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Application Specification Coaxial Snap- Lock Connectors
NOTE
114-- 13125
07 DEC 09 Rev D
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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 Coaxial Snap--Lock Jack and Plug Connectors used to mate the electrical interface of a radio to the antenna in free--hanging applications. The connectors consist of a jack or plug body, spacer (when required), and straight ferrule. Also available with the plug connector is a ferrule for right--angle applications. The spacer is used to prevent the contact from moving into the cable dielectric. The ferrules are terminated using manual hand--held tools and semi--automatic machines. These plugs and jacks mate, and the plug is designed to also mate with the coaxial Snap--Lock pc (printed circuit) board jack. The connectors accept jack (male) and plug (female) stamped and formed contacts. These contacts must be ordered separately. The serrations inside the contact wire barrel provide maximum contact and tensile strength after crimping. The contacts are available in reeled form for terminating with semi--automatic electrically--powered machines. When corresponding with Tyco Electronics Personnel about this product, 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.
Jack Connector
Plug Connector Spacer Straight Ferrule
Spacer
Straight Ferrule
Plug Body Support Sleeve Jack Body Cutoff Tab Right Angle Ferrule
Collar
Mating End
Wire Barrel Jack (Male) Contact Plug (Female) Contact
Figure 1
2. REFERENCE MATERIAL 2.1. Revision Summary
S Updated document to corporate requirements S New logo and format
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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Coaxial Snap- Lock Connectors 2.2. Customer Assistance
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Reference Base Product Part Number 1326571 and Product Code D958 are representative numbers of Snap--Lock Connectors. Use of these numbers will identify the product line and expedite your inquiries through a service network established to help you obtain product and tooling information. Such information can be obtained through a local Tyco Electronics Representative or, after purchase, by calling the Product Information Center at the number at the bottom of page 1.
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. If there is a conflict between the information contained in the Customer Drawings and this specification or with any other technical documentation supplied, call the Product Information Center at the number at the bottom of page 1.
2.4. Specifications
Application Specification 114--13138 provides product description and application requirements for pc board jack 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 of machines. Documents available which pertain to this product are: Document Number 408--2498 408--3295 408--4070 408--4303 408--4550 408--7424 408--8040 408--8053 408--8059 408--8547 408--8589 408--8590 408--8892 408--9816 408--9830 408--9930 409--5842 409--5862 1673771 Document Title Crimping Head Cross Reference for Pneumatic Tools Preparing Reel of Contacts for Applicator Tooling Pneumatic Head Assembly 679304--1 Pneumatic CERTI--CRIMP* Tool Holder Assemblies 356302--1 and 356303--1 Coaxial Snap--Lock Cable Jack Connectors Checking Terminal Crimp Height Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type) Miniature (Mini) Quick--Change Applicators General Preventative Maintenance for Applicators CERTI--CRIMP II Straight Action Hand Tools Crimping Die Assembly 1338120--1 Crimping Die Assembly 1338650--1 Coaxial Snap--Lock Cable Plug Connectors Handling of Reeled Products PRO--CRIMPER* III Hand Tool Assembly 58499--1 with Die Assembly 58483--1 PRO--CRIMPER III Hand Crimping Tool Frame 354940--1 AMP--O--LECTRIC* Model "G" Terminating Machine 354500--[ ] 626 Pneumatic Tooling Assemblies 189721--[ ] and 189722--[ ] Instruction Manual SDE 1600
3. REQUIREMENTS 3.1. Safety
Do not stack component packages so high that the shipping containers buckle or deform.
3.2. Limitations
Connector assemblies are designed to operate in a temperature range of --40_ to 85_C [--40_ to 186_F].
3.3. Material
The plug body is made of phosphor bronze plated with bright tin, and the collar is made of PBT; the plug contact is made of phosphor bronze plated with tin. The jack body is made of brass plated with bright tin; the jack contact is made of brass plated with tin. The ferrule is made of copper or brass with tin plating. The spacer is made of nylon. The plug and jack dielectric is made of TPX (Polgmethylpentene).
3.4. Storage A. Ultraviolet Light
Prolonged exposure to ultraviolet light may alter the properties of the materials used in the connector.
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Coaxial Snap- Lock Connectors B. Shelf Life
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The connectors and contacts should remain in the shipping containers until ready for use to prevent deformation to the connectors or contacts. The connectors and contacts should be used on a first in, first out basis to minimize storage contamination that could adversely affect performance.
C. Reeled Contacts
When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically.
