865656-2 - Tyco Electronics

Instruction Sheet

7-Pin Plug Kit 408-10113

LOC B

of 2

2008 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

06 MAR 08 Rev B

(Potted Version)

Plug Kit 865594-1

Plug Kit 865656-[ ]

Boot

Polyester Cap

Housing

Plug Housing

Brass Cap

Contact Solder Cups

Silicone Insert

or Slug

7-PIN PLUG KITS

PLUG KIT TYPE PART NUMBER DESCRIPTION

Plastic Shell 865594-1 Standard Plug Kit

865656-1 Straight Shrinkable Boot

Metal Shell 865656-2 Right-Angle Shrinkable Boot

865656-3 No Shrinkable Boot

Figure 1

1. INTRODUCTION

This instruction sheet covers the assembly

procedures for the 7–Pin Plug Kit (Potted Version).

This plug kit will accept a wire size range of 16–22

AWG and the insulation must be rated for at least

15kVDC with a maximum diameter of 4.70 mm

[.185 in.]. Figure 1 provides connector features and

terms used in this document. Use these terms when

corresponding with Tyco Electronics Representatives

to facilitate assistance. See the table in Figure 1 for

related product part numbers and descriptions.

Dimensions on this instruction sheet are in

millimeters [with inches in brackets]. Figures and

illustrations are for identification only and are not

drawn to scale.

2. WIRE SELECTION AND TERMINATION

Select the correct wire size for your production

requirements and refer to the following procedures.

1. Strip the wire insulation to a maximum of

3.56 mm [.140 in.].

NOTE

408-10113

7-Pin Plug Kit (Potted Version)

Rev

of 2 Tyco Electronics Corporation

Be careful not to nick or cut the conductors.

2. Dress the leads through the holes in the plug

housing towards the end with the keyways.

3. Solder the leads to the contacts of the silicone

insert. Clean soldered connector thoroughly.

3. SILICONE APPLICATION

Apply a thin coating of silicone adhesive (RTV–732 or

equivalent) to only the shoulder of the silicone slug or

insert. Insert the slug or insert into the plug housing

until the interface of the silicone slug or insert is flush

with the housing.

4. PREPARING THE HOUSING

The surface of the plug housing and the potting shell

should be prepared for potting in conjunction with the

manufacturers recommended procedures for the

appropriate potting material.

5. ASSEMBLY

Refer to the following steps for assembly procedures:

1. Slip the cap over the back of the plug housing.

2. Apply epoxy adhesive to the threads of the

potting shell, and attach to the plug housing.

The straight potting shell has a positive stop so

the cap will rotate freely. Allow the adhesive to

cure before final potting.

Kits without potting shells are filled to the top of

the plug housing.

6. POTTING

The potting material selected must be compatible

with the wire insulation and preparation

procedure used, the polyester housing, the

operating voltage stress levels, and the

environmental conditions in which the unit will be

operated.

Fill the potting area with the compound, taking

proper precautions to avoid producing any voids.

Allow the compound to cure fully before finishing

the assembly and applying the voltage.

7. SHIELD TERMINATION

Refer to Figure 2 for shield termination dimensions.

8. REVISION SUMMARY

Updated logo.

This document supercedes Instruction Sheet

866109–1

Figure 2

Polyolefin shrink tubing (located as shown below)

and formed at 90

during heating and shrinking

operation. Add metal braid, protective jacket and

conductive shrink boot as shown below.

Right-Angle Version

Straight Version

Place Lip

in Groove

Ferrule

Cap

Metal Braid (Customer Supplied)

Protective Jacket (Customer Supplied)

Conductive Shrink Boot

25.4 [1.000]

6.35 [.250]

3.05 [.120]

Polyolefin Shrink Tubing to Protect Wire Insulation (Optional)

Hook-Up Wire (Customer Supplied)

CAUTION

NOTE