Table of Contents
Advertisement
Quick Links
NUMBER
GS-20-0454
TITLE
OCTIS PLUG KIT ASSEMBLY - HYBRID, SIGNAL & POWER
Section
1.
OCTIS PLUG KIT ASSEMBLY - USER INSTRUCTION............................................................. 3
1.1.
Hybrid - Signal & Power (Combo) connector interface (Crimped type) ..................................... 3
1.2.
Signal Metral HDXS connector interface Crimped type) .............................................................. 4
1.3.
2 position Power - Pwr Profile connector interface Crimped type) ........................................... 5
1.4
2 position Power - Pwr Profile connector interface (Screw type).......................................6
1.5
3 position Power - Pwr Profile connector interface (Screw type).......................................7
2.
OBJECTIVE ............................................................................................................................................... 8
3.
SCOPE ...................................................................................................................................................... 8
4.
GENERAL ................................................................................................................................................. 8
5.
DRAWINGS AND APPLICABLE DOCUMENTS ...................................................................................... 8
6.
APPLICATION REQUIREMENTS ............................................................................................................ 8
7.
RECOMMENDED WIRE SIZES AND INSULATIONS.............................................................................. 8
7.1.
Wire insulation materials ............................................................................................................... 8
7.2.
Maximum insulation diameters and wire sizes ............................................................................ 9
7.2.1 Signal Contact ................................................................................................................................. 9
7.2.2 Power Contact ................................................................................................................................. 9
7.2.3 Crimp on Wire (Power Contact) .................................................................................................. 10
8.
ACCEPTABLE WIRE TERMINATION .................................................................................................... 11
8.1.
Termination requirements, visual ............................................................................................... 11
8.1.1 Wire Location ................................................................................................................................ 11
8.1.2 Wire Depth ..................................................................................................................................... 12
8.1.3 Strain Relief ................................................................................................................................... 13
8.1.4 IDC Terminal Damage .................................................................................................................. 13
8.1.5 Wire Damage ................................................................................................................................. 13
8.2.
Tool setup and destructive inspection techniques ................................................................... 13
8.2.1 Wire Removal ................................................................................................................................ 13
8.2.2 IDC Terminal Damage .................................................................................................................. 13
8.2.3 Acceptable Metallic Contact ........................................................................................................ 13
9.
APPLICATION TOOLING ....................................................................................................................... 14
10.
APPLICATION PROCEDURES .............................................................................................................. 15
10.1.
Cable preparation for Power Profile Contact .............................................................................. 15
10.2.
Cable preparation for Signal Contact .......................................................................................... 18
Copyright FCI
Form E-3334
Rev F
TYPE
APPLICATION SPECIFICATION
TABLE OF CONTENTS
Form E-3334
Rev F
PAGE
REVISION
1 of 30
AUTHORIZED BY
DATE
Stalin Alosius
2019-09-12
CLASSIFICATION
UNRESTRICTED
PDS: Rev :D
STATUS:Released
D
Page no.
Printed: Sep 18, 2019
Advertisement
Table of Contents
Summary of Contents for FCI OCTIS 10135748-101LF
-
Page 1: Table Of Contents
8.2.3 Acceptable Metallic Contact ......................13 APPLICATION TOOLING ........................14 APPLICATION PROCEDURES ......................15 10.1. Cable preparation for Power Profile Contact ................15 10.2. Cable preparation for Signal Contact ..................18 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released... - Page 2 10.4.1 Assembling Hybrid-Signal & Power(Combo)Connector ............24 10.4.2 Assembling Signal Metral HDXS Connector ................29 10.4.3 Assembling Power-Profile connector(2 and 3 position power connector) ......29 10.5 OCTIS EMI cap assembly........................30 REVISION RECORD ..........................30 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F...
