166981-005 FCI, 166981-005 Datasheet

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... IDC Terminal Damage..................................................................................................................13 9.1.5 Wire Damage................................................................................................................................13 9.2 Tool Setup and Destructive Inspection Techniques.............................................................................13 9.2.1 Wire Removal ...............................................................................................................................13 9.2.2 IDC Terminal Damage..................................................................................................................13 9.2.3 Acceptable Metallic Contact .........................................................................................................13 Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION TABLE OF CONTENTS PDM: Rev:J NUMBER GS-20-002 PAGE REVISION AUTHORIZED BY DATE J ...

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... USE OF CONNECTORS WITH MATING PRODUCTS.......................................................................26 13.1 72476 and 72477 type Metral™ Unshielded Connectors................................................................26 13.2 88940 type Metral™ Unshielded Connectors ..................................................................................26 14.0 NOTES .................................................................................................................................................28 15.0 NOTES .................................................................................................................................................28 16.0 REFERENCE DOCUMENTS ...............................................................................................................28 Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION PDM: Rev:J NUMBER GS-20-002 PAGE REVISION ...

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... Figure 22 Preparing Wire for Reinsertion ...........................................................................................23 Figure 23 HT-0525 Wire Insertion Repair Tool...................................................................................24 Figure 24 BPY75D37 Wire Insertion Repair Tool ...............................................................................24 Figure 25 Solder Repair of Defective Insertion...................................................................................25 Figure 26 Mating Headers & Shrouds ................................................................................................26 Figure 27 Mating Retainers.................................................................................................................27 Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION PDM: Rev:J NUMBER GS-20-002 ...

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... No deviation of wire size, insulation type or insulation thickness from those listed in section “Recommended Wire Sizes and Insulations” should be used without approval of the FCI engineering design group responsible for this product. Please refer all question to your local FCI representative. • Recommended requirements on completed termination • ...

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... In certain cases the use of multiple cables or the stripping of the cable jacket above the cable tie area of the connector will allow the user to overcome some restrictions. Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION “ ...

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... Metral™ Unshielded Connector These connectors come in 2x10 & 2x6 2mm pitch cable connector with IDC type contacts. Please contact your FCI representative to obtain data on cables that can be used with this connector. The connectors are sold only with 0.8um GXT plating on the separable contacts and for gage wire sizes ...

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... In addition, on connectors using more than one connector sub- assembly, the cable assembly drawing and wiring diagram must specify a scheme to identify which connector sub-assembly will occupy which position in the connector assembly. Figure 5 Wiring Diagram - 72476 Unshielded Connectors Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION ...

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... Certain stranded wires can be successfully inserted in the contact IDC but must be qualified individually. The specification of the cable using the stranded wire must have the wire insulation type, wire insulation thickness, number of strands, size of strands and twist of strands controlled. Copyright FCI Form E-3334 Rev E ...

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... The cable assembly designer may have to specify that the heat shrink tube be slid on each bundle of wires before wire insertion depending on size and shrink rate of the tubing selected. Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION ...

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... The automatic wire terminators will set all the unused contacts unless the machine cycle is interrupted. When using hand tools, the operator must index the connector sub- assembly to all unused positions and activate the hand tool. Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION ...

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... The copper conductor shall extend at least .75mm beyond the IDC dimples. This requirement shall be considered met if the wire insulation extends at least 1.00mmj beyond the IDC dimples maximum the insulation may extend to surface ‘D’. See Figure 9 Figure 9 - Wire Insertion Visual Requirements Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION ...

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... This measurement should be done when the insertion equipment is set up. If the measurement is less than specified, reduce the depth of insertion until it is meet. Contact you FCI representative if the wire you selected cannot meet all requirements. ...

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... Contact Retention Contacts shall be held securely in the insulator and be capable of withstanding a 13.4N (3.0 lb. ) axial pull. A contact which becomes dislodged at an axial force of less than 8.9N (2.0 lb.) will be considered a major defect. Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION PDM: Rev:J NUMBER ...

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... The punches are very similar but can be identified by the part number etched on the sides. On the punches for the TL-230, punch 166981-005 replaces the 166981-002. The 166981-005 punch produces a better connection on wires with insulation diameters above 0.8mm ...

