TYPE
NUMBER
APPLICATION SPECIFICATION
TITLE
PAGE
GS-20-002
REVISION
Specification of Requirements for Cable Preparation, Wire Termination and
Assembly of Connectors Using 72392-type Contacts
1 of 29
AUTHORIZED BY
DATE
J
25-Apr-06
J.R. Volstorf
STATUS
UNRESTRICTED
TABLE OF CONTENTS
1.0
2.0
PURPOSE..................................................................................................................................................4
SCOPE.......................................................................................................................................................4
3.0 GENERAL..................................................................................................................................................4
3.1 Method of Specifying ..............................................................................................................................4
3.2 Workmanship ..........................................................................................................................................4
3.3 Usage .....................................................................................................................................................4
3.4 Visual ......................................................................................................................................................4
4.0 PRODUCT DESCRIPTIONS .....................................................................................................................5
4.1 72476 type 4-row Metral™ Unshielded Connector ................................................................................5
4.2 72477 type 4-row Metral™ Unshielded Connector ................................................................................6
4.3 88940 type 4-row Metral™ Unshielded Connector ................................................................................6
5.0 CABLE PREPARATION ...........................................................................................................................7
5.1 72476, 72477 and 88940 type 4-row Metral™ Unshielded Connectors ................................................7
6.0
DESIGNING WIRING DIAGRAMS............................................................................................................7
7.0 RECOMMENDED WIRE SIZES AND INSULATIONS..............................................................................8
7.1 Wire Insulation Materials ........................................................................................................................8
7.2 Maximum Insulation Diameters and Wire Sizes .....................................................................................8
7.3 Uninsulated Wires ..................................................................................................................................9
7.4 Conductor Materials ...............................................................................................................................9
8.0 POSITION OF CONNECTOR SUB-ASSEMBLY TO CABLE ..................................................................9
8.1 72476 and 72477 type 4-row Metral™ Unshielded Connectors ............................................................9
8.2 88940 - type Metral™ Unshielded Connectors ....................................................................................10
9.0 ACCEPTABLE WIRE TERMINATION ....................................................................................................10
9.1 Termination Requirements, Visual .......................................................................................................11
9.1.1
Wire Location................................................................................................................................11
9.1.2
Wire Depth....................................................................................................................................12
9.1.3
Strain Relief ..................................................................................................................................13
9.1.4
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
PDS: Rev :J
Copyright FCI
Form E-3334
Rev E
STATUS:Released
Printed: Aug 22, 2011
GS-01-001
TYPE
NUMBER
APPLICATION SPECIFICATION
TITLE
PAGE
GS-20-002
REVISION
Specification of Requirements for Cable Preparation, Wire Termination and
Assembly of Connectors Using 72392-type Contacts
2 of 29
AUTHORIZED BY
DATE
J
25-Apr-06
J.R. Volstorf
STATUS
UNRESTRICTED
CONNECTOR SUB-ASSEMBLIES - GENERAL ................................................................................13
10.0
10.1
Contact Retention ............................................................................................................................13
10.2
Connector Insulator Damage ...........................................................................................................14
10.2.1 Termination Tool Misalignment ....................................................................................................14
10.3
Wire Terminators .............................................................................................................................14
10.3.1 Automatic Terminators .................................................................................................................14
10.3.2 Hand Tools ...................................................................................................................................16
11.0
ASSEMBLY OF COMPONENTS AFTER WIRE INSERTION ............................................................17
11.1
72476 and 72477 type Metral™ Unshielded Connectors ................................................................17
11.1.1 Assembly of Covers to Connector Sub-Assemblies ....................................................................17
11.1.2 Assembly of Latch Finger to Covers ............................................................................................19
11.1.3 Assembly of Cable Tie .................................................................................................................19
11.1.4 Assembly of Optional Coding Keys to Covers .............................................................................20
11.2
88940 type Metral™ Unshielded Connectors ..................................................................................20
12.0
REPAIR PROCEDURES......................................................................................................................21
12.1
Repair Tooling ..................................................................................................................................21
12.2
Wire Replacement ...........................................................................................................................21
12.3
Damaged Contacts in a Completed Connector ...............................................................................21
12.4
Removing Contacts from the Insulator ............................................................................................21
12.5
Inserting Contacts into the Insulator ................................................................................................21
12.6
Wires Inserted in Wrong Position or Defective Insertion .................................................................22
12.6.1 Preferred Method of Repair ..........................................................................................................22
12.6.2 Alternate Methods of Repair.........................................................................................................23
12.6.2.1
Wires Inserted in Wrong Position..........................................................................................23
12.6.2.2
Defective Insertions...............................................................................................................23
