User Manual - Equip-Test
Contents
1. N X HOLDING FIXTURE Figure D After the contact has cooled for at least 10 seconds remove the contact and cable from the holding fixture Inspect the completed termination for correct assembly The cable shield must extend into the contact at least as far as the front edge of the rear inspection windows The center conductor must be visible through one of the forward inspection windows revised 2 06 02 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Instructions Section 5 VPC P N 610 104 114 CASS P N 1899AS270 01 RG316 VPC Tools Required For the assembly of the Mini Coaxial Contact VPC P N 610 104 114 CASS P N 1899AS270 01 the following parts are required by VPC Tools P N Description 910 121 143 Center conductor enlargement tool for female mini coax contact 910 121 119 Center conductor forming tool for mini coax contact 910 101 115 Hex crimp tool kit for mini coax contact 254108 Hex crimp tool die part of 910 101 115 254117 Hex crimp tool handle part of 910 101 115 Gages amp Weights P N Description 910 121 156 Inspection gage to verify depth setting of center conductor on female mini coax contact 910 121 131 Weight gage kit for female mini coax contact 432026000 4 0 oz weight part of kit P N 910 121 131 with tip B 432046102 432025000 0 5 oz weight part of kit P N 910 121 131 with tip A 432044102 AN CAUTION Never probe a contact without using2. Steinel Heat Gun with Reflector P N 910 121 160 or Raychem MiniGun Heater with Reflector P N 910 121 148 Mini Coax Contact Receiver Solder Sleeve P N 610 104 142 INSTRUCTIONS le 2 14 15 Strip the coaxial cable to the dimensions shown Fig A Straighten the center conductor making sure the stranded center conductor is twisted into its original lay Pretin stranded center conductor with Sn63 solder per QQ S 571 Use RMA flux per MIL F 14256 Alpha 611 or equivalent Fold the center conductor back on itself as shown Fig B Make sure the shield braid is trimmed evenly and no loose strands extend out across the exposed dielectric or cable jacket Smooth the braid ends flat against the cable jacket Slip the contact over the end of the prepared cable and carefully push the contact onto the cable until it stops Rotating the contact slightly during cable insertion will help prevent the braid from catching Inspect for proper insertion Fig C The center conductor must be visible through one of the forward inspection windows The distance from the rear of the contact outer body to the cable jacket insulation should be 015 015 Install the adapter onto the holding fixture Fig D Insert a contact in the adapter side marked S for socket and set up the dimensions as shown in Figure D Insert the contact cable assembly into the adapter Clamp the cable in the holding fixture The cable must rem
3. Receiver Hi Density Contact Removal Remove the two cap securing screws using a Phillips screwdriver the Module does not have to be removed from the system Re move the cap Place the Signal Contact Extraction Tool VPC P N 910 110 102 over the Contact to be removed replaced until the Tool touches the face of the Module releasing the locking tab Press on Tool The spring action in the Tool will extract the Contact Replace the Contact if needed cap and screws CAUTION rotate tool slightly prior to pushing out contact to ensure that the retaining ring s ears have collapsed When replacing the upper portion of the two piece Module torque both screws 3 to 4 inch pounds using a Phillips screwdriver Torque above 4 inch pounds can cause serious damage to Module lower portion In order to maintain contact float wires should be restrained a minimum of 2 inches from the back face of the Module by using a strain relief plate ID Hi Density Contact Removal Place the Signal ID Extraction Tool VPC P N 910 110 102 over the Contact to be removed replaced until the Tool touches the face of the Module releasing the locking tab Press on Tool The spring action in the Tool will extract the Contact On the rear side of the Module grasp the Contact with your fingers and hold it while removing the Extraction Tool This will avoid pulling the Contact back into a locked position CAUTION rotate tool slightly prior to pushing out contact to e
4. To enlarge the shield conductor gently insert the enlarging tool into the contact Be careful not to bend the contact center conductor Once inserted into the contact pivot the enlarging tool to increase the shield diameter Repeat until 3 ounce weight gage can be held by contact 13 Check maximum extraction force of 20 ounces with P N 414853000 Fig O Slide contact into tip of weight gage Insert approximately 15 into tip be careful not to insert chamfer of contact into tip of weight gage Fig P The weight gage should fall off the contact as the contact is slowly lifted and suspended in the air If weight gage falls off move to step 14 If weight gage remains mated with contact the extraction force is too high and the shield conductor needs to be closed with the outer shield conductor forming tool P N 910 121 126 Fig Q Squeezing the tool handles will reposition the contact legs This FR procedure should be done in three different locations approximately 120 apart on the same shield to obtain proper Fe sizing Repeat steps 12 and 13 y Lames o Y g o Fig Q ae 2 52 Oe f I v f CHAMF ER 414852000 3 OZ Fig M MF EI E o Fig P con t page 34 revised 11 21 01 Virginia Panel Corporation 33 CASS USER S MANUAL Ver 2 7 Wiring Assembly Instructions Section 5 P N 610 103 130 CASS P N 1899AS284 02 RG178 P N 610 103 157 CASS P N 1899
5. and 20 l fs E VOJ po AS 7 Fig G Fig H 8 Check 01 01 02 dimension Fig H by using P N 910 121 157 Fig G Insert contact into gage until contact stops If pointer is between the two markers 90 amp 20 go to step 9 If the pointer is out of the range of the two markers check dimensions and or repeat steps 1 7 9 Slide crimp ring into position over the braid Fig 10 Crimp using the Hex Crimp Tool 910 101 115 Fig J in Hex Position A for the larger end first and in Hex position B for the smaller section of the crimp ring for 1899AS284 01 Fig I To ensure CRIME A POSITION proper crimp position slide shield RING conductor over pin on locator Fig K AE S Wire must not be allowed to pull on see STE ne the center conductor during crimping B POSITION for example long wire hanging down to floor Fig Fig K con t page 28 revised 11 21 01 Virginia Panel Corporation 27 CASS USER S MANUAL Ver 2 7 Wiring Assembly Instructions Section 5 P N 610 103 115 CASS P N 1899AS284 01 RG316 P N 610 103 159 CASS P N 1899AS284 04 RG316 11 Check minimum extraction force of 3 ounces with P N 414852000 Fig L Slide contact into tip of weight gage Insert approximately 15 into tip be careful not to insert chamfer of contact m into tip of weight gage Fig M The weight gage should v I remain mated with t
