552444-1 - Tyco Electronics

Application Specification

114--6041

CHAMP*

Cable Connectors

LOC B

1of 10

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

(Standard and Shielded) 15 SEP 09 Rev A

All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and

inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2_.

Figures and illustrations are for identification only and are not drawn to scale.

1. INTRODUCTION

This specification covers the requirements for application of CHAMP Cable Connectors (standard and

shielded). These requirements are applicable for hand or automatic machine installation. These CHAMP Cable

Connectors are intermateable and interchangeable with existing connectors of a similar design. The CHAMP

Connector product line is ideally suited for use in all phases of the telecommunications industry, computer

terminals, test equipment, business and copying machines, telemetering, and various equipment used in the

security industry. The standard CHAMP Cable Connectors are available in 14--, 24--, 36--, 50--, and 64--position

sizes. The shielded CHAMP Cable Connectors are available in 24--, 36--, and 50-- position sizes.

When corresponding with personnel, use the terminology provided in this specification to facilitate your

inquiries for information. Basic terms and features of this product are provided in Figure 1.

Figure 1

Receptacle Connector

Assembly

Plug Connector

Assembly

Contact Letter Code

Locking Tabs

Housing Color Dot Code

(on back of plug and

receptacle connector)

Standard CHAMP

Connector

Shielded CHAMP

Connector

NOTE

114- 6041CHAMP Cable Connectors

Rev A2 of 10 Tyco Electronics Corporation

2. REFERENCE MATERIAL

2.1. Revision Summary

SUpdated document to corporate requirements

SNew logo and format

SRenumbered headings

SAdded new Section 4 and renumbered

2.2. Customer Assistance

Reference Part Number 229974 and Product Code 1210 are representative numbers that identify the CHAMP

Cable Connectors. These numbers are used in the network of customer service to access tooling and product

application information. This service is provided by your local Tyco Electronics Representative or, after

purchase, by calling the Product Information number at the bottom of page 1.

2.3. Drawings

Customer Drawings for specific products are available from the responsible Tyco Electronics Engineering

Department via the service network. The information contained in the Customer Drawings takes priority if there

is a conflict with this specification or with any other technical documentation supplied by Tyco Electronics.

2.4. Specifications

Product Specification 108--6005 provides applicable performance requirements and test data relative to

CHAMP Cable Connectors.

2.5. Instructional Material

The following list includes available instruction sheets (408--series) that provide assembly procedures for

product, operation, maintenance and repair of tooling, as well as setup and operation procedures of

applicators; and customer manuals (409--series) that provide setup, operation, and maintenance procedures of

machines.

Document Number Document Title

408--3133 CHAMP Discrete Wire Tooling Assembly 231593--2

408--3137 CHAMP Laminated Cable Tooling Assembly 231592--2

408--3159 Strain Relief Hardware For CHAMP Connectors

408--3160 Mounting Hardware For CHAMP Connectors

408--3188 Shielded CHAMP 180 Connector Kits and Cover Kits

408--7558 CHAMP T--Handle Wire Insertion Tool 229384--1

408--7559 CHAMP Portable Hand Operated Tool (MI--1) 229378

408--7564 CHAMP Cable--to--Cable and Cable--to--Panel Connectors

408--7642 Palm Grip Hand Tool Kit 229764--2

408--7787 Insertion/Extraction Tool 230238--1

409--5411 CHAMPOMATOR* Insertion Machine

409--5771 CHAMPOMATOR 3A Terminating Machine

3. REQUIREMENTS

3.1. Wire

A. Selection

Contacts are available for the wire sizes specified in the chart in Figure 2. Housing assemblies (plug/

receptacle) are also specified in Figure 2. The wires may be solid or stranded.

B. Wire Size

The color dots on the housings and the letter codes on the contacts designate wire size.

114- 6041

CHAMP Cable Connectors

Rev A 3 of 10Tyco Electronics Corporation

WIRE SIZEHHOUSING COLOR CONTACT

SOLID 7 STRAND

DOT CODE

LETTER CODE

22 22 Green C

22 22 Brown FD

24--26 24 Blue B

-- -- -- 26--27--28 Yellow E

NOTES: HAll connector styles may not be available in each position and each wire size. DConnectors for

large insulation diameter wire (1.42 mm [.056 in.]) maximum.

Figure 2

C. Wire Placement

Wire must be below transition of lead--in to contact slot as indicated in Figure 3. See Figure 4 for F slot

contact wire placement.

Figure 3

Strain--Relief Slot

Thinning of Insulation is

Acceptable to Point

Where Material

Appears Translucent

Wire Must be

Below

Transition of

Lead--In to

Contact Slot

Conductor

Window Height

Insulated Conductor Must Extend

0.89 mm [.035 in.] Below Contact Slot

Contact

Slot

Barrier Pad

Inserter imprint in conductor insulation acceptable to one--half of

insulation wall thickness. Thinning to point where insulation

appears translucent is acceptable.