3.5. Chemical Exposure
Do not store connectors or contacts near any chemical listed below as they may cause stress corrosion cracking in the connectors or contacts. Alkalies Amines Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Sulfur Compounds Tartrates
3.6. Cable Selection and Preparation
The connectors will accept the contacts crimped onto solid strand coaxial cable sizes RG--59/U, RG--62/U, RG--62/U Modified, RG--71/U, RG--71/U Modified, or stranded 1.5CS--QEHV(TA). The conductor must be straight and free of burrs. The cable must meet the following preparation requirements: 1. The ferrule must be assembled onto the unstripped cable. 2. Proper strip length is necessary to properly insert the center conductor into the contact. Reasonable care must be taken not to nick, scrape, or cut the center conductor or any strands of the braid during the stripping operation. The strip length of the cable is shown in Figure 2. 3. The spacer, if required, must be assembled onto the cable center conductor and bottomed on the cable dielectric. The spacer is not required on RG--59/U cable. Recommended Stripping Dimensions for RG- 59/U, RG- 62/U, RG- 62/U Modified, RG- 71/U, and RG- 71/U Modified Jacket
Dielectric With Spacer 5.27 +0.38 [.205 +.015] Dielectric Without Spacer 5.66 +0.38 [.223 +.015]
5.46+1.32 [.215+.052] Conductor
5.27 +0.38 [.205 +.015] Braid 5.46+1.32 [.215+.052] Conductor 8.18 +0.38 [.322 +.015]
Ferrule
Recommended Stripping Dimensions for 1.5CS- QEHV(TA)
Note: Not to Scale
Figure 2
5.08 +0.38 [.200 +.015] Braid
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Coaxial Snap- Lock Connectors 3.7. Crimped Contact Requirements
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The contact must be crimped to the cable according to instructions packaged with applicable tooling. These requirements apply equally to the plug and jack. CAUTION Cable jacket shall NOT be cut or broken during the crimping operation. Reasonable care should be taken to provide undamaged cable terminations.
!
A. Spacer Location (If Required)
The spacer must be against the cable dielectric, and the end of the contact wire barrel must be no more than 0.38 [.015] from the spacer as shown in Figure 3.
B. Cable Braid
The end of the cable braid must be folded back over the cable jacket in order to access the applicator tooling.
C. Cutoff Tab and Burr
Cutoff tabs are the remaining portion of the carrier strip after the contact is cut from the strip. The following dimensional requirements will ensure proper application for these contacts: 1. The cutoff tab must not exceed the dimension shown in Figure 3. 2. The burr resulting from the cutoff tab shearing must not exceed the dimension shown in Figure 3.
D. Crimp Height
The crimp applied to the wire barrel is critical in ensuring optimum electrical and mechanical performance of the crimped contact. The crimp height must be within the dimensions provided in Figure 3.
E. Effective Crimp Length
Effective crimp length is defined as that portion of the wire barrel, excluding bellmouths, fully formed by the crimping tool. For optimum crimp effectiveness, the crimp must be within the area shown and must meet the dimensions provided in Figure 3.
F. Wire Barrel Seam
The seam between the two sides of the wire barrel must be completely closed, and there must be no evidence of the conductor protruding from the seam.
G. Bellmouths
The rear bellmouth and the front bellmouth must not exceed the dimensions show in Figure 3.
H. Flash
The flash on the wire barrel crimp must not exceed the dimension show in Figure 3.
I. Conductor Location
The conductor must be flush with or extend beyond the wire barrel to the maximum dimension shown in Figure 3.
J. Bend Allowance
The force applied during crimping may cause some bending between the wire barrel and cable. Such deformation is acceptable within the following limits: 1. Up and Down The crimped portion must not be bent beyond the limits shown in Figure 4. 2. Side--to--Side The crimped portion must not be bent from one side to the other beyond the limits shown in Figure 4.
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Crimped Contact Cable Braid Wire Barrel
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Jack
Plug
Spacer (If Required) Spacer Against Cable Dielectric (If Required)
No Conductor Protruding from Wire Barrel Seam 0.13 [.005] (Min) Rear Bellmouth Front Bellmouth Permissible 2.03 [.080] Min Effective Crimp Length 0.38 [.015] (Max) Between Wire Barrel and Spacer, or Wire Barrel and Cable Dielectric if Spacer is Not Required X
End of Conductor Flush with or Extend 3.7 [.145] (Max) from Wire Barrel
X See Detail Detail 0.13 [.005] (Max) Burr
No Nicked Conductor Section X- X
0.38 [.015] (Max) Cutoff Tab
WIRE SIZE RG--59/U RG--62/U, RG--71/U RG--62U Modified, RG--71/U Modified 1.5CS--QEHV(TA) Figure 3
0.13 [.005] (Max) Wire Barrel Flash
Wire Barrel Crimp Height (See Table)
CRIMP HEIGHT 0.826--0.902 [.0325--.0355] 0.91--1.02 [.036--.040] 0.43--0.508 [.017--.020] 0.508--0.584 [.0200--.0230]
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The developed crimp configurations result from using the specific tooling described in Section 5, TOOLING.