6. mating with the keying tab on the top of the Receiver 4 Due to additional equipment being added onto the ID the user may find that the ID and Receiver will not line up as described above One reason may be that the additional weight on the ID will cause it to pull away from the Receiver at the top The user should apply pressure to the top of the ID to counter the weight that is pulling the top of the ID away from the Receiver with the Receiver handle in the open position The user may then carefully engage the system by raising the handle until the handle makes contact with the Receiver The handle may now be allowed to slide down to it s storage position In the event of complications such as improper alignment of modules or the ID a trained technician should be notified immediately to avoid any damage to the system This should also apply to any difficulties that may be experienced during engagement NOTE The ID and Receiver have been cycled 36 000 times with a 25 Ib weight attached to the ID extended 6 inches from center of ID without having any of the contacts breaking continuity or having any parts of the system fail or show significant signs of wear This life cycle test data may change if the weight of the ID is increased revised 11 21 01 Virginia Panel Corporation 5 CASS USER S MANUAL Ver 2 7 General Maintenance Section 4 Care amp Maintenance of Interface Device ID AN CAUTION e Serious
7. 2 7 CASS USER S MANUAL Product Cross Reference Section 7 The purpose of the cross reference tables are to provide the user with quick identification of necessary parts and or tools It matches the tools with their respective parts for more comprehensive replacements insertions or configurations Receiver Modules Crimp Tools amp Dies see E Q C Tools Receiver Contacts 8 Patchcords 510 113 124 1899AS275 02 510 113 125 1899AS273 02 510 113 120 1899AS266 02 510 113 121 1899AS269 02 510 113 122 1899AS271 02 910 101 102 910 101 103 910 101 115 910 104 107 910 104 116 910 110 102 910 112 104 910 121 119 910 121 143 2038AS393 910 121 156 910 121 131 610 104 114 1899AS270 01 610 104 141 1899AS270 02 610 110 122 1899AS276 01 610 110 123 1899AS276 02 610 110 124 1899AS276 03 610 110 125 1899AS274 01 610 110 174 1899AS268 01 610 116 112 1899AS267 01 Virginia Panel Corporation 37 CASS USER S MANUAL Product Cross Reference Section 7 Ver 2 7 ID Contacts amp Patchcords 610 103 115 1899AS284 01 o co A O lt o o co lt o E o LO ID Mo o o co N O lt o o co MR o o LO dules o co co A O lt o co lt co o E o LO o LO co A YN L o o co o o E o LO Crimp Tools a
8. If weight gage remains mated za 1 move to step 9 O If weight gage falls off the extracrtion force is too low and the center conductor needs to be closed with the PESE center conductor forming tool P N 910 121 119 Fig J Recheck 1 2 ounce retention force Fig H con t page 18 revised 11 21 01 Virginia Panel Corporation 17 CASS USER S MANUAL Ver 2 7 Wiring Assembly Instructions Section 5 VPC P N 610 104 114 CASS P N 1899AS270 01 RG316 9 Check maximum extraction force of 4 ounces with 432026000 Slide female center conductor over approximately 3 4 of the length of the tip in the weight gage Fig K The weight gage should fall off the contact as the contact is slowly lifted and suspended in the air If weight gage falls off move to step 10 If weight gage remains mated with contact the extraction force is too high and the center conductor needs to be opened with the center conductor enlarging tool P N 910 121 143 Fig L tool Insert and remove tool inline with contact to advoid breaking tip of tool or contact Use Caution when using this Fig L To enlarge the center conductor remove it from shield assembly and gently insert the Enlarging Tool into the Center Conductor Insert Enlarging Tool until Center Conductor stops on shoulder Be careful not to break or fracture Center Conductor Recheck 0 5 and 4 ounce retentio
9. Replacement reference guide Section 2 Installation Removal of Modules and Contacts 3 Describes the step by step required instructions on the removal and installation of the Modules and Contacts Section 3 Engaging Interface Device With Receiver 5 Discusses the proper operation engagement of the CASS Receiver and ID Cover all necessary precautions prior to engagement Section 4 General Maintenance 6 Removal and Installation of Micro Switch Section 5 Contact Assembly Requirements 7 This Section is about the required tools and parts needed to operate the Interface System at an optimum level of performance by following step by step wiring instructions Section 6 Trouble Shooting and Solutions 35 Possible trouble areas and the simple required necessary actions Section 7 Product Cross Reference Tables 37 Provides the user with quick access to tools needed for removal and installation of contacts crimping and associated equipment Section 8 Diagrams 40 Diagrams of the Receiver ID and Modules dimensions and part numbers are specified to be used in identifying and inspecting parts of the System ii VMCASSUS Ver 2 7 CASS USER S MANUAL CASS Interface System Parts Section 1 Receiver VPC P N ASS P N Description 310 115 101 1899AS265 01 CASS Receiver Interface accepts 19 Modules Interface Device VPC PIN CASS PIN Descripti 410 113 101 1899AS279 01 CASS ID Frame accepts 19 Modules Receiver Modul
10. Section 5 VPC P N 610 104 141 CASS P N 1899AS270 02 RG178 10 Check maximum extraction force of 4 ounces with tip B 432046102 in 432025000 attached to 432026000 Slide female center conductor over approximately 3 4 of the length of the tip in the weight gage Fig K The weight gage should fall off the contact as the contact is slowly lifted and suspended in the air If weight gage falls off move to gt step 11 If weight gage remains mated with contact the extraction force is too high and the center conductor needs to be opened with the center conductor enlarging tool P N 910 121 143 Fig L Use caution when using this tool Insert and remove tool in line with contact to avoid breaking tip of tool or contact Fig L To enlarge the center conductor remove it from shield assembly and gently insert the Enlarging Tool into the Center Conductor Insert DA Enlarging Tool until Center Conductor stops on shoulder Be careful not to break or fracture Center Conductor Recheck 0 5 and 4 ounce retention force go to step 9 11 Turn braid back toward the front of the shield conductor Fig M NN SHOULDER 432026000 4 00 OZ I STAH Fig K Fig M 12 If braid extends beyond shoulder trim braid back to face of shoulder 13 Slide crimp ring into position over the braid 14 Crimp using the Hex Crimp Tool P N 910 101 115 Fig N in Hex Position A for the larger end fir
11. See enclosed diagrams Contact Virginia Panel Corporation user adjustments to System unless authorized will void the warranty Check for foreign objects tools _ Verify the orientation of the Receiver and ID Modules See Section 2 Inspect the mating of Modules Power ID Module to mate with Power Receiver Module etc See Section 2 Forceful engagement of the Receiver and the ID may result in serious damage to multiple parts of the system Modules Receiver ID and Contacts Excessive force on the Handle is needed to engage system This may indicate that the ID was dropped and is out of alignment or that a Module is not mating with its intended Module Remove and inspect the ID for alignment See enclosed diagrams Contact Virginia Panel Corporation user adjustments to System unless authorized will void the warranty Check for foreign objects tools A damaged Contact s may provide enough resistance to notice Upon replacing a Contact in the ID the mating Contact on the other side Receiver Contact should also be inspected and replaced if necessary See Section 2 Verify the orientation of the Receiver and ID Modules See Section 2 Inspect the mating of Modules Power ID Module to mate with Power Receiver Module etc See Section 2 Forceful engagement of the Receiver and the ID may result in serious damage to multiple parts of the system Modules Receiver ID and Contacts Virginia Pane
