MATE-N-LOK* LGH* 9-Position Receptacle Connector Kit 443160-{ ] Instruction Sheet 408-4336 16SEP 97 RevO Long Keying Pin 9 Position Receptacle Short Keying Pin Type XI Pin Contact Figure 7 1. INTRODUCTION AMP* MATE-N-LOK LGH 9-Position Receptacle Connector Kit 443160| ] is designed for high voltage wireto-wire (freehanging or panel-mounted) applications. The receptacle connector accepts single conductor high voltage wire size 24-20 AWG with a maximum insulation diameter of 2.54 mm [.100 in. ]. NOTE For suilability of other cable sizes and required fooling, contact AMP Product Engineering. Read this and all referenced material before assembling the receptacle connector kit. Dimensions on this sheet are in millimeters [followed by inches in brackeis}. Figures are nol drawn to scale. NOTE 2. DESCRIPTION (Figure 1) The receptacle connector kit consists of a 9position receptacle, nine Type Xl pin contacts, two short keying pins, and one long keying pin. The receptacle has polarizing contact cavities on the mating face and will accept a plug connector containing socket contacts in identical circuit positions. The keying pins prevent inadvertent mating of similar connectors. The pin contact is crimped onto the wire using Hand Crimping Tool 902601. Detailed instructions on operating the tool are provided in AMP instruction sheet 408-7484. 3. PREPARATION Determine the number of contact cavities (maximum of eight signal plus the ground} to be loaded in the receptacle. Strip the wire according to the appropriate dimension provided in Figure 2. Be careful not to nick or cut the conductors. Note: Not to Scale Strip Length a STRIP LENGTH Wire with Insulation Diameter Less Than 1.65 [.065] 4.00+0.38 [.157+.015] Wire with Insulation Diameter Greater Than 1.65 [.065] 6.70+40.50 [.264+.020] Figure 2 4, ASSEMBLY 4.1. Crimping the Contact Obtain appropriate tooling for crimping the contact onto the wire conductor and proceed as follows: 1. Set the tool insulation crimp adjustment lever to the appropriate position according to the instructions packaged with the tool. NOTE if crimping wire with an insulation diameter greater than 1.66 [.065}, use Position 2. 2. Place the contact, insulation barrel first, into the front of the appropriate crimping chamber according to the wire size marking on the tcol. 3. Align the contact locator slot with the tool locatorinsulation stop. When located properly, the contact is recessed from the back of the tool. 4, Holding the contact in position, close the tool handles just enough to hold the contact in place without deforming the wire barrel or insulation barrel. 5. Insert the conductor into the contact wire barrel until the insulation butts against the locatorjnsulation stop. When crimping wire with an insulation diameter greater than 1.66 [.065], the insulation will butt against the die. ion 6. Hold the wire in place and squeeze the tool handles until the ratchet releases. 7. Allow the tool handles to open fully, then remove the crimped contact from the tool. ANP Incorporated, Harrisburg, PA 17105 TOOLING ASSISTANCE CENTER 1-800-722-1111 AMP FAX*/PRODUCT INFO 1-800-522-6752 10f4 This AMP controlled document is subject to change. For latest revision call the AMP FAX number. Copyright 1997 by AMP Incorporated. All Rights Reserved. Trademark LOC BANP Receptacle Connector Kit 443160-[ ] 408-4336 8. Inspect the crimpthe insulation barrel must be tight enough to hold the insulation firmly without cutting into it. For wire with an insulation diameter greater than 1.65 [.065], make sure that there isa gap of 1.30+0.30 [.051+.012] between the contact insulation barrel and the wire insulation. Refer to Figure 3. Neva See Application Specification 1174-10002 for specific inspection requiremenis for the crimped coniacts. For wire with an insulation diameter greaier than 1.65 [065], referto 114-1110. 1.3040.30 [.0514.012] Gap Between Insulation Barrel and Insulation Wire (Insulation Diameter Greater crimped than 1.65 [.065}) Contact NOTE If problems arise with properly masking the housing for blasting, contact AMP Product Engineering for assisiance. 2. Clean the wire insulation (of each crimped contact) thoroughly with alcohol, and allow to dry. See Figure 4, Detail B. en if wire other ihan recommended is used, prepare the insulation according to the recommendations of the manufaciurer of the poiting material. 