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Up and Down Alignment 3_ (Max)
Datum Line
3_ (Max) Side- to- Side Alignment 3_ (Max)
Datum Line
3_ (Max)
Figure 4
K. Twist and Roll
There should be no twist or roll of the wire barrel or mating portion of the crimped contact beyond the limits shown in Figure 5.
+15_
+15_
Datum Line
Crimped Portion
Avoid Twist and Roll
Figure 5
3.8. Placement of Crimped Contact in Connector
The crimped contact must be inserted into the connector body with the following requirements which apply to the plug and jack:
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1. The crimped coax cable must be fully seated against the connector dielectric. The crimped contact must be located within the dimensions given in Figure 6. Pin Contact 1.61+0.36 [.063+.014] Socket Contact 1.17+0.30 [.046+.012]
Figure 6
2. The cable braid must be positioned over the support sleeve of the connector. See Figure 7.
Ferrule Crimped Contact in Connector Body
Cable Braid Over Connector Support Sleeve
Figure 7
3.9. Crimped Ferrule Requirements
The ferrule is required for terminating the cable. The ferrule must be crimped onto the jacket of the cable according to instructions packaged with applicable tooling. The following requirements apply equally to the plug (with straight or right angle ferrule) and jack.
A. Ferrule Location
The ferrule must be over the cable braid with no braid strands showing, and the end of the ferrule must be over the support sleeve towards the connector body. The plug ferrule should be located 0.38--0.89 [.015--.035] from the connector collar. The jack ferrule should be located against the shoulder of the connector body. The overall dimension, measured from the front of the connector body to the end of the ferrule, must not exceed the dimension shown in Figure 8.
B. Crimp Height
The crimp applied to the ferrule is critical in ensuring optimum electrical and mechanical performance of the crimped ferrule. The crimp height must be within the dimensions provided in Figure 8.
C. Crimp Claw Crimp (Right Angle Ferrule Only)
The crimp claw on the right angle ferrule must be wrapped around the cable. See Figure 8.
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Coaxial Snap- Lock Connectors D. Crimp Width
The crimp width must not exceed the dimension shown in Figure 8.
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E. Bellmouths
There shall be no front bellmouth. The rear bellmouth shall be evident and conform to the dimensions given in Figure 8. Y Section Y- Y 3.25 +0.10/-- 0.05 [.128 +.004/-- .002] No Front Bellmouth X 1.52 [.060] Max Rear Bellmouth
Snap- Lock Connector No Cable Braid Strands Showing Crimped Straight Ferrule Ferrule Crimped onto Cable Jacket End of Ferrule Over Support Sleeve and Against Shoulder of Connector Body End of Ferrule Over Support Sleeve
Y
X Overall Dimension (See Table) 1.52 [.060] Max Rear Bellmouth A A X No Front Bellmouth
Crimped Right Angle Ferrule
X Crimp Claw Wrapped Around Cable 7.37 [.290] Max Crimp Height Section A- A
WIRE TYPE RG--59/U, RG--62/U, RG--62/U Modified, RG 62/U Modified RG--71/U, RG--71/U Modified 1.5CS--QEHV(TA) FERRULE TYPE Straight Right Angle Straight Figure 8
0.38-- 0.89 [.015-- .035] 7.24 [.285] Max Crimp Width
Overall Dimension (See Table) 7.37 [.290] Max Crimp Width 6.60-- 7.11 [.260-- .280] Max Crimp Height Section X- X
OVERALL DIMENSION (Max) PLUG JACK 36.7 [1.44] 39.2 [1.54] -----35.0 [1.38] 35.8 [1.41] 32.51 [1.280]
NOTE
The developed crimp configurations result from using the specific tooling described in Section 5, TOOLING.
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The inside diameter of the ground clips inside the plug connector must be maintained after completion of the crimping process as shown in Figure 9.
5.54 [.218] Max After Crimping
Figure 9
3.10. Mating and Unmating Connectors
The plug has internal locking latches that should be fully seated and latched to the jack after mating. When unmating connectors, the latches must be released by slightly pulling the collar of the plug away from the jack. See Figure 10.
Connectors Fully Seated After Mating
Plug Collar Pull Back to Release Plug From Jack
Figure 10
3.11. Repair
Damaged connectors must be removed, discarded, and replaced. Damaged or worn contacts must be replaced.
4. QUALIFICATION
Coaxial Snap--Lock Connectors are not required to be agency evaluated.
5. TOOLING
Tooling for manual application of the ferrules and contacts and semi--automatic machines for power assisted application of reeled contacts are available to cover the full cable size range. Tooling part numbers and instructional material packaged with the tooling are shown (in parenthesis) in Figure 11. NOTE Modified designs and additional tooling concepts may be available to meet other application requirements. For assistance in setting up prototype and production line equipment, contact the Tooling Assistance Center at the number at the bottom of page 1.