12. position the contact in the heating tool reflector with the forward O inspection window centered in the reflector Continue heating until the small solder preform Leal in the forward inspection window has melted and flowed The large solder preform in the rear inspection window should have melted and flowed by this time if it has not direct hot air at the N HOLDING roeure rear inspection window until it does 12 If contact is UNDERHEATED there will be visible remnants of the original shapes of the Figure C solder preforms An underheated contact must be reheated If contact is OVERHEATED solder will wick away from the joint areas leaving no solder fillets An overheated contact must be removed and a new contact installed 13 After the contact has cooled for at least 10 seconds remove the contact and cable from the holding fixture 14 Inspect the completed termination for correct assembly The cable shield must extend into the contact at least as far as the front edge of the rear inspection windows The center conductor must be visible through one of the forward inspection windows revised 2 06 02 Virginia Panel Corporation 13 CASS USER S MANUAL Ver 2 7 Wiring Assembly Instructions Section 5 VPC P N 610 104 142 CASS P N 2038AS397 01 RG178 PARTS REQUIRED Solder Kit for Mini Coax includes holding fixture and adapter P N 910 121 144 Adapter for those who already own a holding fixture P N 910 121 149
13. 121 144 Adapter for those who already own a holding fixture P N 910 121 149 Steinel Heat Gun with Reflector P N 910 121 160 or Raychem MiniGun Heater with Reflector P N 910 121 148 Mini Coax Contact ID Solder Sleeve P N 610 103 140 or 610 103 158 INSTRUCTIONS 1 Strip the coaxial cable to the dimensions shown Fig A 150 015 290 015 2 Straighten the center conductor making sure the stranded center conductor is twisted into its original lay HZ gt 215 015 i 3 Pretin stranded center conductor with Sn63 solder per QQ S 571 Use RMA flux per MIL F 14256 Alpha 611 or equivalent BRAID FOLDED 4 Fold the center conductor back on itself as shown Fig B Figure A 5 Make sure the shield braid is trimmed evenly and no loose strands are extending out across the exposed dielectric or cable jacket 029 MAX 6 Smooth the braid ends flat against the cable jacket 7 Slip the contact over the end of the prepared cable and carefully push the CRUE I contact onto the cable until it stops Rotating the contact slightly during cable Figure B insertion will help prevent the braid from catching 8 Inspect for proper insertion Fig C The center conductor must be visible 0157915 through one ofthe forward inspection windows The distance from the rear of the contact outer body to the cable jacket insulation should be 015 015 9 Install the adapt
14. Kit for Solder Sleeve Mini Coax Contact 910 121 147 i Super Heater Gun with Reflector for Solder Sleeve Mini Coax Contact 910 121 148 Mini Heater Gun with Reflector for Solder Sleeve Mini Coax Contact 910 121 149 i Holding Fixture Adapter for Solder Sleeve Mini Coax Contact Indicates that no CASS P N has been assigned to this part 2 VMCASSUS Ver 2 7 CASS USER S MANUAL Installation Removal Section 2 Receiver Module Installation Removal Place the Module in the Receiver until the upper and lower module screws touch the mating holes in the inner frame of the Receiver Using a 3 16 socket wrench tighten the top screw while pushing lightly against the face of the module Tighten the bottom screw Torque the screw until it is 3 to 4 inch pounds clamping load 175 to 200 pounds To remove loosen the bottom screw completely Then loosen top screw to remove module assembly Caution Improper installation removal could result in the failure of the Jackscrew ID Module Installation Removal Install the Module in the ID until the upper and lower module screws touch the mating holes in the inner frame of the ID Using a 7 64 hex wrench tighten the top screw while pushing lightly agianst the face of the module Tighten the bottom screw Torque the screw until it is 3 to 4 inch pounds clamping load 175 to 200 pounds To remove loosen the bottom screw completely Then loosen top screw to remove module assembly
15. O oo SN o O O OF oo oo oo oo O OF poles oo RJ o OL zma zel en Ny Es Qu S Ko P N 510 114 109 1899AS285 01 P N 510 114 106 1899AS286 01 P N 510 114 107 1899AS280 01 Let 79D gt 200 790 2S i Hl O 000000000C 0000000000 J000 10 000 P N 510 114 108 1899AS283 01 P N 510 113 106 1899AS288 01 Virginia Panel Corporation 43
16. a mating contact patchcord as a probe to avoid damaging the contact s being tested revised 11 21 01 Virginia Panel Corporation 15 CASS USER S MANUAL Ver 2 7 WiringAssembly Instructions Section 5 VPC P N 610 104 114 CASS P N 1899AS270 01 RG316 1 Strip the outer insulation cut braid and expose the conductor wire as shown Fig A EDEELECTALS BRAID 7 __ CONDUCTOR 5 get Za ON TRE OUTER ve 33 25 a E RNA INSULATION 5 a Ve Fig A ji 2 Slide the crimp ring onto the wire Fig B CRIMP RING N Fig B gt 3 Turn braid back over outer insulation Fig C AE Fig C 4 Solder wire into center conductor and clean Fig D Cut a 3 16 long piece of solder and place it into the center conductor Apply heat using a soldering iron on the outside of the contact until the solder melts Insert wire into contact while heat is still being applied until an acceptable solder joint is obtained Note Center conductor and dielectric must touch zob PL AGUA reat Z ANE s l Mo LA ee Ag Fig D 5 Slide shield conductor over center conductor until the center conductor stops in the Teflon shield Fig E Note Shield Conductor and Teflon insulator are supplied as an assembly GAP TO ENSURE THA El ULL SMALI COAX CAB HAS BEEN JLLY Ao SHIELD CONDUCTOR 7 SHIELD CONDUC es 5 Rail SES CENTER CONDUCTOR Fig
17. damage can be caused due to mishandling or dropping the ID or any system parts The CASS Interface System has been designed to be maintenance free yet care does need to be taken when handling the ID Micro Switch Removal amp Installation CAUTION e Disconnect all electrical supplies to the system prior to any servicing The CASS Interface System has been designed to be maintenance free The only maintenance that is needed for the system to continue functioning effortlessly is the Micro switch For replacement of the Microswitch the following steps need to be followed 1 Disengage the ID from the Receiver remove the ID completely 2 With the Receiver Handle still in the open position Handle down unscrew the two plate retaining screws using a Phillips screwdriver that are located immediately above the top right engaging mechanism slot this will expose the Microswitch 3 Remove the necessary Modules so that the Microswitch retaining screws may be accessed 4 Unscrew the retaining screws using a Phillips screwdriver removing each as they are loosened caution should be used so that the screw s don t fall into the system 5 Carefully remove the Microswitch for continuity testing For Microswitch installation repeat steps 1 5 in reverse order Microswitch is P N 010025 revised 11 21 01 6 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Requirements Section 5 Virginia Panel Corporati