Section A--A Section B--B

114- 6041CHAMP Cable Connectors

Rev A4 of 10 Tyco Electronics Corporation

Figure 4

Distance 2

Section A--A

Section B--B

Strain--Relief

Slots

Barrier Pad

Contact Slot

Window Height

Wire Must Be Below

Transition Of Lead--In

To Contact Slot

--- Y---Terminal perpendicularity of 0.30 mm [.012 in.] to Datum --Y--.

Maximum distance after conductor termination is 3.30 mm [.130 in.].

Maximum marking of surface 0.25 mm [.010 in.] from noted edge, typical.

0.30 [.012] Y

Large Wire Contact Terminating Inspection

-- Notes on Customer Manual 409--5411 apply

-- Additional allowances are:

D. Wire Exposure

Insulated conductor must extend 0.89 mm [.035 in.] below contact slot.

E. Insulation Range

Insulation range for standard cable connectors should be 1.14 mm [.045 in.] maximum diameter for tools

that mass terminate conductors on one side at a time. For tools that insert one conductor per side at a

time, 1.09 mm [.043 in.] insulation diameter is the maximum. Insulation range for F slot contacts is

1.42 mm [.056 in.] maximum diameter.

F. Workmanship

Minor nicks and scrapes or saddling of the metal bridge are acceptable provided the two slots remain

parallel to each other and perpendicular to the housing. Minor plastic shaving and rolling over of barrier

pads are acceptable provided that contacts are not damaged. Shaving of barrier pads is acceptable up to

0.15 mm [.006 in.] maximum in direction of connector length. Nicks in the insulation above the connector

should not exceed one half of insulation wall thickness.

114- 6041

CHAMP Cable Connectors

Rev A 5 of 10Tyco Electronics Corporation

G. Inserter Imprint

Inserter imprint in conductor insulation should not exceed one half of insulation wall thickness. Thinning of

insulation is acceptable to the point where the insulation appears translucent.

3.2. Shielded CHAMP Cable Connectors

Shielded CHAMP Cable Connectors consist of contacts on 2.16 mm [.085 in.] centerlines; pre--assembled

housings with 24, 36, or 50 slotted contacts; a choice of two wire slot sizes, B or E; bail--lock or screw--lock

hardware, with metric hardware for IEEE applications; 180_ cable entry; and the same full tooling capabilities

that are used with standard CHAMP Cable Connectors.

The main design difference in shielded CHAMP Cable Connectors is the addition of small holes or windows

around the peripheral skirt of each plug housing. These holes accept the spring fingers of a two--piece

wraparound metal shield. The spring fingers interact with the contact plates on the receptacle connector and

thus provide minimal leakage and maximum shielding effectiveness.

The application requirements are basically the same (except where noted otherwise) for shielded and standard

CHAMP Cable Connectors.

3.3. Locking Hardware

Locking hardware is used to secure mating CHAMP Connectors and to prevent accidental separation. Refer to

Instruction Sheet 408--3160 for further information. See Figure 5 for the different types of locking hardware.

A. Locking Latch (CHAMP- LOK* Connector Design)

Standard CHAMP connectors (except for IEEE applications) have guide tracks and slots (on plugs) and

lead--in ramps (on receptacles) to allow the use of a metal locking clip for securing connectors.

B. Screw- Lock Hardware

Screw--lock hardware is used in applications where positive locking is required to secure connectors to pc

boards, to panels, and/or to each other. In cable--to--cable applications, two captive screws threaded into

pre--tapped holes are generally the only screw--lock requirements.

C. Bail- Lock Hardware (Standard or Bent)

Bail--lock hardware provides both locking and quick--release capabilities at both ends of mated connectors.

Flanges on CHAMP plug connectors must be open ended for all bail--lock applications. The open--end

flanges accept bail clips which are used primarily with right angle (90_) cable terminations where space is

limited.

D. J- Hook Hardware

The J--hook is a precision--formed metal bracket used as an alternate quick--fastening method for

assembly hardware. Two tabs fit into recesses in the connector housing flange for screw--fastening. The

inverted end of the J--hook snaps on the end of a mating connector, and holds it in place.

114- 6041CHAMP Cable Connectors

Rev A6 of 10 Tyco Electronics Corporation

Figure 5

A. CHAMP--LOK :Locking Latch B. Screw--Lock Hardware

C. Bail--Lock Hardware (Standard/Bent 90

) D. J--Hook Hardware

114- 6041

CHAMP Cable Connectors

Rev A 7 of 10Tyco Electronics Corporation

Figure 6

180

Snap--On Strain Relief Cover

Low--Profile Strain Reliefs (Hermaphroditic)

3.4. Accessories

CHAMP cable connectors are compatible with the accessories shown in Figures 6 and 7. The instructional

material listed with each accessory provides details for product selection and assembly procedures.

