Application Specification
114-2086
36-Series and 50-Series
Flat-Cable SDL
LOC B
1
of 7
E
2004 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
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Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1-800-722-1111
FAX/PRODUCT INFO 1-800-522-6752
For Regional Customer Service, visit our website at
www.tycoelectronics.com
This controlled document is subject to change.
For latest revision, call the FAX/PRODUCT INFO number.
Plug Connectors
NOTE
25 OCT 04 Rev G
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 36–Series and 50–Series Flat–Cable SDL Plug
Connectors. These connectors are available in 4–, 6–, 8–, and 16–position configurations. The plug connectors
will mate with SDL Printed Circuit (PC) Board Receptacle Connectors.
When corresponding with Tyco Electronics Personnel about this product, 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
Contact(s)
Plastic Plug Housing
Locking Latch
4-Position 36-Series
Flat-Cable SDL Plug
Connector
16-Position 50-Series
Flat-Cable SDL Plug
Connector
Locking Latch
2. REFERENCE MATERIAL
2.1. Revision Summary
Per EC 0990–1269–04
S
Updated document to corporate requirements
S
Complete revision of all sections
S
Added new art to Figures 1 and 7
S
Added new Figure 2 table and renumbered; and new tooling table in Figure 7
NOTE
114-2086
36-Series and 50-Series Flat-Cable SDL Plug Connectors
Rev
G2
of 7
2.2. Customer Assistance
Reference Base Part Numbers 520423, 520527, and Product Code 1003 are representative numbers of
36–Series and 50–Series Flat–Cable SDL Plug Connectors. Use of these numbers will identify the product line
and expedite your inquiries through a service network established to help you obtain product and tooling
information. Such information can be obtained through a local Tyco Electronics Representative (Field Service
Engineer, Field Applications Engineer, etc.) or, after purchase, by calling the Product Information Center at the
number at the bottom of page 1.
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. If there is a conflict
between the information contained in the Customer Drawings and this specification, or with any other technical
documentation supplied by Tyco Electronics, call the Product Information Center number at the bottom of
page 1.
2.4. Specifications
Product specification 108–2047 provides product performance requirements and test information. Application
Specification 114–2081 covers SDL Top–Entry and Side–Entry PC Board Receptacles, and Application
Specification 114–2090 covers 36–Series and 50–Series Round–Cable SDL Plug Connectors.
2.5. Instruction Material
The following list includes available instruction sheets (408–series) that provide assembly procedures for
product, operation, maintenance and repair of tooling, and customer manuals (409–series) that provide setup,
operation, and maintenance of machines.
Document Number Document Title
408–6974 SDL Flat–Cable Plug Connector Cable Guide/Adapters 63394–1 and 63396–1
408–9072 SDL Plugs and Receptacles
408–9113 CER TI–LOK* Hand Crimping Tool 58194–1
408–9115 Crimping Die Assemblies 58261–1, 58261–2, 58261–3, and 58261–6
408–9164 Die Holder Assembly 58201–1 for SDL Connector Crimping Dies
409–5843 2700–lb. Pneumatic Power Unit 312522–[ ]
3. REQUIREMENTS
3.1. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the connectors.
B. Shelf Life
The connectors should remain in the shipping containers until ready for use to prevent damage to the
connectors. The connectors should be used on a first in, first out basis to avoid storage contamination that
could adversely affect performance.
C. Chemical Exposure
Do not store connectors near any chemical listed below as they may cause stress corrosion cracking in
the contacts.
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfur Nitrites Tartrates
D. Stacking
Do not stack shipping containers so high that they bend or buckle and damage the product.
114-2086
36-Series and 50-Series Flat-Cable SDL Plug Connectors
Rev
G 3
of 7
3.2. Materials
The internal contacts are made from copper alloy, and the connector shield is made from brass with bright tin
or tin–lead over nickel. The connectors are molded from polycarbonate resin which can be adversely affected
by strong commercial and industrial cleaners, solvents, and thinners containing hydrocarbons, amines, esters,
and ketones. The use of these types of products should be avoided in the general area of any polycarbonate
material. The following is a partial listing of approved commercially available products. For a more complete
list, contact Tyco Electronics.
A. Cleaning Solvents
Heptane Fisher Scientific Co, Cat. H20
Denatured Alcohol #1430 American Mineral Spirits
Methanol Fisher Scientific Co. Cat. E412
Ethanol Fisher Scientific Co. Cat. A405
Isopropyl Alcohol Fisher Scientific Co. Cat. A416
B. Greases
G–692, G–623, G–660, G–624 G.E. Silicone Prod. Dept.
Marfak 3, Marfak 2 Texaco
C. Lubricating Oils
Hydrotherm Oil C BP
A90 NR, Teresso 56 Exxon
Amberex 830, Vacuoline JJ Mobil Oil Co.
Spirax 9CEP Shell Oil Co.
3.3. Cable Selection and Stripping
A. Cable Selection
Select the correct cable from the table in Figure 2.
CONNECTOR SERIES TYPE POSITION CONDUCTOR SIZE CABLE CUSTOMER DRAWING
36 4, 8, 16 26 and 28 AWG 520822 (4-Position, 28 AWG)
Extrapolate Other Positions and 26 AWG
From This Drawing
4 520471
50
6
24 AWG
520473
50
8
24 AWG
520475
16 520477
Figure 2
B. Cable Stripping
Cable shall be prepared as indicated in Figure 3. The continuity to the end of the conductors shall be
preserved when stripping the cable jacket.