18. wire Fig B NOTE Always drop female contact without wire attached into contact locator allowing it to orient seat itself properly squeeze handles of crimp tool slightly to hold contact in position while inserting wire Note that tool cannot be opened without completing cycle Never attempt to disassemble tool Never tighten or loosen stop nuts on back of tool 10 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Instructions Section 5 VPC P N 610 103 140 CASS P N 2038AS396 01 P N 610 103 158 CASS P N 2038AS396 02 RG316 PARTS REQUIRED Solder Kit for Mini Coax includes holding fixture and adapter P N 910 121 144 Adapter for those who already own a holding fixture P N 910 121 149 Steinel Heat Gun with Reflector P N 910 121 160 or Raychem MiniGun Heater with Reflector P N 910 121 148 Mini Coax Contact ID Solder Sleeve P N 610 103 140 or 610 103 158 INSTRUCTIONS 1 Prepare the coaxial cable to the dimensions shown Fig A 2 Straighten the center conductor making sure the stranded center conductor is twisted into its original lay 170 015 190 015 115 015 EZZZZIT 3 Pretin stranded center conductor with Sn63 solder per QQ S 571 Use RMA flux per MIL F 14256 Alpha 611 or equivalent K 4 Make sure the shield braid is trimmed evenly and no loose strands are extending out across the exposed dielectric o
19. 178 VPC Tools Required For the assembly of the Mini Coaxial Contact VPC P N 610 104 141 CASS P N 1899AS270 02 the following parts are required by VPC Tools P N Description 910 121 143 Center conductor enlargement tool for female mini coax contact 910 121 119 Center conductor forming tool for mini coax contact 910 101 115 Hex crimp tool kit for mini coax contact 254108 Hex crimp tool die part of 910 101 115 254117 Hex crimp tool handle part of 910 101 115 Gages amp Weights P N Description 910 121 156 Inspection gage to verify depth setting of center conductor on female mini coax contact 910 121 131 Weight gage kit for female mini coax contact 432026000 4 0 oz weight part of kit P N 910 121 131 with tip B 432046102 432025000 0 5 oz weight part of kit P N 910 121 131 with tip A 432044102 A CAUTION Never probe a contact without using a mating contact patchcord as a probe to avoid damaging the contact s being tested revised 11 21 01 20 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Instructions Section 5 VPC P N 610 104 141 CASS P N 1899AS270 02 RG178 1 Strip the outer insulation cut braid and expose the conductor wire as shown Fig A y DIELECTRIC BRAID __ CONDUCTOR OUTER __ Je Sofas ze 177 14 INSULATION a dele ae Fig A 2 Slide the crimp ring onto the wire Fig B CI gt RING N N S IIA Fig B 3 T
20. AS284 03 RG178 14 Use P N 910 121 157 to check 010 010 020 dimension See step 9 15 During installation of contact into module listen for retaining clip ears to spring out then push on front of contact to ensure that it is locked into position 34 VMCASSUS Ver 2 7 CASS USER S MANUAL Trouble Shooting and Solutions Section 6 ID or Receiver Modules are Installed up side down The orientation of the Modules is critical Those Modules that are improperly installed will need to be removed and oriented properly See Section 2 Forceful engagement of the Receiver and the ID may result in serious damage to multiple parts of the system Modules Receiver ID and Contacts ID Engagement Bearings Studs are not lining up with the Engagement Slots of the Receiver Check the alignment of the ID Frame There is a possibility that the ID Frame will have misaligned itself if it is dropped See enclosed diagrams Contact Virginia Panel Corporation user adjustments to System unless authorized will void the warranty Forceful engagement of the Receiver and the ID may result in serious damage to multiple parts of the system Modules Receiver ID and Contacts ID Frame is not lined up while in the process of engagement with the Receiver This may indicate that the ID was dropped and is out of alignment or that a Module is not mating with its intended Module Remove and inspect the ID for alignment
21. Accessories VPC PIN CASS PIN Descripti 910 101 102 E MS31 Microcrimp Tool for Hi Density Power Contact ID amp Receiver 910 101 103 i Microcrimp Tool for Hi Density Signal Contact ID amp Receiver 910 101 115 Hex Crimp Tool for Mini Coax Contact 910 104 107 i Locating Die for Hi Density Signal Contact ID amp Receiver 910 104 116 Locating Die for Hi Density Receiver Power Contact 910 104 118 Locating Die for Hi Density ID Power Contact Insertion amp Extraction Tools VPC P N ASS P N Description 910 110 102 Extraction Tool for Signal Contact ID amp Receiver 910 112 104 Extraction Tool for Mini Coax and Power Contacts ID amp Receiver Quality Control Tools amp Accessories VPC PIN CASS PIN Descripti 910 121 119 Center Conductor Forming Tool for female Mini Coax Contact 910 121 126 Outer Shield Conductor Forming Tool for Male Mini Coax Contact 910 121 131 Weight Gage Kit for female Mini Coax Contact 910 121 142 Outer Shield Conductor Expanding Tool for Male Mini Coax Contact 910 121 143 2038AS393 Center Conductor Enlargement Tool for Female Mini Coax Contact 910 121 155 Weight Gage Kit for male Mini Coax Contact 910 121 156 Inspection Gage Kit to verify depth setting for center conductor on female Mini Coax Contact 910 121 157 Inspection Gage to verify depth setting of conductor on male Mini Coax Contact Soldering Tools amp Accessories VPC P N ASS P N Description 910 121 144 Solder
22. E con tpage 17 revised 01 04 04 16 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Instructions Section 5 VPC P N 610 104 114 CASS P N 1899AS270 01 RG316 6 Calibrate gage P N 910 121 156 Fig F by loosening the dial face retaining screw until the dial face allows itself to be turned Insert the calibration plug P N 414 854 104 into base of gage While keeping constant pressure on the plug adjust the dial by rotating it such that the pointer points to 0 Re tighten retaining screw Adjust locating markers to 80 and 40 7 Check 06 02 dimensions Fig G with P N 910 121 156 Fig F Push the contact onto the pressure plunger of the gage Fig F After attaining positive stop and while holding firm pressure push plunger on top of dial to push collar over Teflon read the dial on the gage Go to step 8 if the indicator is between the two marker bands 80 amp 40 Repeat steps 1 6 ami should the range of dimensions not meet the criterion PRES 8 Check minimum extraction force of 1 2 ounce with 432025000 Assembly Fig H Slide female center conductor over approximately 3 4 of the length of the tip in the weight gage Fig Le g6 92 Fig F a SS Ss LLLEE IIL LLY Z III SILE Fig G The weight gage should remain mated with the center conductor as the center conductor is slowly lifted and suspended zi in the air
23. HM for RG178 1899AS284 02 Mini Coaxial ID Terminal 50 OHM for RG178 1899AS284 03 Mini Coaxial ID Terminal 50 OHM for RG316 1899AS284 04 Virginia Panel Corporation 7 CASS USER S MANUAL Ver 2 7 Wiring Assembly Instructions Section 5 P N 610 110 108 610 110 125 610 110 146 CASS P N 1899AS287 01 1899AS274 01 1899AS287 02 Set up crimp tool P N 910 101 103 Fig A by loosening the latch locking screw counter clockwise until turning stops Remove any previously used crimp contact locator Insert the open end of crimp contact locator P N 910 104 107 into crimp tool contact locator retainer Slide the retaining latch toward contact locator until contact locator is securely locked into place cios The contact locator may have to be twisted to A TNDICATOR A allow latch to retain contact locator Tighten latch locking screw Y Using the table below adjust the crimp tool setting by pulling adjusting knob and turning it at the same time clockwise increases counter clockwise decreases setting until the desired setting is achieved on the microcrimp indicator Recommended maximum wire gauge is 22 AWG however 18 AWG and 20 AWG will work when crimped properly Itis preferred that wire 26 AWG or smaller be soldered Using the table above determine the strip length according to wire gauge Strip wire Fully insert stripped wire into contact P N 610 110 146 1899AS287 02 or