-
Page 3: Octis Plug Kit Assembly - User Instruction
2019-09-12 CLASSIFICATION UNRESTRICTED ASSEMBLING OF OCTIS KITS – USER INSTRUCTION 1.1. CRIMPED TYPE: Hybrid - Signal & Power (Combo) connector interface Plug Kit Part Number 10135748-101LF Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released... -
Page 4: Signal Metral Hdxs Connector Interface Crimped Type)
OCTIS PLUG KIT ASSEMBLY – HYBRID, SIGNAL & POWER AUTHORIZED BY DATE Stalin Alosius 2019-09-12 CLASSIFICATION UNRESTRICTED 1.2. CRIMPED TYPE: Signal Metral HDXS connector interface Plug kit Part Number 10135750-101LF Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released Printed: Sep 18, 2019... -
Page 5: Position Power - Pwr Profile Connector Interface Crimped Type)
AUTHORIZED BY DATE Stalin Alosius 2019-09-12 CLASSIFICATION UNRESTRICTED 1.3. CRIMPED TYPE: Power - Pwr Profile connector interface Plug Kit Part Number 10135752-101LF Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released Printed: Sep 18, 2019... -
Page 6: Position Power - Pwr Profile Connector Interface (Screw Type)
DATE Stalin Alosius 2019-09-12 CLASSIFICATION UNRESTRICTED 1.4. SCREW TYPE: 2 position Power - Pwr Profile connector interface 10143760-101NLF Plug Kit Part Number Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released Printed: Sep 18, 2019... -
Page 7: Position Power - Pwr Profile Connector Interface (Screw Type)
DATE Stalin Alosius 2019-09-12 CLASSIFICATION UNRESTRICTED 1.5. SCREW TYPE: 3 position Power - Pwr Profile connector interface 10143759-101NLF Plug Kit Part Number Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released Printed: Sep 18, 2019... -
Page 8: Objective
DRAWINGS AND APPLICABLE DOCUMENTS FCI product drawings and specifications are available by accessing the FCI website or contacting the FCI Technical Service. In the event of a conflict between this specification and the product drawing, the drawing takes precedence. -
Page 9: Maximum Insulation Diameters And Wire Sizes
7.2.2 Power Contact Wire Size Range (mm²) Insulation Diameter (mm) 1.00 2.50 2.00 3.00 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released Printed: Sep 18, 2019... -
Page 10: Crimp On Wire (Power Contact)
OCTIS PLUG KIT ASSEMBLY – HYBRID, SIGNAL & POWER AUTHORIZED BY DATE Stalin Alosius 2019-09-12 CLASSIFICATION UNRESTRICTED CRIMP ON WIRE (POWER CONTACT) 7.2.3 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released Printed: Sep 18, 2019... -
Page 11: Acceptable Wire Termination
The copper conductor shall extend at least 0.75mm beyond the IDC dimples. This requirement shall be considered to meet if the wire insulation extends at least 1.00mm beyond the IDC dimples. At a maximum the insulation may extend to surface “D” (See fig Copyright FCI Form E-3334 Form E-3334... -
Page 12: Wire Depth
Contact your FCI representative if the wire you selected cannot meet all requirements. A standard depth gage is available for the measurement of “ab” as listed below. We have observed that with some wire insulation types, the insulation gradually lifts off the wire after insertion. -
Page 13: Strain Relief
IDC dimple a maximum of 0.10 millimeters (0.004 inches) during wire insertion. 8.2.3 Acceptable Metallic Contact The removed wire shall show evidence of metallic contact with all four IDC dimples. Copyright FCI Form E-3334 Form E-3334 Rev F... -
Page 14: Application Tooling
Octis Signal Crimping Tool (Fig 9) Cable stripper General available cable stripper Figure 6: 10137182-001 Figure 7: 10135856-001 Figure 8: 10135701-001 Figure 9: 10141086-001 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released Printed: Sep 18, 2019... -
Page 15: Application Procedures
The braid should be equally distributed No Bundles Figure 10 Step 3 Cut the braid to 9mm (Fig 11) Figure 11 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released Printed: Sep 18, 2019... - Page 16 Remove the two fillers (Fig 14) When cutting away the fillers, make sure that no wires of the braid or the individual wire insulation are being damaged Figure 14 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D...
