Cover Closing Kits 543508-1 and 543526-1
and Staple Inserter Kit 543515-1 for
AMPLIMITE* .050 Series Connector Assembly
Instruction Sheet
408-9820
24 NOV 08
Rev A
Cover Closing Tool 543508-1
(Standard Connectors)
Cover Closing Tool 543526-1
(Busing Connectors)
Cover Closing
Upper Tool
Lower Tooling
Subassembly
Staple Insertion Kit 543515-1
Upper Tooling
Small
Upper Tooling Sizes
Medium
20-40-Position
Connector
50-68-Position
Connector
D
Large
80-120-Position
Connector
Lower Plate
D
Use large upper tooling for 68-position shielded
enclosure kit with male jackscrews.
Figure 1
1. INTRODUCTION
NOTE
Dimensions in this instruction sheet are in metric
units [with U.S. customary units in brackets].
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.
NOTE
For preparation and assembly requirements, refer
to Application Specification 114-40029 for the
i
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.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
i
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).
E
2008 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
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LOC B
*Trademark. Other products, logos, and company names used are the property of their respective owners.
Cover Closing Kits 543508-1 and 543526-1 and Staple Inserter Kit 543515-1
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.
408-9820
3. Assemble the standard cover or termination
covers (with wires) onto the connector assembly
and close it partially by hand.
NOTE
If using round-to-flat wire or flat ribbon cable,
insert the cable between the cover and contacts
i
and pre-close the covers by hand, clamping the
cable in place.
Frame Assembly
(Ref)
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.
Ram Tooling
Adapter
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.
Cover Closing
Upper Tool
Figure 2
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.
Lower Tooling
Subassembly
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.
CAUTION
It is extremely important to ensure that all
conductors extending from the strain relief area to
Inscription
!
Machined Base
Plate (Ref)
Pins
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
Figure 3
the upper backshell is assembled to the lower
backshell.
2
of 3
Tyco Electronics Corporation
Rev
A
Cover Closing Kits 543508-1 and 543526-1 and Staple Inserter Kit 543515-1
408-9820
Detail A
Upper Bar
Finger Lever
Detail B
Lower Bar
Termination
Covers
Surface
Busing Connector
Assembly
Standard Connector
Assembly
Detail C
Surface
Figure 4
Cross-Section of Metal Strain Relief Staple
After Installation In Lower Metal Backshell
0.127-0.254 mm
[.005-.010 in.]
Staple Insertion Depth
Wire
Metal Strain
Relief Staple
Connector
Assembly
Staple
Figure 5
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.
Lower Plate
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 SERVICE (038–035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105–3608
Figure 6
5. REVISION SUMMARY
Revisions to this instruction sheet include:
S
Updated document to corporate requirements
S
Added reference part number for busing
connectors
S
Added text to Section 2
Rev A
Tyco Electronics Corporation
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