12.6.2.2.1 Reinsertion of Wire in IDC of Contact ..............................................................................23
12.6.2.2.2 Soldering of Wire in Contact ............................................................................................25
12.7
Replacing Latches ...........................................................................................................................26
12.8
Replacing or Removing Covers .......................................................................................................26
13.0
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
15.0
16.0
NOTES .................................................................................................................................................28
NOTES .................................................................................................................................................28
REFERENCE DOCUMENTS ...............................................................................................................28
PDS: Rev :J
Copyright FCI
Form E-3334
Rev E
STATUS:Released
Printed: Aug 22, 2011
GS-01-001
TYPE
NUMBER
APPLICATION SPECIFICATION
TITLE
PAGE
GS-20-002
REVISION
Specification of Requirements for Cable Preparation, Wire Termination and
Assembly of Connectors Using 72392-type Contacts
3 of 29
AUTHORIZED BY
DATE
J
25-Apr-06
J.R. Volstorf
STATUS
UNRESTRICTED
Figure 1 4x6 Unshielded Connector .....................................................................................................5
Figure 2 4x12 Unshielded Connector ...................................................................................................6
Figure 3 2x10 & 2x6 Unshielded Connector .........................................................................................6
Figure 4 Cable Preparation - Unshielded Connectors ..........................................................................7
Figure 5 Wiring Diagram - 72476 Unshielded Connectors .................................................................7
Figure 6 Wiring Diagram - 72477 Unshielded Connectors ..................................................................8
Figure 7 Dimensions - Single Or Multiple Cables per Unshielded Connector ......................................9
Figure 8 Dimensions - Multiple Unshielded Connectors per Cable ....................................................10
Figure 9 - Wire Insertion Visual Requirements .....................................................................................11
Figure 10 - Wire Depth Gage ................................................................................................................12
Figure 11 TL-230 AutomaticTerminator ..............................................................................................15
Figure 12 BPY6737PC1xx AutomaticTerminator ...............................................................................16
Figure 13 Hand Tool Terminator .........................................................................................................16
Figure 14 Assembly of Covers - 72476 type Connectors ...................................................................17
Figure 15 Assembly of Covers - 72477 type Connectors ...................................................................18
Figure 16 Cover Assembly Fixture......................................................................................................18
Figure 17 Assembly of Latch Finger ...................................................................................................19
Figure 18 Assembly of Cable Tie ........................................................................................................19
Figure 19 Assembly of Coding Keys ...................................................................................................20
Figure 20 Checking for Proper Contact Latching After Insertion ........................................................22
Figure 21 Checking for Damaged Terminal After Insertion ................................................................22
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
PDS: Rev :J
Copyright FCI
Form E-3334
Rev E
STATUS:Released
Printed: Aug 22, 2011
GS-01-001
TYPE
NUMBER
APPLICATION SPECIFICATION
TITLE
PAGE
GS-20-002
REVISION
Specification of Requirements for Cable Preparation, Wire Termination and
Assembly of Connectors Using 72392-type Contacts
4 of 29
AUTHORIZED BY
DATE
J
25-Apr-06
J.R. Volstorf
STATUS
UNRESTRICTED
1.0
PURPOSE
This specification covers end product and workmanship requirements for cable preparation, wire termination and
assembly of the following Metral™ connectors using the 72392 type insulation displacement contacts.
72476-type 4x6 Metral™ unshielded cable connectors
72477-type 4x12 Metral™ unshielded cable connectors
88940-type 2x6 & 2x10 Metral™ unshielded cable connectors
2.0
SCOPE
•
•
Recommended cable preparation
Recommendations on wire types that may be terminated.
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
Recommended repair procedures for wire terminations
Assembly of components after wire termination
•
•
•
3.0
GENERAL
3.1
Method of Specifying
The cable assembly and detail drawings should reference this specification when applicable. All
exceptions to the requirements of this specification should be clearly described in the notes of the cable
assembly drawing. We do not recommend any exceptions unless approval is obtained in advance from
the FCI engineering design group.
3.2
Workmanship
Workmanship shall be of a level that indicates controlled conditions of manufacture such that subsequent
operations, functionality and performance are not degraded.
3.3
Usage
The connectors covered by this instruction are intended for use in a wide variety of environments and are
designed to meet the conditions specified in Bellcore GR-1217-CORE and IEC-61076-4-110.
Banned/Restricted Substances
All product where the part number ends in ‘LF’ meet the European Union directives and other country
regulations as described in GS-22-008. The part numbers that do not end in ‘LF’ meet all regulations
except for Pb in SnPb plating.
Manufacturing Processability
All products covered by this specification will not withstand exposure to convection, infra-red or vapor
phase reflow ovens. Do not heat this product above 110°C.
3.4
PDS: Rev :J
Copyright FCI
Form E-3334
Rev E
Visual
Visual examinations shall be performed with a magnification of up to 10x. (8 to 10x recommended)
STATUS:Released
Printed: Aug 22, 2011
GS-01-001
TYPE
NUMBER
APPLICATION SPECIFICATION
TITLE
PAGE
GS-20-002
REVISION
Specification of Requirements for Cable Preparation, Wire Termination and
Assembly of Connectors Using 72392-type Contacts
5 of 29
AUTHORIZED BY
DATE
J
25-Apr-06
J.R. Volstorf
STATUS
UNRESTRICTED
4.0
Product Descriptions
4.1
72476 type 4-row Metral™ Unshielded Connector
This connector is a 4x6 2mm pitch cable connector with IDC type contacts. The connectors are sold in
kits with the following variations.
as 72476-wxy1 where
“w” specifies the plating on the separable contact
“x” specifies the latch finger type
w = 1 , for 0.8um Gold
x = 1 , for cable diameters up to 7.0mm
w = 2 , for 2.0um Gold
x = 2 , for cable diameters up to 11.0mm
w = 3 , for 1.3um Gold
w = 9 , for 0.8um GXT
“y” specifies the wire gage capacity
y = 1 , for 26-24 gage wire
y = 2 , for 30-28 gage wire
Figure 1 4x6 Unshielded Connector
Product Number
72476-w1y1
Product Number
72476-w2y1
Standard Latch Finger
Short Latch Finger
The difference between the standard latch finger ( x = 1 ) and the short latch finger ( x = 2 ) is that the
standard latch stands above the cable tie and is easier to access but thus restricts the maximum diameter
cable that can be used. 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.
PDS: Rev :J
Copyright FCI
Form E-3334
Rev E
STATUS:Released
Printed: Aug 22, 2011
GS-01-001
Linux开发
京公网安备 11010802033920号
Copyright © 2005-2026 EEWORLD.com.cn, Inc. All rights reserved
电子工程世界