A. 90_Slide- On Strain Relief Covers

90_Slide--On Strain Relief Covers (Instruction Sheet 408--3159) are available for 50 position CHAMP

cable connectors. The covers come in three versions — 90_tapered, 90_straight, 90_straight (adjustable

or ratchet style). All three versions are designed for use in cable--to--cable applications; however, the

straight (ratchet style) is recommended for use with CHAMP--LOK Connector Locking Latch 552723--1.

B. Snap- On Strain Relief Covers

Snap--on strain relief covers (Instruction Sheet 408--3159) are available in both a 90_version and a 180_

version.

C. Low Profile Strain Relief Covers

Low profile strain relief covers (Instruction Sheet 408--3159) are used in cable--to--panel applications

where height is a concern.

D. Dust Cover

Dust covers (Instruction Sheet 408--7564) are used to protect the mating face of connectors that are NOT

mated.

114- 6041CHAMP Cable Connectors

Rev A8 of 10 Tyco Electronics Corporation

Figure 7

Dust Covers for Plugs, Receptacles

Cable Clamp

Tapered Style Standard Style Standard Style with

Adjustable Clamp

(Ratchet Style)

Three Types of Slide--On Covers for 90

Entry (50 Positions Only)

4. QUALIFICATIONS

CHAMP Cable Connectors are Component Recognized by Underwriters Laboratories Inc. (UL) in File E28476

and Listed in File E81956. They are also Certified by CSA International in File LR7189.

5. TOOLING (Figure 8)

For insertion or extraction of CHAMP connector contacts, use Insertion/Extraction Tool 230238 (Instruction

Sheet 408--7787). For minor termination repair work, use T--Handle Wire Insertion Tool 229384. For field

applications and low volume production, the Palm Grip Hand Tool Kit 229764--2 is recommended. For field

applications and medium volume production, the Portable Hand Operated Tool 229378 (Instruction Sheet

408--7559) is recommended. It terminates all CHAMP connectors up to 50 positions with 90_wire dress. For

information on other portable hand--operated tools, refer to Instruction Sheet 408--7559. For termination of

laminated cables, use CHAMP Arbor Tooling System 231592--2 (Instruction Sheet 408--3137. For termination

of discrete wires, use CHAMP Arbor Tooling System 231593--2 (Instruction Sheet 408--3133). For termination

of CHAMP connectors in high volume production, use the CHAMPOMATOR Insertion Machine “Model G”

(Customer Manual 409--5411) or CHAMPOMATOR 3A (Customer Manual 409--5771).

114- 6041

CHAMP Cable Connectors

Rev A 9 of 10Tyco Electronics Corporation

Figure 8

CHAMP T--Handle Wire

Insertion Tool

229384--1

Insertion/Extraction

Tool 230238--1

CHAMP Palm--Grip

Insertion Tool

229451--1

CHAMP Portable Hand

Operated Tools

Multi--Insertion

(MI--1) 229378--[ ] and

231925--1

CHAMP Connector Applicator

231593--2 for Discrete Wire/

Cable Terminations

CHAMP Connector Applicator

231592--2 for Laminated

Cable Terminations

114- 6041CHAMP Cable Connectors

Rev A10 of 10 Tyco Electronics Corporation

6. VISUAL AID

Figure 9 shows a typical application of CHAMP Cable Connectors. This illustration should be used by

production personnel to ensure a correctly applied product. Applications which DO NOT appear correct should

be inspected using the information in the preceding pages of this specification and in the instructional material

shipped with the product or tooling.

FIGURE 9. VISUAL AID

CONNECTORS MUST BE FULLY

MATED AND HARDWARE EVENLY

AND FIRMLY TIGHTENED

The following conditions constitute non- acceptable terminations, and the contact should be removed and re-

placed.

1. Shoulders are bent and not parallel.

2. Shoulders are bent, bowed, and not parallel.

3. Contact is broken.

4. Strain relief slot is bent inward.

5. Strain relief slot is bent outward.

6. Strain relief slot is bent outward and contact slot is bent inward.

7. Contact is loose and bent.

8. Contact is crushed.

9. Two wires are in the same slot.

NOTE: This condition is non- acceptable

only if the slot is not specifically

designed for a two- wire application.

123

NON- ACCEPTABLE CONTACTS

INSPECTION FEATURES

ACCEPTABLE

DEFORMATION

SLOT MUST

REMAIN

PARALLEL

WIRE SHOULD

BE BELOW

LEAD- IN

WIRE SHOULD

BE IN BOTH

SLOTS

WIRE END

MUST

PROTRUDE

FROM

SECOND

CONTACT

BEAM