24. NE TR ANEP a o D o o o D o o o o D o D D D L 18 EOL SPCS J a 800 Los TYP 10 730 J 500 s sos s 5 o s s so s 3 ee DIA 1 TYP MOUNT ING_HOLES 164 32UNC 2B X 5 DP 188 15 594 W SELF LOCK ING THREADED INSERTS 175 TYP 12 PLACES gt 2 000 a ea 1 3 Bog a 3 3 3 y k ik M1 wow woe 2 000 o o J 4 615 TYP 2 PLCS 6 000 10 380 et 585 9o 08 Y a o o o 5 o o o o o o a 750 6 985 TYP 000 13 970 TYP TYP P N 410 113 101 1899AS279 01 Virginia Panel Corporation CASS USER S MANUAL Ver 2 7 Diagrams Section 8 CASS Receiver Modules 4 do E i L Loy 4 me t j PIN 510 113 124 1899AS275 02 _ o P N 510 113 125 1899AS273 02 P N 510 113 122 1899AS271 02 P N 510 113 121 1899AS269 02 A mu P N 510 113 120 1899AS266 02 42 VMCASSUS Ver 2 7 CASS USER S MANUAL Diagrams Section 8 CASS ID Modules 200 730 Pe pee 790 3 A a A ka ii T ENT RE alc 4 Bo ia E ort E N o Ol oo o Ok O Ol oo oo oo O Ok o O OO 10 000 oo oo sa O On JOO O Ol OO 8 525 oo oo O OF oo Peer O
25. P N 610 110 108 1899AS287 01 Fig B P N 610 110 125 1899AS274 01 Fig C With the crimp tool in the open position insert the prepared contact and wire through the indenter opening While keeping the wire fully inserted into the contact squeeze the handles of the crimp tool until a positive stop is reached Tool will release and return into fully open position Remove crimped contact and wire CIN LI gt Fig B P N 610 110 108 1899AS287 01 610 110 146 1899AS287 02 OS Sy TN lan y A am k aj O y Nx LL pls aci RA Fig C P N 610 110 125 1899AS274 01 EA NOTE Always drop female contact without wire attached into contact locator allowing it to orient seat itself properly squeeze handles of crimp tool slightly to hold contact in position while inserting wire Note that tool cannot be opened without completing cycle Never attempt to disassemble tool Never tighten or loosen stop nuts on back of tool rev 11 06 2003 8 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Instructions Section 5 P N 610 110 172 amp 610 110 173 CASS P N 1899AS282 01 amp 1899AS282 02 Set up crimp tool P N 910 101 102 Fig A by loosening the latch locking screw counter clockwise until turning stops Remove any previously used crimp contact locator Insert the open end of crimp contact locator P N 910 104 118 into crimp tool contact locator retainer Slide the retaining latch tow
26. Virginia Panel Corporation s CASS User s Manual Installations Operations and General User Guide Official Edition 2 7 Updated February 1998 Updated November 21 2001 Updated February 6 2002 Updated January 5 2004 Updated May 18 2007 Ver 2 7 CASS USER S MANUAL OBJECTIVE The following is a Consolidated Automated Support System CASS Interface System User s Manual It has been written to educate CASS users of the required set up operations and trouble shooting procedures of the Interface System The objective of the User s Manual is to aid the user in the everyday operations of the Interface System s The Contents of this Manual are based on the field and Life Cycle Test observations BACKGROUND Virginia Panel Corporation VPC has long been recognized for the design and manufacture of Modular Interface Systems Since developing the industry s first hybrid Modular Interface System in 1968 VPC has been dedicated to providing its customers with the most effective economical and dependable methods of interconnecting test devices VPC s introduction of the CASS is the next stepping stone for an interface providing high pin density small footprint multiple termination methods and high quality at an economical price Virginia Panel Corporation i CASS USER S MANUAL Ver 2 7 TABLE OF CONTENTS Section 1 CASS Interface System Parts 1 To be used in the identification of part s or part number s
27. act 910 121 155 Weight gage kit for male mini coax contact 414853000 20 oz weight part of kit P N 910 121 155 414852000 3 oz weight part of kit P N 910 121 155 AX CAUTION Never probe a contact without using a mating contact patchcord as a probe to avoid damaging the contact s being tested revised 11 21 01 30 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Instructions Section 5 P N 610 103 130 CASS P N 1899AS284 02 RG178 P N 610 103 157 CASS P N 1899AS284 03 RG178 1 Strip the outer insulation cut braid and expose the conductor wire as shown Fig A BRAID DIELECTRIC Fig A CONDUCTOR y WIRE Y _ Z OUTER zo 50 gt La 174 14 INSULATION ki 534 02 2 Slide the crimp ring onto the wire Fig B os sae Fig B 3 Turn braid back over outer insulation Fig C 4 Solder wire into center conductor and clean Fig C Note Center conductor and dielectric must touch Fig C NO GAP PERMISSABLE HEAT K CENTER pi CONDUCTOR SOLDER 5 Slide the spacer tube over dielectric to edge of the braid Fig D Heat spacer tube with a heat gun until it has shrunk to hold on to dielectric AS ela eee SEE NO GAP PERMISSABLE Fig D EN 4 CONDUCTO SOLDER JU 6 Slide shield conductor over center conductor until the center conductor stops in the Teflon shield To en
28. ain fully inserted in the contact and the contact must be fully inserted in the adapter for the adapter to act as a heat sink The cable must be straight between the contact and the cable clamp Attach the appropriate reflector to the heating tool See separate Heat Gun instruction sheet included with tool for tool operation and safety precautions Using the holding fixture position the contact in the heating tool reflector with the forward inspection window centered in the reflector Continue heating until the small solder preform in the forward inspection window has melted and flowed The large solder preform in the rear inspection window should have melted and flowed by this time if it has not direct hot air at the rear inspection window until it does If contact is UNDERHEATED there will be visible remnants of the original shapes of the solder preforms An underheated contact must be reheated If contact is OVERHEATED solder will wick away from the joint areas leaving no solder fillets An overheated contact must be removed and a new contact installed 150 015 T 290 015 REIZ R mmg 215 015 BRAID FOLDED BACK a Figure A 029 MAX ae Jf 115 015 Figure B 015 015 FORWARD CENTER CONDUCTOR INSPECTION WINDOW Figure C 0 5 0 7 INCH ADAPTER CONTACT PT gt 5 p o FORWARD INSPECTION WINDOW SIDE MARKED S y 7
