Amphenol AMPHE-EX L-2124 Інструкція з монтажу Посібник з монтажу - Сторінка 3

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Familiarization & Assembly Information

Read manufacturer's assembly instructions before actually starting

to assemble connectors. Besides the matter of instruction on correct

procedures, there are two important reasons for this preliminary

step: To identify the various component parts, and to check for any

missing parts.

Cut cable jacket and sheathing squarely and sheathing squarely and

to correct length, using only wire strippers that have been approved

for the operation. In preparing the individual wires in cables and

harnesses for assembly, make allowances in length for reaching the

outer most circle of contacts cavities in the conductors. The

insulation should be cut progressively longer as they extend out

from the center of the cable or harness to assure sufficient length.

Follow chart on Page 5 covering maximum cable stripping lengths

for effective cable gland sealing. All conductors should be fit into

contact wire wells correctly. A practice layout should be done so

that an assembler can oversee what the finished will look like when

finished.

Before starting actual termination of wires, it is essential that cables

and harnesses be laid out in a specific order in accordance with the

wiring diagram. Proper layout will eliminate the need for twisting

and crossover of conductors. If the wiring layout is not correct, the

termination operation will be difficult or even impossible and the

chances for making errors will be increased. Cable and harness

assemblies having a spiral layout must also be matched carefully to

the correct contacts in both the male and female inserts.

Some cables that will be used will have a "basket weave" type of

armor under the outer jacket (sheath) and over the inner jacket. Since

many regulatory entities require that the armor be grounded at least

at the source end, it is beneficial to ground the armor via a spare

contact within the connector. Follow the removal of sufficient

amount of outer jacket (see chart on Page 5) ample amount of armor

can be clipped away, but not all. An adequate amount should remain

in order that a small cross-section conductor, short in length, be

woven into the remaining armor weave and either soldered or

covered with mastic impregnated heat shrink, creating an intimate

bond to the armor. At the opposite end of the short piece of wire a

contact should be crimped and inserted into the insert.

Use only correctly sized and ingress protected certified glands

provided to assure resistance to moisture and other contaminates.

Use only the proper crimping tools that have been set or calibrated

with precision gages.

Make certain that all contacts are the correct size before attempting

to assemble in insert cavities. This point is particularly important

when both power and control types of contacts are used in the same

connector.

Be sure that any ground contacts (when applicable) are correctly

located.

10. Seat all contacts properly so that they will not be damaged or

become disengaged during connectors mating operation.

11. Use only the proper insertion tools and be sure that they are

aligned axially when pushing contact into their fully seated

position.

12. When inserts have more cavities than the conductors, plug unused

cavities with furnished contacts.

13. After all terminated contacts are inserted in their respective

cavities and inspected (detailed on page 5), the cable adapter

should be installed and tightened with a strap wrench (detailed on

page 8).

14. When handling cables, use adequate support to prevent damage

to the internal wires. Exd glands are intended for sealing purposes

and should not be used as a cable grip.

15. If for any reason, terminated conductors have to be removed from

an insert because of an assembly error or change in circuitry, be

sure to remove the cable gland or cable adapter first before

extracting the contact and re-inserting it.

16. If one of the connector poles is a ground wire, make sure that it is

grounded properly before the connector actually is engaged.

17. When connectors have the same configuration are to be mounted

closer together, different or alternate key arrangements should be

used to prevent mismatching and possible damage to the

electrical system.

18. Always inspect all aspects of connector assembly operations

before putting connector into actual operation.

19. Crimping and terminating of conductors to contacts must be done

carefully. Make certain that all wire strands are fully bottomed in

contact wells by checking through inspection hole provided

(detailed on page 5).

20. Never try to straighten bent contacts. Straightening cannot be

done properly and the plating on contacts very likely will be

marred. This will result in a high resistance connection and will

expose the base material to possible corrosion.

21. Each assembly operator should be his own inspector. Worn,

damaged, or defective tolls should be reported immediately to

foreman and supervisors. Assembly operators should be

indoctrinated with this attitude and made to understand the

importance of always guarding quality. Assembly workmanship

is significant factor in terminating the quality of multiple contact

connectors. Quality cannot be "inspected" into connectors; it must

be "built-in" during each and every assembly operation.

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