamp halves bottom on each other.

Excess foil may remain secured with tape or may

be trimmed directly behind clamp with a sharp

trimming tool. Take care not to nick or cut

conductors. If heat--shrinkable tubing was used to

secure foil, do NOT trim the tubing.

Figure 5

Slot Cable Clamp

Latching Block

Spring Latch

Strain--Relief

End

Latching Block

4. LATCHING BLOCKS (Figure 5)

The cable clamps may be mounted to a

connector--mounted block or a panel--mounted block.

Cable clamps may be used with latching blocks

(208101, 745007, 745245, and 745286) by removing

mounting screws and replacing them with spring

latches (745255--2). Refer to Instruction Sheet

408--9130 and to Figure 5 of this document for proper

assembly of spring latches.

5. SPLIT RING FERRULE ASSEMBLY (Figure 6)

Refer to the table in Figure 8 for the proper ferrule for

the cable and for the AMPLIMITE connector you are

using, and proceed as follows:

1. Cut the cable to the desired length and slide the

ferrule onto the cable.

2. Strip cable jacket from end of conductors. Take

care not to nick or cut braid. Refer to the table in

Figure 6 for the cable jacket strip length for HD--20

and HD--22 connectors.

3. If using braided cable, fold braid back over cable

without splitting or slicing the braid. If using foil

cable with a drain wire, cut the foil to the jacket and

remove foil. Wrap the drain wire once around the

ferrule, making sure that the drain wire is NOT left

in the slotted opening in the ferrule. If using cable

with both foil and braid, cut foil to jacket and

remove foil after folding braid back over jacket.

Slide ferrule under braid to end of cable jacket.

4. Trim excess braid or drain wire to approximately

15.24 mm [.600 in.] from end of cable jacket.

5. Terminate conductors with contacts and insert

contacts into rear of connector or terminate to

connector per the appropriate document listed in

Figure 4.

6. Position one half of cable clamp on cable and

connector. Ensure that flange of connector is

behind flange gripper of clamp and that ferrule is

positioned against inner strain--relief bar of cable

clamp (see Figure 10).

7. Position other half of cable clamp on top of

cable and secure with attaching hardware.

Figure 6

Cable

Drain Wire

Wrapped Once

Around FerruleB15.24 [.600]

Connector

Braid Slotted Opening

of Ferrule

Split-Ring Ferrule

BDrain wire shown in this position for clarity. Wrap drain

wire around ferrule on side opposite slot.

6. CRIMP FERRULE ASSEMBLY (Figure 9)

Refer to the table in Figure 2 for the proper ferrule for

the cable and for the AMPLIMITE connector you are

using, and proceed as follows:

CAUTION

408- 6609

AMPLIMITE Connector HD- 20 Shielded Cable Clamp Kits

Rev G4 of 8 Tyco Electronics Corporation

Crimp ferrules are for use with cables with

braided shield ONLY. They are not for use with

foil shield cable. If a cable with both braid and foil

is being used, remove the foil before crimping

ferrules.

1. Slide outer ferrule over cable.

2. Strip cable jacket from end of conductors. Be

careful not to cut braid. Refer to the table in

Figure 7 for the cable jacket strip length for HD--20

and HD--22 connectors.

3. Cut braid approximately 12.7 mm [.500 in.] from

end of cable jacket.

4. Flare braid and slide inner ferrule under it. Do

NOT unweave braid. Make sure that inner ferrule

butts against cable jacket.

5. Slide outer ferrule over inner ferrule.

6. Place the cable assembly into Hand Crimping

Tool 543344--1, equipped with Die Assembly

543013--[ ], if crimping manually. See Instruction

Sheet 408--9318, packaged with the die set, for

specific crimping instructions. The hand crimping

tool is described in Instruction Sheet 408--9315. If

using an applicator in an automatic machine,

consult the appropriate applicator instruction sheet

or consult your local Tyco Electronics

Representative.