29. ard contact locator until contact locator is securely locked into place The contact locator may have to be twisted to allow latch to retain contact locator Tighten latch locking screw Using the table below adjust the crimp tool setting by pulling adjusting knob and turning it at the same time clockwise increases counter clockwise decreases setting until the desired setting is achieved on the microcrimp indicator Wire Gauge Strip Length 05 0 0 Crimp Max MICROCRIMP ADJUSTING KNOB M CROCRIMP I NDICATOR EN LATCH ASSEMBLY LOCKING SCREW CONTACT LOCATOR DIE o Fig A Crimp Min NPENTER PENING Pullout Force Ib Using the table above determine the strip length according to wire gauge Strip wire Fully insert stripped wire into contact P N 610 110 172 1899AS282 01 or P N 610 110 173 1899AS282 02 Fig B With the crimp tool in the open position insert the prepared contact and wire through the indenter opening While keeping the wire fully inserted into the contact squeeze the handles of the crimp tool until a positive stop is reached Tool will release and return into fully open position Remove crimped contact and wire NOTE Observe precision ratchet action by opening and closing tool fully several times Note that tool cannot be opened without completing cycle Never attempt to disassemble tool Never tighten or loosen stop nuts on back of tool Virginia Pan
30. d The user can extend the Receiver s handle by pushing the slotted handle part up until it extends above the Receiver The handle may now allow itself to be rotated to the lowered position allowing the ID to be inserted 2 Prior to engaging an ID with the Receiver for the first time the user must check to see if all the Modules ID and Receiver have been installed properly This would involve the inspection of the Module ends ensuring the even height of all Module ends relative to one another While checking this the user should verify the positioning of the modules themselves It is crucial for all modules to be installed properly Improper installation will cause damage to the modules and possibly to the ID and or Receiver All ID Modules have to match the Receiver Modules This means that upon engaging an ID Module will mate with its respective Receiver Module Power ID to mate with Power Receiver etc 3 The ID upon being inspected is now ready for engagement with the Receiver The Receiver should be checked one last time for any foreign objects that may hinder the engagement The top rollers of the ID may then be placed onto the Receiver s built in hangers with the handle in the closed and handle not extended position The ID may be engaged with the Receiver only if properly lined up meaning that the ID must be placed onto the Receiver in the upright position Care should be taken to have the top side notch of the ID align for
31. d safety precau NO tions HOLDING FIXTURE 11 Using the holding fixture position the contact in the heating tool reflector with the ew forward inspection window centered in the reflector Continue heating until the small Mate solder preform in the forward inspection window has melted and flowed The large solder preform in the rear inspection window should have melted and flowed by this time if it has not direct hot air at the rear inspection window until it does 12 If contact is UNDERHEATED there will be visible remnants of the original shapes of the solder preforms An underheated contact must be reheated If contact is OVERHEATED solder will wick away from the joint areas leaving no solder fillets An overheated contact must be removed and a new contact installed 13 After the contact has cooled for at least 10 seconds remove the contact and cable from the holding fixture 14 Inspect the completed termination for correct assembly The cable shield must extend into the contact at least as far as the front edge of the rear nspection windows The center conductor must be visible through one of the forward inspection windows revised 2 06 02 Virginia Panel Corporation 11 CASS USER S MANUAL Ver 2 7 Wiring Assembly Instructions Section 5 VPC P N 610 103 140 CASS P N 2038AS396 01 P N 610 103 158 CASS P N 2038AS396 02 RG178 PARTS REQUIRED Solder Kit for Mini Coax includes holding fixture and adapter P N 910
32. el Corporation CASS USER S MANUAL Ver 2 7 Wiring Assembly Instructions Section 5 P N 610 110 174 CASS P N 1899AS268 01 Set up crimp tool P N 910 101 102 Fig A by loosening the latch locking screw counter clockwise until turning stops Remove any previously used crimp contact locator Insert the open end of crimp contact locator P N 910 104 116 into crimp tool contact locator retainer Slide the retaining latch toward contact locator until contact locator is securely locked into place ADJUSTING KNOB MIOROCRIMP LATCH Agoma Y The contact locator may have to be twisted to N se allow latch to retain contact locator Tighten E Ri g o latch locking screw E om O Using the table below adjust the crimp tool 2 gt DONE setting by pulling adjusting knob and turning it at the same time clockwise increases counter clockwise decreases setting until Fig A the desired setting is achieved on the microcrimp indicator Using the table above determine the strip length according to wire gauge Strip wire Fully insert stripped wire into contact P N 610 110 174 1899AS268 01 Fig B With the crimp tool in the open position insert the prepared contact and wire through the indenter opening While keeping the wire fully inserted into the contact squeeze the handles of the crimp tool until a positive stop is reached Tool will release and return into fully open position Remove crimped contact and
33. er onto the holding fixture Fig D Insert a contact in the adapter side marked P for Pin and set up the dimensions as shown in Figure D INSPECTION CENTER CONDUCTOR WINDOW 10 Insert the contact cable assembly into the adapter Clamp the cable in the holding Figure C fixture The cable must remain fully inserted in the contact and the contact must be fully inserted in the adapter for the adapter to act as a heat sink The cable must be straight between the contact and the cable clamp G02 O7INCH T CONTACT 11 Attach the appropriate reflector to the heating tool see separate Heat Gun instruction sheet included with tool for tool operation and safety precau ka e tions umu ons FORWARD INSPECTION II WINDOW SIDE 12 Using the holding fixture position the contact in the heating tool reflector with the OS forward inspection window centered in the reflector Continue heating until the small solder preform in the forward inspection window has melted and flowed The large solder preform in the rear inspection window should have melted and flowed FT O by this time ifithas not direct hot air atthe rear inspection window until it does ra ADAPTER 13 If contact is UNDERHEATED there will be visible remnants of the original shapes of the solder preforms An underheated contact must be reheated If contact is NO OVERHEATED
34. es VPC P N ASS P N Description 510 113 120 1899AS266 02 Power Module RCVR 76 Positions for Discrete Wiring 40 20 AMP and 36 10 AMP Hi Density for 14 AWG 510 113 121 1899AS269 02 Coaxial Module RCVR 64 Positions for Discrete Wiring or for side PCB Mount 510 113 122 1899AS271 02 Coaxial Module RCVR 64 Positions for Center PCB Mount 510 113 124 1899AS275 02 Signal Module RCVR with 210 Contacts for Right Angle PCB Mounting 510 113 125 1899AS273 02 Signal Module RCVR 210 Positions for Discrete Wiring ID Modules VPC P N CASS P N Description S 510 114 106 1899AS286 01 Signal Module ID 210 Positions for Discrete Wiring 510 114 107 1899AS280 01 Power Module ID 76 Positions for Discrete Wiring 40 20 AMP and 36 10 AMP Hi Density for 14 AWG 510 114 108 1899AS283 01 Coaxial Module ID 64 Positions for Discrete Wiring 510 114 109 1899AS285 01 Coaxial Module ID 64 Positions for Center PCB Mounting Blank Modules VPC P N ASS P N Description 510 113 106 1899AS288 01 Blank Module for ID and Receiver Receiver Contacts VPC P N CASSP IN Description O do Oooo 610 104 114 1899AS270 01 Mini Coaxial Contact RCVR 50 OHM for RG316 610 104 141 1899AS270 02 Mini Coaxial Contact RCVR 50 OHM for RG178 610 104 142 2038AS397 01 Mini Coaxial Contact RCVR 50 OHM Solder Sleeve for RG316 or RG178 610 110 122 1899AS276 01 Hi Density Signal Contact RCVR for PCB Mounting Row 1 610 110 123 1899AS276 02 Hi De
