787032-7 - Tyco Electronics

Instruction Sheet

Cover Closing Kits 543508-1 and 543526-1

and Staple Inserter Kit 543515-1 for 408-9820

LOC B

of 3

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

24 NOV 08 Rev A

AMPLIMITE* .050 Series Connector Assembly

Figure 1

Staple Insertion Kit 543515-1

Cover Closing Tool 543508-1

(Standard Connectors) Cover Closing Tool 543526-1

(Busing Connectors)

Lower Plate

Small

20-40-Position

Connector

Medium

50-68-Position

Connector

Large

80-120-Position

Connector

Use large upper tooling for 68-position shielded

enclosure kit with male jackscrews.

Cover Closing

Upper Tool

Lower Tooling

Subassembly

Upper Tooling

Upper Tooling Sizes

1. INTRODUCTION

Cover Closing Tooling Kits 543508–1 and 543526–1

and Staple Insertion Kit 543515–1 are used to

terminate AMPLIMITE .050 Series standard plug

(reference part number 749621–2) and receptacle

(reference part number 749699–4) connectors and

busing connectors (reference part number 319361–1)

onto a variety of cable types (shielded, round, and

jacketed cable, flat ribbon cable, laminated and

round–to–flat wire with multiple wire or twisted pair

conductors). The standard connector is available in

20 to 120 positions. The busing connector is available

in 50 and 68 positions.

For preparation and assembly requirements, refer

to Application Specification 114-40029 for the

standard connectors and 114-40041 for the

busing connectors.

The kits are designed to be used with Manual

Miniature Applicator Frame Assembly 91295–1

(408–9817).

Dimensions in this instruction sheet are in metric

units [with U.S. customary units in brackets].

Figures are not drawn to scale.

Reasons for reissue of this instruction sheet are

provided in Section 5, REVISION SUMMARY.

2. DESCRIPTION

Each kit consists of the parts shown in Figure 1.

The staple insertion kit includes a small, medium, and

large upper tooling.

Two termination covers assist in locating the wires

over the insulation displacement contacts of the

connector. A metal strain relief staple, which is

pressed over the cable and into a corresponding slot

in the cable exit of the lower backshell, provides strain

relief for the cable as well as grounding continuity for

the cable braid to the metal backshell or shields.

NOTE

408-9820

Cover Closing Kits 543508-1 and 543526-1 and Staple Inserter Kit 543515-1

Rev

of 3 Tyco Electronics Corporation

3. SETUP

3.1. Cover Closing Kit

Set the

shut height

of the manual miniature applicator

frame to 47.63 mm [1.875 in.] according to 408–9817,

then proceed as follows:

1. Push the cover closing upper tool into the ram

tooling adapter. See Figure 2.

Figure 2

Cover Closing

Upper Tool

Ram Tooling

Adapter

Frame Assembly

(Ref)

2. Locate the lower tooling subassembly by

inserting the pins into the machined base plate.

Make sure that the inscription “CENTER

CONNECTOR” is facing front. Refer to Figures 1

and 3.

Figure 3

Machined Base

Plate (Ref)

Lower Tooling

Subassembly

Pins

Inscription

3. Assemble the standard cover or termination

covers (with wires) onto the connector assembly

and close it partially by hand.

If using round-to-flat wire or flat ribbon cable,

insert the cable between the cover and contacts

and pre-close the covers by hand, clamping the

cable in place.

4. Depress the finger lever (see Figure 4, Detail A)

and insert the connector assembly (centered) into

the lower tooling assembly between the upper and

lower bars (see Figure 4, Detail B). The connector

is properly located if the upper and lower

termination covers rest on the surfaces indicated in

Figure 4, Detail C.

5. Grasp the applicator handle and pull down with

a steady firm pressure; the upper tool will touch the

upper bar of the lower tooling subassembly. With

added firm pressure, the downward movement of

the handle is completed when the ratchet releases

and the handle is able to return to its original

position.

3.2. Staple Insertion Kit

After the closing covers have been seated and the

backshell components have been assembled, apply

the strain relief staple to the connector assembly as

follows:

1. Refer to Figure 5 for the recommended staple

insertion depth. For most cables, this depth will be

sufficient to provide adequate strain relief. Some

smaller diameter cables may require the staple to

be inserted deeper in order to obtain the required

strain relief. Inserting the staple too deeply will

cause breakage of the cable conductors. Not

inserting the staple deeply enough will result in

inadequate strain relief for the cable.

2. Select the proper upper tooling based on the

staple size. See Figure 1.

3. Push the selected upper tool into the ram tooling

adapter similar to Figure 2.

4. Locate the lower plate of the staple inserter kit

by inserting the pins into the machined base plate

similar to Figure 3.

5. Place the connector assembly on the lower

plate as shown in Figure 6.

6. Align the strain relief staple into the backshell

slot with your fingers.

It is extremely important to ensure that all

conductors extending from the strain relief area to

the connector assembly are positioned within the

sides of the lower backshell. Any conductors

extending over the sides of the lower backshell

will be pinched, and consequently shorted, when

the upper backshell is assembled to the lower

backshell.

NOTE

CAUTION

408-9820

Cover Closing Kits 543508-1 and 543526-1 and Staple Inserter Kit 543515-1

of 3Rev

Tyco Electronics Corporation

Figure 4

Busing Connector

Assembly

Upper Bar

Lower Bar

Standard Connector

Assembly

Finger Lever

Detail A Detail B

Detail C

Surface

Termination

Covers

Figure 5

Cross-Section of Metal Strain Relief Staple

After Installation In Lower Metal Backshell

0.127-0.254 mm

[.005-.010 in.]

Staple Insertion Depth Staple

Wire

7. Check the staple by grasping the cable behind

the staple and by

gently

moving the cable around.

Note whether the wires within the backshell remain

stationary. If the wires within the backshell move, it

will be necessary to press the staple deeper.

4. REPLACEMENT

Order replacement kits through your representative,

or call 1–800–526–5142, or send a facsimile of your

purchase order to 717–986–7605, or write to:

CUSTOMER SER VICE (038–035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105–3608

Figure 6

Metal Strain

Relief Staple

Connector

Assembly

Lower Plate

5. REVISION SUMMARY

Revisions to this instruction sheet include:

Updated document to corporate requirements

Added reference part number for busing

connectors

Added text to Section 2