CABLE JACKET STRIP LENGTH FOR HD--20/HD--22 CONNECTORS

CONNECTOR TYPE

POSITION

HD--20/

HD--22

GROMMET/

FERRULE STYLE STRIP LENGTHG

MASS TERM.GG HAND

TOOLING DIMENSION

(Tooling Ident.)

HDE--20 9None/Grommet 25.4--38.1 [1.00--1.50] J

HDE--20 9Split Ring 25.4--38.1 [1.00--1.50] J

HDE--20 9Crimp Style 48.3--53.33 [1.90--2.10] F

HDE--20 15 None/Grommet 25.4--38.1 [1.00--1.50] J

HDE--20 15 Split Ring 25.4--38.1 [1.00--1.50] J

HDE--20 15 Crimp Style 48.3--53.33 [1.90--2.10] F

HDE--20 25 None/Grommet 33.0--40.6 [1.30--1.60] J

HDE--20 25 Split Ring 33.0--40.6 [1.30--1.60] J

HDE--20 25 Crimp Style 48.3--53.33 [1.90--2.10] F

HDE--20 37 None/Grommet 35.6--43.2 [1.40--1.70] J

HDE--20 37 Split Ring 35.6--43.2 [1.40--1.70] J

HDE--20 37 Crimp Style 55.9--61.0 [2.20--2.40] F

HDP--20/--22 9/15 None/Grommet 25.4--38.1 [1.00--1.50] -- -- --

HDP--20/--22 9/15 Split Ring 25.4--38.1 [1.00--1.50] -- -- --

HDP--20/--22 9/15 Crimp Style 48.3--53.33 [1.90--2.10] -- -- --

HDP--20/--22 15/26 None/Grommet 25.4--38.1 [1.00--1.50] -- -- --

HDP--20/--22 15/26 Split Ring 25.4--38.1 [1.00--1.50] -- -- --

HDP--20/--22 15/26 Crimp Style 48.3--53.33 [1.90--2.10] -- -- --

HDP--20/--22 25/44 None/Grommet 27.9--40.6 [1.10--1.60] -- -- --

HDP--20/--22 25/44 Split Ring 27.9--40.6 [1.10--1.60] -- -- --

HDP--20/--22 25/44 Crimp Style 55.9--61.0 [2.20--2.40] -- -- --

HDP--20/--22 37/62 None/Grommet 27.9--40.6 [1.10--1.60] -- -- --

HDP--20/--22 37/62 Split Ring 27.9--40.6 [1.10--1.60] -- -- --

HDP--20/--22 37/62 Crimp Style 55.9--61.0 [2.20--2.40] -- -- --

HDP--20/--22 50/78 None/Grommet 27.9--40.6 [1.10--1.60] -- -- --

HDP--20/--22 50/78 Split Ring 27.9--40.6 [1.10--1.60] -- -- --

HDP--20/--22 50/78 Crimp Style 55.9--61.0 [2.20--2.40] -- -- --

GThe strip length dimension range is designed to accommodate a variety of cable designs. In order to determine the proper strip length, before

beginning production runs, consideration must be given to the flexibility and type of wire, bundling of wire due to circuit arrangement, and other

like factors. In any case, the ferrule placement discussed in the assembly procedures must be per Figure 10 for split ring ferrules and per

Figure11forcrimpferrules.GGMass termination hand tooling dimension pertains to HDE connectors ONLY.

Figure 7

NOTE

408- 6609

AMPLIMITE Connector HD- 20 Shielded Cable Clamp Kits

5of 8Rev GTyco Electronics Corporation

CONNECTOR SIZE CABLE RANGE SPLIT--RING STRAIN--RELIEF 180°CABLE

(HD--20/HD--22)

(OD)

FERRULE ZINC DIE CAST PLATED PLASTIC

4.06--5.08 [.160--.200] 745508--2 745171--2 745854--5

(

)

5.33--6.10 [.210--.240] 745508--3 745171--1 745854--3

(

)

