CHAMP*
Cable Connectors
(Standard and Shielded)
NOTE
Application Specification
114-- 6041
15 SEP 09 Rev A
i
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 CHAMP Cable Connectors (standard and
shielded). These requirements are applicable for hand or automatic machine installation. These CHAMP Cable
Connectors are intermateable and interchangeable with existing connectors of a similar design. The CHAMP
Connector product line is ideally suited for use in all phases of the telecommunications industry, computer
terminals, test equipment, business and copying machines, telemetering, and various equipment used in the
security industry. The standard CHAMP Cable Connectors are available in 14--, 24--, 36--, 50--, and 64--position
sizes. The shielded CHAMP Cable Connectors are available in 24--, 36--, and 50-- position sizes.
When corresponding with personnel, 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.
Receptacle Connector
Assembly
Plug Connector
Assembly
Standard CHAMP
Connector
Contact Letter Code
Housing Color Dot Code
(on back of plug and
receptacle connector)
Locking Tabs
Shielded CHAMP
Connector
Figure 1
TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111
E2009
Tyco Electronics Corporation, Harrisburg, PA
PRODUCT INFORMATION 1-- 800-- 522-- 6752
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.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
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2. REFERENCE MATERIAL
2.1. Revision Summary
114- 6041
S
S
S
S
Updated document to corporate requirements
New logo and format
Renumbered headings
Added new Section 4 and renumbered
2.2. Customer Assistance
Reference Part Number 229974 and Product Code 1210 are representative numbers that identify the CHAMP
Cable Connectors. These numbers are used in the network of customer service to access tooling and product
application information. This service is provided by your local Tyco Electronics Representative or, after
purchase, by calling the Product Information number at the bottom of page 1.
2.3. Drawings
Customer Drawings for specific products are available from the responsible Tyco Electronics Engineering
Department via the service network. The information contained in the Customer Drawings takes priority if there
is a conflict with this specification or with any other technical documentation supplied by Tyco Electronics.
2.4. Specifications
Product Specification 108--6005 provides applicable performance requirements and test data relative to
CHAMP Cable Connectors.
2.5. Instructional Material
The following list includes available instruction sheets (408--series) that provide assembly procedures for
product, operation, maintenance and repair of tooling, as well as setup and operation procedures of
applicators; and customer manuals (409--series) that provide setup, operation, and maintenance procedures of
machines.
Document Number
408--3133
408--3137
408--3159
408--3160
408--3188
408--7558
408--7559
408--7564
408--7642
408--7787
409--5411
409--5771
Document Title
CHAMP Discrete Wire Tooling Assembly 231593--2
CHAMP Laminated Cable Tooling Assembly 231592--2
Strain Relief Hardware For CHAMP Connectors
Mounting Hardware For CHAMP Connectors
Shielded CHAMP 180 Connector Kits and Cover Kits
CHAMP T--Handle Wire Insertion Tool 229384--1
CHAMP Portable Hand Operated Tool (MI--1) 229378
CHAMP Cable--to--Cable and Cable--to--Panel Connectors
Palm Grip Hand Tool Kit 229764--2
Insertion/Extraction Tool 230238--1
CHAMPOMATOR* Insertion Machine
CHAMPOMATOR 3A Terminating Machine
3. REQUIREMENTS
3.1. Wire
A. Selection
Contacts are available for the wire sizes specified in the chart in Figure 2. Housing assemblies (plug/
receptacle) are also specified in Figure 2. The wires may be solid or stranded.
B. Wire Size
The color dots on the housings and the letter codes on the contacts designate wire size.
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WIRE SIZEH
SOLID
22
22
24--26
------
7 STRAND
22
22
24
26--27--28
HOUSING COLOR
DOT CODE
Green
Brown
Blue
Yellow
114- 6041
CONTACT
LETTER CODE
C
FD
B
E
NOTES:
H
All connector styles may not be available in each position and each wire size.
D
Connectors for
large insulation diameter wire (1.42 mm [.056 in.]) maximum.
Figure 2
C. Wire Placement
Wire must be below transition of lead--in to contact slot as indicated in Figure 3. See Figure 4 for F slot
contact wire placement.
Inserter imprint in conductor insulation acceptable to one-- half of
insulation wall thickness. Thinning to point where insulation
appears translucent is acceptable.