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Coaxial Snap- Lock Connectors 5.1. Hand Crimping Tools
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The hand crimping tools for the center conductor contacts consist of a handle assembly and head which contains integral dies to crimp the contact onto pre--stripped cable. The hand crimping tools for the ferrules are hand crimping frames with interchangeable die assemblies. These tools have a ratchet to ensure full crimping pressure is applied to the crimp.
5.2. Power Units
The AMP--O--LECTRIC machine is a semi--automatic, electrical power unit designed for terminating pre--stripped cable to reel--fed contacts. It is designed to be bench mounted and used for high volume applications.
5.3. Applicators
The applicator is designed to crimp reeled contacts onto pre--stripped cable, and provides for high volume, heavy duty production requirements. The applicator must be installed onto a power unit. The applicator used to crimp the contacts includes the crimping dies. Hand Crimping Tool 1752690--1 (408--8547)
Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type), with Mechanical Feed System (408--8040)
AMP--O--LECTRIC Model "G" Terminating Machines 354500--[ ] (409--5842)
TOOLING FOR CONTACT CABLE SIZE (RG/U) 59, 62, 71 62 Modified, 71 Modified 1.5CS--QEHV(TA) APPLICATOR FOR AMP-- O-- LECTRIC MODEL "G" TERMINATING MACHINE 354500-- [ ] 680900--1, 1385623--3 680901--1, 1385624--3 1385674--3 Figure 11 (cont'd) HAND TOOL
1752690--1 1752690 1 ------
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Die Set 1338650--1 for Right--Angle Ferrules (Crimp Claw Only) (408--8590) PRO--CRIMPER II Hand Crimping Tool Frame Assembly 354940--1 (408--9930) with Die Set 58483--1 (408--9830)
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Die Set 1338120--1 for Straight and Right--Angle Ferrules (Straight Portion Only) (408--8589)
Battery Operated Pneumatic Tooling SDE PH1600 1583034--1, - 2 (1673771) Pneumatic Head Assy 679304--1 (408--4070)
Pneumatic Tool Holder 189767--1 (408--2498)
Hand Actuated System (Without Logic) 189721--1 (408--2498 and 409--5862)
Foot Actuated System (Without Logic) 189722--1 (408--2498 and 409--5862) Pneumatic Tool Holder 356302--1 (408--4303)
TOOLING FOR FERRULE CABLE SIZE (RG/U) DIE SET PNEUMATIC TOOLING HEAD ASSY TOOL HOLDER ACTUATION TYPE ASSY BATTERY OPERATED PNEUMATIC TOOLING SDE PH1600 HAND TOOL
CONN
TYPE
Plug 59, 62, 62 Mod, 71, 71 Mod Jack
Straight
13381201338120 - 1 1338120-- 1 (Straight Portion) 1338650-- 1 (Crimp Claw Portion) Ratchet 679304-- 1 189767-- 1 Hand 189721-- 1 1.1mm Hose 1583034-- 1 354940-- 1
Plug
R/A
1.5CS-QEHV(TA)
Jack
Straight Hex Crimp 3.25 [.128]
58483-- 1
Non-Ratchet
356302-- 1
Foot
189722-- 1
2.2mm Hose
1583034-- 2
Figure 11 (end)
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Coaxial Snap- Lock Connectors 6. VISUAL AID
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Figure 12 shows a typical application of Snap--Lock connectors. This illustration should be used by production personnel to ensure a correctly applied product. Applications which DO NOT appear correct should be inspected using the information in the preceding pages of this specification and in the instructional material shipped with the product or tooling. CRIMPED CONTACT CABLE JACKET MUST NOT BE CUT OR BROKEN
SPACER MUST BE AGAINST CABLE DIELECTRIC WIRE BARREL SEAM MUST BE COMPLETELY CLOSED AND NO EVIDENCE OF CONDUCTOR SHALL PROTRUDE FROM THE SEAM
CABLE BRAID MUST NOT BE NICKED OR CUT
END OF CONDUCTOR MUST BE FLUSH WITH OR EXTEND FROM WIRE BARREL
REAR BELLMOUTH MUST BE EVIDENT CONTACT WIRE BARREL MUST BE CLOSE TO SPACER
CONTACT MUST BE STRAIGHT AND NOT DAMAGED IN ANY WAY CRIMPED FERRULE THERE MUST BE NO FRONT BELLMOUTH
THERE MUST BE NO CABLE BRAID STRANDS SHOWING AROUND FERRULE
FERRULE MUST BE CRIMPED ONTO CABLE JACKET END OF FERRULE MUST BE OVER SUPPORT SLEEVE AND AGAINST SHOULDER OF CONNECTOR BODY END OF FERRULE MUST BE OVER SUPPORT SLEEVE
FIGURE 12.
VISUAL AID
CRIMP CLAW MUST BE WRAPPED AROUND CABLE
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