8.38--9.40 [.330--.370] 745508--6 745171--5 745854--1

4.70--5.72 [.185--.225] 745508--3 745172--3 747099--7

26.10--7.62 [.240--.300] 745508--4 745172--2 747099--5

(15--Posn/26--Posn) 8.51--9.52 [.335--.375] 745508--6 745172--1 747099--3

9.91--10.92 [.390--.430] 745508--1 745172--3 747099--1

6.10--7.11 [.240--.280] 745508--4 745173--5 745833--9

7.87--8.89 [.310--.350] 745508--5 745173--4 745833--7

(

)

9.91--10.92 [.390--.430] 745508--1 745173--3 745833--5

(

)

11.18--12.19 [.440--.480] 745508--1 745173--2 745833--3

12.45--13.46 [.490--.530] 745508--9 745173--1 745833--1

7.87--8.89 [.310--.350] 745508--5 745174--5 747100--9

9.91--10.92 [.390--.430] 745508--1 745174--4 747100--7

(

)

11.68--12.7 [.460--.500] 745508--8 745174--3 747100--5

(

)

13.59--14.60 [.535--.575] 1--745508--0 745174--2 747100--3

15.49--16.51 [.610--.650] 1--745508--1 745174--1 747100--1

8.51--9.52 [.335--.375] 745508--6 745175--6 -- -- --

10.41--11.43 [.410--.450] 745508--7 745175--5 -- -- --

512.32--13.34 [.485--.525] 745508--9 745175--4 -- -- --

(50--Posn/78--Posn) 14.22--15.24 [.560--.600] 1--745508--0 745175--3 -- -- --

16.13--17.14 [.635--.675] 1--745508--1 745175--2 -- -- --

18.03--19.05 [.710--.750] 1--745508--2 745175--1 747098--1

Figure 8

Figure 9

Outer Ferrule Cable Jacket

Inner Ferrule

Flared Braid

Conductors

Slipping Inner Ferrule Under Braid

Cable

Outer Ferrule

Inner Ferrule

Flange

Connector

Strain--Relief Bars

Installing Cable Into Cable Clamps

Crimp Ferrules

7. Crimp the ferrules and remove crimped

assembly from crimping dies. Trim excess braid

from between the two ferrules. Take care not to

nick or cut conductors.

8. Terminate conductors with contacts and insert

contacts into rear of connector or terminate to

connector per the appropriate document listed in

Figure 4.

408- 6609

AMPLIMITE Connector HD- 20 Shielded Cable Clamp Kits

Rev G6 of 8 Tyco Electronics Corporation

Figure 10

Slotted Opening

of Ferrule

Strain--Relief

Bars

Drain Wire

Wrapped

Once

Around

FerruleY

Split--Ring

Ferrule

HD Connector

(Shown for Reference)

Flange

Gripper

Connector

Flange

Ferrule Placement

Split--Ring Ferrule

YDrain Wire shown in this position for clarity only. Wrap

drain wire around ferrule on side opposite slot.

9. Position one half of cable clamp on cable and

connector. Ensure that flange of connector is

behind flange gripper of clamp and that inner

ferrule is positioned between the two strain--relief

bars of the clamp (see Figure 11).

Figure 11

Connector Flange

Inner Ferrule Flange

Outer Ferrule

Strain--Relief Bars

HD Connector

(Shown for Reference)

Flange

Gripper

Ferrule Placement

Crimp Ferrule

10. Position other half of clamp on top of cable and

secure with attaching hardware.

Damaged contacts or ferrules may not be used. If

a damaged contact or ferrule is evident, it must

be removed and replaced with a new one.

7. GROMMET ASSEMBLY (Figures 12 and 13)

Refer to the table in Figure 14 to select the proper

cable clamp kit with grommets for the cable you are

using and proceed as follows:

1. Cut the cable to the desired length. Slide the

appropriate size grommet onto the cable with the

large O.D. toward the cable end being terminated.

2. Strip cable jacket from end of conductors. Take

care not to cut any foil, braid, or drain wire if

present. Refer to table in Figure 7 for the cable

jacket strip length for HD--20 and HD--22

connectors.