35. for mini coax contact 254108 Hex crimp tool die part of 910 101 115 254117 Hex crimp tool handle part of 910 101 115 Gages amp Weights P N Description 910 121 157 Inspection gage to verify depth setting of center conductor on male mini coax contact 910 121 155 Weight gage kit for male mini coax contact 414853000 20 oz weight part of kit P N 910 121 155 414852000 3 oz weight part of kit P N 910 121 155 A CAUTION Never probe a contact without using a mating contact patchcord as a probe to avoid damaging the contact s being tested revised 11 21 01 Virginia Panel Corporation 25 CASS USER S MANUAL Ver 2 7 Wiring Assembly Instructions Section 5 P N 610 103 115 CASS P N 1899AS284 01 RG316 P N 610 103 159 CASS P N 1899AS284 04 RG316 1 Strip the outer insulation cut braid and expose the conductor wire as shown Fig A BRAID po DIELECTRLE CONDUCTOR E E MA OUTER z 38 30 4 17 14 NSULATION l 525 0 Fig A 2 Slide the crimp ring onto the wire Fig B S pl KXXX Fig B 3 Turn braid back over outer insulation Fig C S RES m Fig C SPRA 4 Solder wire into center conductor and clean Fig D Cut a 3 16 long piece of solder and place it into the center conductor Apply heat using a soldering iron on the outside of the contact until the solder melts Insert wire into contact while heat is still being applied until a
36. he contact as the contact is slowly lt lt lt lifted and suspended in the air If weight gage remains mated move to step 12 If weight gage falls off the extraction force is too low 8 se Np PA and the shield conductor needs to be opened up with RE the outer shield conductor enlarging tool f es P N 910 121 142 Fig N 4 DIA REF Fig L z Fig N Fig M To enlarge the shield conductor gently insert the enlarging tool into the contact Be careful not to bend the contact center conductor Once inserted into the contact pivot the enlarging tool to increase the shield diameter Repeat until 3 ounce weight gage can be held by contact 12 Check maximum extraction force of 20 ounces with P N 414853000 Fig O Slide contact into tip of weight gage Insert approximately 15 into tip be careful not to insert chamfer of contact into tip of weight gage Fig P The weight gage should fall off the contact as the contact is slowly lifted and suspended in the air If weight gage falls off move to step 13 If weight gage remains mated with contact the extraction force is too high and the shield conductor needs to be closed with the outer shield conductor forming tool P N 910 121 126 Fig Q _7 CHAMFER Squeezing the tool handles will reposition the contact legs 25 02 re This procedure should be done in three different locations A approximately 120 apart on t
37. he same shield to obtain ao proper sizing Repeat steps 11 and 12 be ae el 414853 o TP REF A Fig P Fig O Fig Q con t page 29 revised 11 21 01 28 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Instructions Section 5 P N 610 103 115 CASS P N 1899AS284 01 RG316 P N 610 103 159 CASS P N 1899AS284 04 RG316 13 Use P N 910 121 157 to check 010 01 02 dimension See step 8 14 During installation of contact into module listen for retaining clip ears to spring out then push on front of contact to ensure that it is locked into position Virginia Panel Corporation 29 CASS USER S MANUAL Ver 2 7 Wiring Assembly Instructions Section 5 P N 610 103 130 CASS P N 1899AS284 02 RG178 P N 610 103 157 CASS P N 1899AS284 03 RG178 VPC Tools Required For the assembly of the Mini Coaxial Contact VPC P N 610 103 130 CASS P N 1899AS284 02 and VPC P N 610 103 157 CASS P N 1899AS284 03 the following parts are required by VPC Tools P N Description 910 121 142 Outer shield conductor expanding tool for male mini coax contact 910 121 126 Outer shield conductor forming tool for male mini coax contact 910 101 115 Hex crimp tool kit for mini coax contact 254108 Hex crimp tool die part of 910 101 115 254117 Hex crimp tool handle part of 910 101 115 Gages amp Weights P N Description 910 121 157 Inspection gage to verify depth setting of conductor on male mini coax cont
38. l Corporation 35 CASS USER S MANUAL Ver 2 7 Trouble Shooting and Solutions Section 6 ID will not engage with the Receiver after diagnosing the above problems Check the System for foreign objects Check the alignment of the ID Frame There is possibility that the ID Frame could have misaligned itself if it was dropped See enclosed diagrams Contact Virginia Panel Corporation user adjustments to System unless authorized will void the warranty No continuity upon engagement Upon replacing a Contact in the ID the mating Contact on the Receiver side Receiver Contact should also be inspected and replaced if necessary See Section 2 Check Wiring replace if necessary A short in the wiring upon engagement A damaged Contact s may provide enough resistance to notice Upon replacing a Contact in the ID the mating Contact on the Receiver side Receiver Contact should also be inspected and replaced if necessary See Section 2 Check wiring replace if necessary Receiver and ID will not disengage This may indicate that the Engagement Mechanism within the Receiver is faulty contact Virginia Panel Corporation immediately user adjustments to System unless authorized will void the warranty VPC may be contacted at the following telephone number and address Virginia Panel Corporation 1400 New Hope Road Waynesboro VA 22980 Tel 540 932 3300 Fax 540 932 3369 36 VMCASSUS Ver
39. mmed evenly and no loose strands are extending out across the exposed dielectric or cable jacket 5 Smooth the braid ends flat against the cable dielectric 3 ee 6 Slip the contact over the end of the prepared cable and carefully push the contact onto ALGA d ts the cable until it stops Rotating the contact slightly during cable insertion will help prevent BAA the braid from catching WINDOW CENTER CONDUCTOR Figure B 7 Inspect for proper insertion Fig B The center conductor must be visible through one of the forward inspection windows The distance from the rear of the contact outer body to the cable jacket insulation should be 065 015 8 Install the adapter onto the holding fixture Fig C Insert a contact in the adapter side marked S for Socket and set up the dimensions as shown in Figure C CONTACT 0 5 0 7 INCH 9 Insert the contact cable assembly into the adapter Clamp the cable in the holding fixture Z ADAPTER The cable must remain fully inserted in the contact and the contact must be fully inserted in the adapter for the adapter to act as a heat sink The cable must be straight between the lt P contact and the cable clamp E S ESA FORWARD ra m INSPECTION A WINDOW MARKED S 10 Attach the appropriate reflector to the heating tool See separate instructions sheet included with tool for tool operation and safety precautions 11 Using the holding fixture