- Page 17 Black wire on top Crimp position on top, no rotation allowed Grey wire on bottom Crimp position on top, no rotation allowed Figure 16 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released Printed: Sep 18, 2019...
-
Page 18: Cable Preparation For Signal Contact
The braid should be equally distributed No Bundles Step 4 Cut the braid to 9mm (Fig 18) Figure 18 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released Printed: Sep 18, 2019... -
Page 19: Cable Idc
10.3.1 Crimping Process – Method 1 (by using 10135856-001, IDC table top pistol for Metral HDXS Octis Cable Connector) Step 1 First place the connector housing into the nest or positioning body. (Fig 22) Copyright FCI Form E-3334 Form E-3334 Rev F Rev F... - Page 20 Step 3 Fix the cable by means of a cable clamp. This will ensure a correct positioning of the cable and guarantees a correct length of the individual wires for easy cover mounting. (Fig 24) Copyright FCI Form E-3334 Form E-3334...
- Page 21 Straighten the wire by a slight pulling force and activate simultaneously the tool by pulling down the hand lever till the end position. The wire is now crimped and excess wire is cut off. (Fig 26) Copyright FCI Form E-3334 Form E-3334...
- Page 22 Repeat all different steps as described above. After crimping all the contacts, the required terminal block assembly is completed. (Fig 27) Figure 27 Copyright FCI Form E-3334 Form E-3334 Rev F...
-
Page 23: Crimping Process-Method 2
CLASSIFICATION UNRESTRICTED Crimping Process – Method 2 10.3.2 (by using 10141086-001, Octis Signal Crimping Tool) Cable preparation See 10.2 IDC termination process Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released Printed: Sep 18, 2019... -
Page 24: Octis Assembly
2. Insert the gland nut through the other end of the cable (Fig 29). Figure 29 Insert the “housing sub set kit combo power/signal” through the front end of the cable (Fig 30) Copyright FCI Form E-3334 Form E-3334 Rev F... - Page 25 Insert the holder kit combo power/signal, as shown in fig 31 Figure 31 Insert the crimped cable assembly into the cable connector housing as shown in Fig 32 Figure 32 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F...
- Page 26 (Fig 34) Figure 34 Tighten the “holder kit combo power/signal” against the cable using clamp, screw and nut. (Fig 35) Figure 35 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F...
- Page 27 (Fig 36) . Figure 36 Place the split rubber gland onto the cable .( Fig 37 & Fig 38) Figure 37 Figure 38 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F...
- Page 28 Tighten the gland nut, close the lever and close the secondary lock/button; Kit assembly is ready now.( Fig 41) (Tighten the nut using Wrench 21mm flat Torque – 2 to 2.5N) Figure 41 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D...
-
Page 29: Assembling Signal Metral Hdxs Connector
10.4.3 Assembling Power - Pwr Profile connector (2 and 3 position power connector) All the procedure is same as that of the assembly of combo connector. Only change in the cable connector Copyright FCI Form E-3334 Form E-3334 Rev F... -
Page 30: Octis Emi Cap Assembly
10.5 OCTIS EMI CAP 10.5.1 OCTIS EMI cap-Assembly 10.5.2 OCTIS EMI cap with strap-Assembly Unscrew the bottom Lock cap in bulkhead Connect the strap Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released Printed: Sep 18, 2019... -
Page 31: Revision Record
EC # DATE Pre release 2015-10-19 Modified ELX-I-27924 2017-08-22 Texts moved to close 7.2.1 ELX-I-32440 2019-01-11 Adding EMI cap user manual ELX-I-348331 2019-09-12 Copyright FCI Form E-3334 Form E-3334 Rev F Rev F PDS: Rev :D STATUS:Released Printed: Sep 18, 2019...