1-552413-1 - Tyco Electronics

Instruction Sheet

Strain Relief Hardware 408–3159

(was IS 3159)

LOC B

1 of 4

2003 T yco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

AMP and Tyco are trademarks. *T rademark

Other products, logos, and company names used are the property of their respective owners.

TOOLING ASSISTANCE CENTER 1–800–722–1 111

F AX/PRODUCT INFO 1–800–522–6752

For Regional Customer Service, visit our website at

www.tycoelectronics.com

This controlled document is subject to change.

For latest revision, call the FAX/PRODUCT INFO number.

08 OCT 03 Rev A

for CHAMP* Connectors

Figure 1

Receptacle

Connector

(Typ)

Plug

Connector

(Typ)

1. INTRODUCTION (Figure 1)

This instruction sheet covers the selection and

installation of strain relief hardware for cable–to–cable

and cable–to–panel CHAMP Connectors. Read this

and all referenced material before starting assembly.

Dimensions in this instruction sheet are in

millimeters [with inches in brackets]. Figures are

for reference only and are not drawn to scale.

Reasons for reissue are provided in Section 5,

REVISION SUMMARY.

2. DESCRIPTION

Strain relief hardware can be selected from the tables

in Figures 2 and 3. Determine what connector is to be

used and what application is required.

3. SELECTING AND INSTALLING STRAIN RELIEF

Strain reliefs are designed for cable and discrete wire

applications where the stress is NOT placed on the

conductors (e.g., when the cable bundle itself is

secured and the connector is concealed – preventing

inadvertent movement of the conductors).

1. Determine the number of positions in the

connector. Refer to the table in Figure 2 and select

the applicable strain relief.

2. Position the first half on the connector as shown

in Figure 2.

3. Hold the first half in position and align the

second half with the connector.

4. Make sure the locking latches are aligned with

the locking tabs, then press the second half onto

the connector until the locks engage.

Strain Relief Halves

Locking Tabs

Locking Latch

CONNECTOR POSITION STRAIN RELIEF PART NUMBER

24 1–552298–1

36 1–552297–1

50 1–552027–1

64 1–552296–1

Figure 2

4. SELECTING AND INSTALLING

STRAIN RELIEF COVERS

Five styles of strain relief covers are available:

– 90° one–piece tapered

– 90° one–piece straight

– 90° two–piece standard profile

– 90° two–piece low profile

– 180° two–piece

The degrees indicate the cable exit in relation to

the mating face of the connector .

Determine the number of contact positions, the

degree of cable exit, and the cable diameter of your

application. Refer to columns 4 and 5 of Figure 3 for

the applicable paragraph in the following text for

installation procedures.

NOTE

408–3159

Strain Relief Hardware for CHAMP Connectors

Rev A2 of 4

CONNECTOR ASSEMBLY STRAIN RELIEF COVER

CONT

POSN CABLE

EXIT CABLE

DIA DESCRIPTION PART

NO.

4.70–5.84

[.185–.230] 90° Two–Piece Low Pf 552412–1

6.10–7.62

[.240–.300] 90° Two–Piece Low Pf 1–552412–1

4.44–5.59

[.175–.220] 180° Two–Piece 552079–1

°5.59–6.73

[.220–.265] 180° Two–Piece 1–552079–1

6.73–7.87

[.265–.310] 180° Two–Piece 2–552079–1

6.10–7.62

[.240–.300] 90° Two–Piece Low Pf 552413–1

7.87–9.14

[.310–360] 90° Two–Piece Low Pf 1–552413–1

7.11–8.13

[.280–.320] 180° Two–Piece 1–552076–1

8.13–9.65

[.320–.380] 180° Two–Piece 2–552076–1

90°7.87–9.14

[.310–.360] 90° Two–Piece Low Pf 552414–1

36 180°7.37–8.64

[.290–.340] 180° Two–Piece 552073–1

90° Taper 229909–1

7.6

–8.

[

–.3

]

90° Straight 552617–1

[00 2]

Cable Clamp for All 3–229910–1

7.6

–1

.16

[ 00 00]

90° Straight 552617–1, –4

[.300–.400] Cable Clamp for Str 552618–4

90° Straight 229909–1

6–9.4

[

5–.37

90° Straight 552617–1

[2 0]

Cable Clamp for All 3–229910–1

8.64–1

.16

[ 0 00]

90° Two–Piece Std Pf 1–552011–1

[.340–.400] 90° Two–Piece Low Pf 552014–1

90° Taper 229909–1

8.89–1

[02]

90° Straight 552617–1

[.350–.425] Cable Clamp for Str 229910–1

Kit for Taper 552560–1

10.54–11.81

[.415–.465] 90° Two–Piece Std Pf 552011–1

00 2

90° Taper 229909–1

–1

[ 2 00]

90° Straight 552617–1

00 2

[.425–.500] Cable Clamp for All 1–229910–1

Kit for Taper 552560–5

Figure 3 (cont’d)

CONNECTOR ASSEMBLY STRAIN RELIEF COVER

CONT

POSN CABLE

EXIT CABLE

DIA DESCRIPTION PART

NO.