Strain-- Relief Slot
Thinning of Insulation is
Acceptable to Point
Where Material
Appears Translucent
Barrier Pad
B
Contact
Slot
Window Height
Insulated Conductor Must Extend
0.89 mm [.035 in.] Below Contact Slot
B
A
Wire Must be
Below
Transition of
Lead-- In to
Contact Slot
Conductor
A
Section A--A
Figure 3
Section B--B
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Strain-- Relief
Slots
114- 6041
Distance
2
Barrier Pad
B
B
Window Height
Section A--A
3
Wire Must Be Below
Transition Of Lead-- In
To Contact Slot
Contact Slot
A
0.30 [.012]
Y
Large Wire Contact Terminating Inspection
- Notes on Customer Manual 409-- 5411 apply
- Additional allowances are:
1
Terminal perpendicularity of 0.30 mm [.012 in.] to Datum - Y-- .
2
Maximum distance after conductor termination is 3.30 mm [.130 in.].
3
Maximum marking of surface 0.25 mm [.010 in.] from noted edge, typical.
Figure 4
---Y---
A
Section B--B
D. Wire Exposure
Insulated conductor must extend 0.89 mm [.035 in.] below contact slot.
E. Insulation Range
Insulation range for standard cable connectors should be 1.14 mm [.045 in.] maximum diameter for tools
that mass terminate conductors on one side at a time. For tools that insert one conductor per side at a
time, 1.09 mm [.043 in.] insulation diameter is the maximum. Insulation range for F slot contacts is
1.42 mm [.056 in.] maximum diameter.
F. Workmanship
Minor nicks and scrapes or saddling of the metal bridge are acceptable provided the two slots remain
parallel to each other and perpendicular to the housing. Minor plastic shaving and rolling over of barrier
pads are acceptable provided that contacts are not damaged. Shaving of barrier pads is acceptable up to
0.15 mm [.006 in.] maximum in direction of connector length. Nicks in the insulation above the connector
should not exceed one half of insulation wall thickness.
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G. Inserter Imprint
114- 6041
Inserter imprint in conductor insulation should not exceed one half of insulation wall thickness. Thinning of
insulation is acceptable to the point where the insulation appears translucent.
3.2. Shielded CHAMP Cable Connectors
Shielded CHAMP Cable Connectors consist of contacts on 2.16 mm [.085 in.] centerlines; pre--assembled
housings with 24, 36, or 50 slotted contacts; a choice of two wire slot sizes, B or E; bail--lock or screw--lock
hardware, with metric hardware for IEEE applications; 180_ cable entry; and the same full tooling capabilities
that are used with standard CHAMP Cable Connectors.
The main design difference in shielded CHAMP Cable Connectors is the addition of small holes or windows
around the peripheral skirt of each plug housing. These holes accept the spring fingers of a two--piece
wraparound metal shield. The spring fingers interact with the contact plates on the receptacle connector and
thus provide minimal leakage and maximum shielding effectiveness.
The application requirements are basically the same (except where noted otherwise) for shielded and standard
CHAMP Cable Connectors.
3.3. Locking Hardware
Locking hardware is used to secure mating CHAMP Connectors and to prevent accidental separation. Refer to
Instruction Sheet 408--3160 for further information. See Figure 5 for the different types of locking hardware.
A. Locking Latch (CHAMP- LOK* Connector Design)
Standard CHAMP connectors (except for IEEE applications) have guide tracks and slots (on plugs) and
lead--in ramps (on receptacles) to allow the use of a metal locking clip for securing connectors.
B. Screw- Lock Hardware
Screw--lock hardware is used in applications where positive locking is required to secure connectors to pc
boards, to panels, and/or to each other. In cable--to--cable applications, two captive screws threaded into
pre--tapped holes are generally the only screw--lock requirements.
C. Bail- Lock Hardware (Standard or Bent)
Bail--lock hardware provides both locking and quick--release capabilities at both ends of mated connectors.
Flanges on CHAMP plug connectors must be open ended for all bail--lock applications. The open--end
flanges accept bail clips which are used primarily with right angle (90_) cable terminations where space is
limited.
D. J- Hook Hardware
The J--hook is a precision--formed metal bracket used as an alternate quick--fastening method for
assembly hardware. Two tabs fit into recesses in the connector housing flange for screw--fastening. The
inverted end of the J--hook snaps on the end of a mating connector, and holds it in place.
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