3. If cable has neither braid nor foil, slide grommet

to end of cable jacket and go to Step 7.

4. If cable has only foil around the conductors,

cut foil to end of jacket and remove. If drain wire is

present, trim to a length of approximately

15.24 mm [.600 in.] from end of jacket. Slide

grommet to end of cable jacket, bend any drain

wire back over top of grommet, and go to Step 7.

5. If cable has only braid, trim braid to

approximately 15.24 mm [.600 in.] from end of

cable jacket. Slide grommet to end of cable jacket

and fold the braid as evenly as possible around the

grommet. It may be easier to fold the braid back

over the jacket end first, then slide the grommet

under it. Go to Step 7.

6. If cable has both foil and braid, trim foil,

braid, and any drain wire to approximately

15.24 mm [.600 in.] from end of cable jacket. Slide

grommet to end of cable jacket and fold the braid

as evenly as possible around the grommet. It may

be easier to fold the braid back over the jacket end

first, then slide the grommet under it. Cut foil to

end of jacket and remove. Fold drain wire, if

present, over the braid and go to Step 7.

7. Terminate conductors with contacts and insert

contacts into rear of connector or terminate the

connector per the appropriate document listed in

Figure 4.

8. Position one half of cable clamp on cable and

connector. Ensure that the flange of the connector

is behind the flange gripper of the clamp and that

the large O.D. of the grommet is seated against

the connector side of the inner strain relief bar of

thecableclamp.

9. In a similar manner, position the other half of the

cable clamp and secure with attaching hardware.

CAUTION

408- 6609

AMPLIMITE Connector HD- 20 Shielded Cable Clamp Kits

7of 8Rev GTyco Electronics Corporation

Figure 12

Connector Flange

Strain--Relief

Bars

Braid

Drain Wire

GrommetD

HD Connector

(Shown for Reference)

Flange

Gripper

Grommet Placement

DNOTE: Large End of Grommet Toward Connector

Figure 13

Braid

Drain Wire

Grommet

Cable

Connector

15.24 [.600]

180°STRAIN--RELIEF

CONNECTOR SIZE

(

)

CABLE

(

)

SHIELDED UNSHIELDED

(

)

(

)

ZINC DIE CAST PLATED PLASTIC UNPLATED PLASTIC

(9--Posn/15--Posn) 4.70--8.13 [.185--.320] 5748676--1 5748677--1 5748678--1

(15--Posn/26--Posn) 4.70--8.13 [.185--.320] 5748676--2 5748677--2 5748678--2

(25--Posn/44--Posn) 4.83--11.94 [.190--.470] 5748676--3 5748677--3 5748678--3

(37--Posn/62--Posn) 4.83--11.94 [.190--.470] 5748676--4 5748677--4 5748678--4

(50--Posn/78--Posn) 4.83--11.94 [.190--.470] 5748676--5 5748677--5 5748678--5

Figure 14

8. OPTIONAL SCREWLOCK (Figure 15)

In some cable--to--cable applications, it is desirable to

install screwlocks in one of the mating assemblies

which can engage mounting screws or jackscrews

from the other assembly. this can be done as follows:

1. Complete the backshell and connector assembly

as described in one of the previous procedures

(other than latching blocks).

2. Insert screwlock from kit 5747223--3 through

each flange of the completed assembly.

3. Install saddle washer 5206473--3 over the

screwlock threads and against the rear of both

backshell flanges.

4. Apply lock washers and hex nuts to the

screwlock threads and tighten to a max of 0.67 Nm

[6 in.--lbs].

9. REVISION SUMMARY

SUpdate document to corporate requirements

SAdded new Section 8 and renumbered

SAdded new Figure 15

408- 6609

AMPLIMITE Connector HD- 20 Shielded Cable Clamp Kits

Rev G8 of 8 Tyco Electronics Corporation

Figure 15

Screwlock 5747223--3

Saddle Washer 5206473--3

Lock Washer

Hex Nut

Cable Clamp Housing

with Mounting Ear