90° Taper 229909–1

°1

.7–13.97

[

–.55

90° Straight 552617–1

[00 0]

Cable Clamp for All 4–229910–1

8.38–10.92

[.330–.430] 180° Two–Piece 3–552008–1

°10.92–12.45

[.430–.490] 180° Two–Piece 552008–1

12.45–13.97

[.490–.550] 180° Two–Piece 4–552008–1

10.41–12.06

[.410–.475] 90° Two–Piece Std Pf 552496–1

°12.06–13.72

[.475–.540] 90° Two–Piece Std Pf 1–552496–1

64 13.72–15.37

[.540–.605] 90° Two–Piece Std Pf 2–552496–1

180°12.19–13.72

[.480–.540] 180° Two–Piece 552082–1

{

A dash one (–1) suffix signifies black and a dash four (–4)

signifies gray.

Figure 3 (end)

4.1. 90° Slide–On Covers (50–Position Only)

Tapered

– Designed for cable–to–cable

applications within a cable diameter range of

7.62–12.7 [.300–.500].

Straight

– Designed for multi–jack adapter

and cable–to–cable applications within a

cable diameter range of 7.62–12.7

[.300–.500].

Straight (Ratchet Style)

– Designed for

cable–to–cable applications with a cable

diameter up to 10.80 [.425] maximum. Strain

relief snaps into cover by use of mating

ratchet teeth on strain relief and cover.

Recommended for use with CHAMP–LOK*

Connector Locking Latch 552723–1.

When installing 90° covers, the wires MUST be

dressed to opposite ends of the plug and

receptacle connectors. (Dress plug wires toward

contacts numbered 1 and 26, and dress

receptacle wires toward contacts numbered 25

and 50.

Install as follows:

1. Grip the connector firmly with one hand, then

draw the other hand over the wire and towards the

proper end of the connector – forming the wires as

indicated in Figure 4. Do NOT overwork the wires.

2. Align the terminated contacts with the contact

groove in the cover.

NOTE

408–3159

Strain Relief Hardware for CHAMP Connectors

3 of 4Rev A

Figure 4

Locking Tab Straight

Captive Screw (Ref)

Tapered

Contact Groove

Locking Latch

Strain Relief

Cable Clamp

90° Cable

Exit

Contacts

Cable Clamp

Straight

(Ratchet Style)

3. While observing the wires, slide the cover onto

the connector until bottomed. Do NOT pull wires.

4. Make sure the cable sheathing is located in the

strain relief of the cover.

5. Install the strain relief clamp on the cover with

your hand or a suitable pair of parallel pliers. Make

sure the locking latches engage the locking tabs.

4.2. 90° Two–Piece Covers

Standard

– Designed for cable–to–cable and

cable–to–panel applications.

Low Profile

– Designed for cable–to–cable

and cable–to–panel applications where height

is a concern.

Install as follows:

1. Grip the connector firmly with one hand, then

draw the other hand over the wires and toward the

proper end of the connector – forming the wires as

indicated in Figure 5. Do NOT overwork the wires.

2. Position the half with the locking latches on the

terminated connector. Make sure the contacts

enter the contact groove, and the wires will fit

inside the cover.

3. Make sure the cable sheathing is located in the

strain relief of the cover.

4. Align the second half of the cover with the first,

then press it onto the connector until the locking

latches engage the locking tabs (a pair of parallel

pliers may be required to close the strain relief).

4.3. 180° Two–Piece Covers

There are two methods of placing the wires

inside the 180° cover . The one used will depend

on the terminated cable bundle in relation to the

connector. If the cable bundle is located at one

end (standard tooling) use Method 1, if the cable

bundle is located in the center (MI–1 tool with

loose combs) use Method 2.

NOTE

408–3159

Strain Relief Hardware for CHAMP Connectors

Rev A4 of 4

Figure 5

Cable Sheathing Locking Latch

Contact Groove

Strain Relief

Locking Tab

A. Method 1

1. Gather the wires at the end of the connector

that is nearest to the cable bundle. See Figure 6.

2. Place the cover half with the locking latches on

one side of the connector, and make sure the

contacts enter the contact groove.

3. Press the wires (at connector end) into the

cover and hold them there with your thumb.

4. Fold the cable bundle to the other end of the

connector and again press the wires into the cover

with your thumb.

5. Hold the wires in the cover half and fold the

cable bundle to the middle of the cover and out

through the strain relief.

6. Make sure the wires will fit inside the cover, and

the cable sheathing is in the strain relief.

7. Align the second half of the cover with the first

half, then press it on to the connector until the

locking latches engage the locking tabs (a pair of

parallel pliers may be required to close the strain

relief).

B. Method 2

1. Gather the wires together at the center of the

connector.

2. Place the cover half with the locking latches on

one side of the connector, and make sure the

contacts enter the contact groove. See Figure 6.

3. Fit the wires inside the cover, and the cable

sheathing in the strain relief.

4. Align the second half of the cover with the first

half, then press it onto the connector until the

locking latches engage the locking tabs (a pair of

parallel pliers may be required to close the strain

relief).

5. REVISION SUMMARY

Revisions to this instruction sheet per

EC 0990–1240–03 include:

Updated document to corporate requirements

Updated document to current format

Deleted obsolete part numbers

Figure 6

Method 1 Method 2

Contact

Groove

Strain Relief

Locking Latch

180° Cover

Halves

Strain Relief

Locking Tab