Do not cut, nick, or otherwise damage the conductor insulation or the conductors when stripping the cable. Do not cut
or scrape the inner layer of aluminum on the foil shield.
The following conditions are acceptable if they occur during the stripping operation:
1. Pinholes of 1.02 [.040] maximum diameter in the foil shield.
2. Removal of part of the outer layer of aluminum only from the foil shield.
CAUTION
114-2086
36-Series and 50-Series Flat-Cable SDL Plug Connectors
Rev
G4
of 7
Figure 3
Cut Foil (Both Sides) 4.75 [.187] Max Cut Into
Outer Jacket of Cable
Fold Back Foil
and Drain Wires
(Top and Bottom)
0.13 [.005] Max
Conductor
Protrusion
Foil Covers
Insulated
Conductors
10.41 +0.25
[.410 +.010]
Strip Length
-A-
0.38 [.015] A
3.4. Assembly Procedures
The assembly procedures for 36–Series and 50–Series Flat–Cable SDL Plug Connectors are provided in
Instruction Sheet 408–9072 (SDL Plug and Receptacle Connectors). When inserting the cable into the plug
cavity, the drain wires must be positioned within the limits of the dimensions provided in Figure 4.
BMax
BMax
Drain Wires
Centerline of
Connector Cavity
Figure 4 (cont’d)
114-2086
36-Series and 50-Series Flat-Cable SDL Plug Connectors
Rev
G 5
of 7
NUMBER OF CONDUCTORS DIMENSION B"
4 1.27 [.050]
6 2.54 [.100]
8 3.81 [.150]
16 8.89 [.350]
Figure 4 (end)
3.5. Crimp Requirements
Crimp the plug connector with the tooling and documentation referenced in Section 5, TOOLING. After the
contact crimping operation is complete, the completed connector shall meet the requirements provided in
Figures 5 and 6.
Figure 5
6.86 +0.08 [.270 +.003] Crimp Height
(Measured within 0.76 [.030] of Radius Tangent)
0.38 [.015] Max
(Conductor Location)
If the crimp height is measured more than 24 hours after crimping, some relaxation may have taken place. If the cable
used meets the requirements of Paragraph 3.3.A, the crimp height should relax to a dimension of no more than 6.98
[.275]. This will not affect the performance of the plug connector.
Figure 6
Secondary Strain Relief 2.34 [.092] Ref
Primary Strain Relief
4.67 +0.13 [.184 +.005]
Keying Letter Code
Located in this Area
3.6. Workmanship Standards
The following workmanship standards shall apply to the terminated plug:
1. There shall be no broken, cut, scraped, or sliced plastic or other visible damage to the housing.
2. The housing may exhibit crazing in the contact area.
NOTE
114-2086
36-Series and 50-Series Flat-Cable SDL Plug Connectors
Rev
G6
of 7
3.7. Keying Letter Codes
A keying letter code is visible in the area of the plastic housing as shown in Figure 6. The plug must be
matched with a receptacle of the same number of positions, and the same letter code.
Do not force the plug into the receptacle. If the fit seems too tight, check the keying letter codes on both parts to
ensure they are compatible with each other.
3.8. Cable Guide Adapter
A cable guide/adapter is available to convert:
1. An 8–position Flat–Cable SDL Plug for use with 4–position flat cable.
2. A 16–position Flat–Cable SDL Plug for use with 8–position flat cable.
Installation information for these guide/adapters is available in Instruction Sheet 408–6974.
Prepare the cable for use with the guide/adapter by stripping the cable to a length of 11.68 +0.25 [.460 +.010]. Do not
strip the cable to the length shown in Figure 3.
4. QUALIFICATIONS
36–Series and 50–Series Flat–Cable SDL Plug Connectors are Recognized by Underwriters Laboratories Inc.
(UL) under File E28476, and Certified by CSA International under File LR7189.
5. TOOLING
Figure 7 provides tooling part numbers and related instructional material to terminate 36–Series and 50–Series
Flat–Cable SDL Plug Connectors.
2700-lb. Pneumatic
Power Unit 312522-[ ]
w/o Crimping Die
Assembly or Die
Holder Assembly
Upper Tooling
Subassembly
Lower
Die Holder
Assembly
Base Plate
Guide Clamp
Typical SDL Crimping
Die Assembly
58261-[ ]
Die Holder Assembly
58201-1
Hand Crimping
Tool 58194-1
w/o Crimping
Die Assembly
CONNECTOR TOOLING (DOCUMENT)
SERIES POSITION DIE ASSEMBLY (408-9115) DIE HOLDER ASSY PNEUMATIC TOOL HAND TOOL
4 58261-1
36-Series
or
6 58261-2 58201-1 312522-
[]
58194-1
or
50-Series 858261-3 (408-9164)
[]
(409-5843) (408-9113)
50 Series
16 58261-6
Figure 7
CAUTION
NOTE
114-2086
36-Series and 50-Series Flat-Cable SDL Plug Connectors
Rev
G 7
of 7
6. VISUAL AID
Figure 8 shows a typical application of a Flat–Cable SDL Plug Connector. 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 8. VISUAL AID
STRAIN RELIEFS
MUST BE LATCHED
NO VISIBLE DAMAGE
TO THE FLAT CABLE
NO VISIBLE DAMAGE
TO THE CONNECTOR
HOUSING
CRAZING MAY
BE PRESENT IN
THIS AREA