3. Apply an even bead of silicone rubber adhesive, such as RTV314588, around each contact, including the ground contact, just behind the locking lances. Refer to Figure 4, Detail B. NOTE If loading less than eight signal contact cavities, prepare a crimped coniact (without a wire) with adhesive for each empty signal contact cavilyunused cavilies must be sealed. Figure 3 4.2. Potting The maximum operating voltage that the receptacle can perform can be obtained through potting. If your application does not require increased operating voltage, proceed to Paragraph 4.3. The potting material must adhere to the wire insulation and to the receptacle housing. We recommend using a silicone rubber compound, such as RTV (room temperature vulcanizingj-5110, or Sylgard 1708, and silicone or siliconecoated Teflane wire. Rens if recommended maierials cannot be used, make sure that the potting material is compatible with ihe wire insulation. Do nal use hard potting materials. Hard potting bes VE ne) : Ft seating? materials prevent coniacts from floating and cause difficulty when maiing the conneciors. 1. Roughen the inner surface of the potting area (at wire end of the receptacle housing) by abrasive blasting. Refer to Figure 4, Detail A. Clean abraded area thoroughly with alcohol, and allow to dry at 66C [150F] for 15 minutes. O Manufactured by General Electric Company 88 Manufactured by Dow Corning, Corp. Trademark of E.1. DuPont de Nemours & Co. Deiail B Deiail A Potting Area (Wire End of Housing) Silicone Rubber Adhesive Figure 4 4. Insert prepared contacts into the receptacle according to Paragraph 4.3. 5. Allow adhesive to cure according to the recommendations of the manufacturer. 6. Fill each individual contact cavity with appropriate potting compound, taking care to minimize any voids in the compound. Use a vacuum chamber to remove any possible voids, 20f4 Rev ANP Receptacle Connector Kit 443160-[ ] 408-4336 then fill the remaining potting area with compound Insert terminated contacts into the appropriate until the recessed part of the housing is filled. receptacle contact cavities marked 1, 3, 5, 7 (bottom Avoid producing any visible voids. See Figure 5. row) and 2, 4, 6, 8 (top row). Insert the ground contact into the contact cavity marked G. Make sure that the contacts snap into place. Pull back lightly on each contact to make sure that it is seated properly. See Figure 7. Recessed Part of Housing Filled Terminated Contacts in Bottom Row and Top Row of Receptacle Figure & 7. Allow the compound to cure according to the recommendations of the manufacturer before applying voltage. ens Coniacis cannot be extracted from the receplacie Figure 7 after potting is applied. 4.3. Receptacle Connector Loading 4.4, Keying Pins (Figure 8) i Refer to 114-1170 or the cusiomer drawing for NOTE The receptacle holds a maximum of four contacts NOTE ea : | NOTE in the top row, and four contacts plus the ground uc the receptacle connector kit for information on contact in the bottom row. If loading less than recommended keying positions. eight signal contact cavilies, refer to Figure 6 for 1. Facing the mating end of receptacle, locate the proper loading of the recepiacie. keying cavity (marked A or B) to be keyed. NUMBER OF CONTACT CAVITY POSITION 2. Align split, tapered end of keying pin with keying CONTACTS BOTTOM ROW TOP ROW cavity. Insert pin straight into cavity until it snaps into position. 1 qs Su 2 1 2 3 1,3 2 4 1,3 2,4 5 1,3,5 24 6 1,3,5 2,4,6 / 1,3, 5,7 2,4,6 Split, Tapered Load contact cavity Position 1 or Position 8 End of Keying Pin when using only one coniact. Cavity (Ref} Mating End Contact in of Receptacle Position 1 (Ref) Figure 8 NOTE if necessary, a drive pin punch (or similar tool) with an end diameter no greater than 1.52 [.060] . and a shaft no shorter than 10 [394] can be used Figure 6 lo aid in fully inserting the short keying pins. Rev O 30f4Receptacle Connector Kit 443160-[ ] 408-4336 5. PANEL MOUNTING (Figure 9) 1. Make a cutout in the panel using the dimensions provided in Figure 9. 2. Insert the receptacle straight into the cutout until the four panel latches engage. Make sure that the anti-vibration tabs are seated against the surface of the panel (the panel mount tabs will not seated against the panel). When using a panel with maximum thickness, the panel mount tabs will seat (along with the anti-vibration tabs) against the panel. Remove any sharp edges on the side of panel cutout that the connector will be inserted: olhernwise, insertion will be difficult. 3. To remove receptacle from panel, depress the panel latches and push the receptacle through the mating side of the panel. 6. CONTACT AND KEYING PIN EXTRACTION Contact and keying pins can be removed from the receptacle using Extraction Tool 4433521. Refer to 408-4368 for specific instructions on using the tool. For additional information on panel mounting, refer to 114-1110. Recommended Panel Cutout 34.0+1.0/-0.00 [1.34+.039/-.000] Panel Latch (4 Places) Wire Side of Panel 1.30-3,20 [.051 126] Panel Thickness R3.60 [.142] Max Typ (Round or Square Corners) 17.5 [.689] +1.0/-0.00 [+.039/.000] (For Panel Thickness Less than 2.90 [.114]) Panel Mount Tab (4 Places) Anti-Vibration Mating Side of Panel Sharp Edges Removed from This Side of Panel Cutout +0.20/-0.00 [.008/-.000] (For Panel Thickness Greater than 2.90 [.114]) Figure 9 4of4 Rev