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... The BPY6737A3xx automatic terminator uses two different adapter kits. Which kit you use depends on the cable connector you are using. The ‘xx’ in the terminator number specifies the keyboard type. There are three versions, ‘UK’, ‘FR’ or ‘SW’ Kit Number BPY6736A1 Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION Figure 11 TL-230 AutomaticTerminator ...

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... The punch is mechanically advanced and spring returned and the connector sub-assembly is manually advanced and retracted from the tool. The hand tool inserts one wire at a time. Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION ...

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... After assembly check to see that the small separator ribs on the covers that go between the insulators ( connector sub- assemblies ) are actually between the insulators and not smashed down under the side of the insulators. FCI Part No. HT-0520 Figure 14 Assembly of Covers - 72476 type Connectors Copyright FCI ...

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... TYPE TITLE Specification of Requirements for Cable Preparation, Wire Termination and Assembly of Connectors Using 72392-type Contacts Figure 15 Assembly of Covers - 72477 type Connectors Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION Figure 16 Cover Assembly Fixture PDM: Rev:J NUMBER GS-20-002 PAGE REVISION AUTHORIZED BY DATE J.R. Volstorf ...

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... Position the head of the tie so that it remains within the projected area of the covers and that it does not block insertion of adjacent connectors. In the case of cable assemblies specifying connectors with the regular latch finger, the tie head must be positioned so that it does not interfere with the action of the latch finger. Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION ...

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... The keys match on the part dash number so 72388-004 works with 70274-004. 11.2 88940 type Metral™ Unshielded Connectors No additional assembly required after wire insertion. Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION Figure 19 Assembly of Coding Keys ...

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... If the contact into which the wire inserted has been used previously, then it must be replaced with an unused contact before insertion. The HT-0517 latch finger removal tool removes an already installed latch finger from the connector assembly. FCI Part No. HT-0522 HT-0523 ...

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... Preferred Method of Repair The preferred method of repair is to cutoff the defective connector sub-assemblies from the cable just above the connectors, strip the end of the cable and insert the wires into new connector sub- assemblies. Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION ...

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... This latter method is not recommended since it is very hard to properly reinsert all the contacts at the same time. 12.6.2.2 12.6.2.2.1 Reinsertion of Wire in IDC of Contact Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION Wires Inserted in Wrong Position Defective Insertions Remove the inserted contact with contact removal kit HT-0522 ...

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... TYPE TITLE Specification of Requirements for Cable Preparation, Wire Termination and Assembly of Connectors Using 72392-type Contacts Figure 23 HT-0525 Wire Insertion Repair Tool Figure 24 BPY75D37 Wire Insertion Repair Tool Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION PDM: Rev:J NUMBER GS-20-002 PAGE REVISION AUTHORIZED BY DATE J ...

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... TITLE Specification of Requirements for Cable Preparation, Wire Termination and Assembly of Connectors Using 72392-type Contacts 12.6.2.2.2 Soldering of Wire in Contact Figure 25 Solder Repair of Defective Insertion Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION Remove the inserted contact with contact removal kit HT-0522. Replace the contact with a new contact ...

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... In all cases two connectors must be placed side-to-side in the retainers to effect latching. The retainers and thus the connectors are end-to-end stackable. All connector can mate with the following range of pin heights. Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION Figure 26 Mating Headers & ...

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... TYPE TITLE Specification of Requirements for Cable Preparation, Wire Termination and Assembly of Connectors Using 72392-type Contacts Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION Figure 27 Mating Retainers PDM: Rev:J NUMBER GS-20-002 PAGE REVISION AUTHORIZED BY DATE J.R. Volstorf 25-Apr-06 STATUS UNRESTRICTED GS-01-001 Released STATUS: Printed: Nov 27, 2010 ...

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... The following table lists the cad files imported into this document. 15.0 NOTES The following table lists the files of the pictures imported into this document. 16.0 REFERENCE DOCUMENTS Bellcore GR-1217-CORE, IEC-1076-4-110 Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION Figure Autocad File 1 G20002_A ...

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... ALL CHANGE 10.3 APP. TOOLING WIRE INSERT EQUIP. CHART G ALL UPDATE INFO ON HAND TOOLS & ALTERNATE AUTO-INSERTER H ALL ADD LEAD FREE INFORMATION J ALL CHANGE LOGO Copyright FCI Form E-3334 Rev E APPLICATION SPECIFICATION REVISION RECORD DESCRIPTION PDM: Rev:J NUMBER GS-20-002 PAGE REVISION ...