CHAMP* Cable Connectors (Standard and Shielded) NOTE i Application Specification 114-- 6041 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. Plug Connector Assembly Receptacle Connector Assembly Standard CHAMP Connector Housing Color Dot Code (on back of plug and receptacle connector) Contact Letter Code Locking Tabs Shielded CHAMP Connector Figure 1 TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111 E2009 Tyco Electronics Corporation, Harrisburg, PA PRODUCT INFORMATION 1-- 800-- 522-- 6752 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. This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 10 LOC B CHAMP Cable Connectors 114- 6041 2. REFERENCE MATERIAL 2.1. Revision Summary S S S S Updated document to corporate requirements New logo and format Renumbered headings Added 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 408--3137 408--3159 408--3160 408--3188 408--7558 408--7559 408--7564 408--7642 408--7787 409--5411 409--5771 CHAMP Discrete Wire Tooling Assembly 231593--2 CHAMP Laminated Cable Tooling Assembly 231592--2 Strain Relief Hardware For CHAMP Connectors Mounting Hardware For CHAMP Connectors Shielded CHAMP 180 Connector Kits and Cover Kits CHAMP T--Handle Wire Insertion Tool 229384--1 CHAMP Portable Hand Operated Tool (MI--1) 229378 CHAMP Cable--to--Cable and Cable--to--Panel Connectors Palm Grip Hand Tool Kit 229764--2 Insertion/Extraction Tool 230238--1 CHAMPOMATOR* Insertion Machine 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. 2 of 10 Tyco Electronics Corporation Rev A CHAMP Cable Connectors 114- 6041 WIRE SIZEH HOUSING COLOR DOT CODE CONTACT LETTER CODE SOLID 7 STRAND 22 22 Green C 22 22 Brown 24--26 24 Blue FD 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. Inserter imprint in conductor insulation acceptable to one-- half of insulation wall thickness. Thinning to point where insulation appears translucent is acceptable. Thinning of Insulation is Acceptable to Point Where Material Appears Translucent Strain-- Relief Slot Barrier Pad B B Contact Slot Window Height Insulated Conductor Must Extend 0.89 mm [.035 in.] Below Contact Slot A Wire Must be Below Transition of Lead-- In to Contact Slot Conductor A Section B--B Section A--A Figure 3 Rev A Tyco Electronics Corporation 3 of 10 CHAMP Cable Connectors Distance 114- 6041 Strain-- Relief Slots 2 Barrier Pad B B Window Height Contact Slot Section A--A A 3 0.30 [.012] Y Wire Must Be Below Transition Of Lead-- In To Contact Slot Large Wire Contact Terminating Inspection - Notes on Customer Manual 409-- 5411 apply - Additional allowances are: ---Y--- 1 Terminal perpendicularity of 0.30 mm [.012 in.] to Datum - Y-- . 2 Maximum distance after conductor termination is 3.30 mm [.130 in.]. 3 Maximum marking of surface 0.25 mm [.010 in.] from noted edge, typical. A Section B--B Figure 4 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. 4 of 10 Tyco Electronics Corporation Rev A CHAMP Cable Connectors 114- 6041 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. Rev A Tyco Electronics Corporation 5 of 10 CHAMP Cable Connectors 114- 6041 A. CHAMP--LOK :Locking Latch B. Screw--Lock Hardware C. Bail--Lock Hardware (Standard/Bent 90_) D. J--Hook Hardware Figure 5 6 of 10 Tyco Electronics Corporation Rev A CHAMP Cable Connectors 114- 6041 90_ Snap--On Strain Relief Cover 180_ Snap--On Strain Relief Cover Low--Profile Strain Reliefs (Hermaphroditic) Figure 6 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. Rev A Tyco Electronics Corporation 7 of 10 CHAMP Cable Connectors 114- 6041 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) Figure 7 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). 8 of 10 Tyco Electronics Corporation Rev A CHAMP Cable Connectors 114- 6041 CHAMP T--Handle Wire Insertion Tool 229384--1 CHAMP Palm--Grip Insertion Tool 229451--1 Insertion/Extraction Tool 230238--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 Figure 8 Rev A Tyco Electronics Corporation 9 of 10 CHAMP Cable Connectors 114- 6041 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. WIRE END MUST PROTRUDE FROM SECOND CONTACT BEAM NON- ACCEPTABLE CONTACTS INSPECTION FEATURES WIRE SHOULD BE BELOW LEAD- IN 1 ACCEPTABLE DEFORMATION SLOT MUST REMAIN PARALLEL 3 2 5 6 4 7 WIRE SHOULD BE IN BOTH SLOTS 9 8 The following conditions constitute non- acceptable terminations, and the contact should be removed and replaced. 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. CONNECTORS MUST BE FULLY MATED AND HARDWARE EVENLY AND FIRMLY TIGHTENED FIGURE 9. 10 of 10 VISUAL AID Tyco Electronics Corporation Rev A