40. mp Dies N o o m o o A 910 101 103 A 910 104 107 O 910 104 118 IH 910 110 102 z 910 112 104 Extraction Tools 910 121 142 2038AS394 ES 910 121 157 610 103 130 1899AS284 02 610 110 108 1899AS287 01 610 110 172 1899AS282 01 610 115 124 2038A5418 01 38 VMCASSUS Ver 2 7 CASS USER S MANUAL Product Cross Reference Section 7 Receiver Assembly amp Extraction Modules ID podu i Tools 9 g UN s 3 2 o ReceiverandlD 8 8 8 Ba a la 5 Solder Sleeve S 3 3 5 5 le ke Contacts ole 5 5 5 z Mi Mi y o le le le o D D D 5 5 Receiver 610 104 142 O s O 2038AS397 01 ID 610 103 140 s 7 s s 2038AS396 01 Virginia Panel Corporation 39 CASS USER S MANUAL Ver 2 7 Diagrams Section 8 CASS Receiver 5 5 26s s Dr a E 3 EQL ES y Be l 2 40 oco o o o o o o o oo 5 oos T OPEN POSITION P N 310 115 101 1899AS265 01 40 VMCASSUS Ver 2 7 CASS USER S MANUAL Diagrams Section 8 CASS Interface Device 15 970 T Lee re
41. n acceptable solder joint is obtained Note Center conductor and dielectric must touch r BA SA PD PAIUGAELL rer En ki al i bes Ag Fig D 5 Slide shield conductor over center conductor until the center conductor stops in the Teflon shield Fig E Note Shield Conductor and Teflon insulator are supplied as an assembly SMALL GAP TO ENSURE TH COAX CABLE HAS BEEN FULLY INSERTED INTO CONTACT p SHIELD CONDUCTOR A a Fe KEJ CENTER Fig E CONDUCTOR 6 Turn braid back toward the front of the shield conductor Fig F If braid extends beyond shoulder trim back to face of shoulder AID F SHOULD RTE con t page 27 Fig F revised 01 05 04 26 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Instructions Section 5 P N 610 103 115 CASS P N 1899AS284 01 RG316 P N 610 103 159 CASS P N 1899AS284 04 RG316 7 Calibrate gage P N 910 121 157 Fig G A by loosening the dial face retaining screw until E the dial face allows itself to be turned Insert the o J calibration plug P N 414855103 into base of gage N a LS While keeping constant pressure on the plug FES E ke adjust the dial by rotating it such that the pointer points to 0 Re tighten retaining screw gt SR Adjust locating markers to 90
42. n force go to step 8 SE 10 Turn braid back toward the front of the shield conductor Fig M Se BRAID p SHOULDER M E 432026000 4 00 OZ Fig M Fig K 11 If braid extends beyond shoulder trim braid back to face of shoulder 12 Slide crimp ring into position over the braid 13 Crimp using the Hex Crimp Tool P N 910 101 115 Fig N in Hex Position A for the larger end first and in Hex position B for the smaller section of the crimp ring of 1899AS270 01 Fig O To ensure proper crimp position slide shield conductor over pin on locator Fig P Wire must not be allowed to pull on center conductor during crimping for example long wire hanging down to floor CRIMP A POSITION RING Val Na ES 1 B POSITION SU tt Fig O a 06 02 RE f K SA y SS S A l gt Y Fig P con tpage 19 revised 11 21 01 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Instructions Section 5 VPC P N 610 104 114 CASS P N 1899AS270 01 RG316 14 Repeat step 7 to verify 06 02 dimension with P N 910 121 156 15 During installation of contact into module listen for retaining clip ears to spring out then push on front of contact to ensure that it is locked into position Virginia Panel Corporation 19 CASS USER S MANUAL Ver 2 7 Wiring Assembly Instructions Section 5 VPC P N 610 104 141 CASS P N 1899AS270 02 RG
43. ns and or repeat steps 1 7 Fig H 10 Slide crimp ring into position over the braid Fig 8994A5284 02 wan ITION Fig I 11 Crimp using the Hex Crimp Tool Fig J in Hex Position A for the larger end first and in Hex Position C for the smaller section of the crimp ring for 1899AS284 02 Fig I To ensure proper crimp position slide shield conductor over pin on locator Fig K Wire must not be allowed to pull on the center conductor during crimping for example long wire hanging down to floor Fig K con t page 33 revised 11 21 01 32 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Instructions Section 5 P N 610 103 130 CASS P N 1899AS284 02 RG178 P N 610 103 157 CASS P N 1899AS284 03 RG178 12 Check minimum extraction force of 3 ounces with P N 414 852 000 Fig L Slide contact into tip of weight gage Insert approximately 15 into tip be careful not to insert chamfer of contact into tip of weight gage Fig M The weight gage should remain mated with the contact as the contact is slowly lifted and suspended in the air If weight gage remains mated move to step 13 SEL s02 If weight gage falls off the extraction force is too low l E and the shield conductor needs to be opened with the outer shield conductor enlarging tool P N 910 121 142 Fig N O Le REF or 1 00 REF Figen Fig L
44. nsity Signal Contact RCVR for PCB Mounting Row 2 610 110 124 1899AS276 03 Hi Density Signal Contact RCVR for PCB Mounting Row 3 610 110 125 1899AS274 01 Hi Density Signal Contact RCVR for Crimp or Solder 50u AU 610 110 174 1899AS268 01 Hi Density Power Contact RCVR 10 AMP for 14 AWG 610 116 112 1899AS267 01 Mini Power Contact RCVR 20 AMP for 8 AWG Indicates that no CASS P N has been assigned to this part Virginia Panel Corporation 1 CASS USER S MANUAL Ver 2 7 CASS Interface System Parts Section 1 ID Contacts VPC P N ASS P N Description 610 103 115 1899AS284 01 Mini Coaxial Contact ID for RG316 30u AU 610 103 130 1899AS284 02 Mini Coaxial Contact ID for RG178 30u AU 610 103 157 1899AS284 03 Mini Coaxial Contact ID for RG178 50u AU 610 103 159 1899AS284 04 Mini Coaxial Contact ID for RG316 50u AU 610 103 140 2038AS396 01 Mini Coaxial Contact ID Solder Sleeve for RG316 or RG178 30u AU 610 103 158 2038AS396 02 Mini Coaxial Contact ID Solder Sleeve for RG316 or RG178 50u AU 610 110 108 1899AS287 01 Hi Density Signal Contact ID for Crimp or Solder 50u AU 610 110 172 1899AS282 01 Hi Density Power Contact ID 10 AMP for 14 AWG 610 110 146 1899AS287 02 Hi Density Signal Contact ID for Crimp or Solder 610 110 173 1899AS282 02 Hi Density Power Contact ID 10 AMP for 14 AWG 50u AU 610 115 124 2038AS418 01 Mini Power Contact ID 50 AMP for 8 AWG Crimping Tools 8
45. nsure that the retaining ring s ears have collapsed Virginia Panel Corporation 3 CASS USER S MANUAL Ver 2 7 Installation Removal Section 2 Receiver Contact Removal from Mini Coaxial and Power Modules For extraction of the Mini Coaxial and Power contacts remove the Module Cap modules 510 113 120 1899AS266 02 510 113 121 1899AS269 02 and 510 113 122 1899AS271 02 use three 086 56 UNC socket head cap screws 510 113 120 1899AS266 02 has an additional two screws due to the extra Hi Density Power contacts cap Remove the socket head cap screws and the Cap Use the Coaxial Power Receiver Contact Extraction Tool VPC P N 910 112 104 and insert firmly over the Contact by applying pressure with the shaft Apply pressure with the handle area only when the Tool has slipped over the retaining ring and has collapsed the tabs twisting the lower portion of the tool will ensure that the tabs have collapsed On the rear side of the Module grasp the Contact with your fingers and hold it while removing the Tool This will avoid pulling the Contact back into the locked positon ID Contact Removal from Mini Coaxial and Power Modules Use of the Coaxial Power Receiver Contact Extraction Tool VPC P N 910 112 104 With the Tool held straight and parallel to the contacts apply pressure to the handle area after the Tool has slipped over the retaining ring and has collapsed the locking tabs twisting the lower portion of the tool will ensure that
46. on has been providing the ATE market with quality parts and accessories for several years It is VPC s goal to continue to provide high performance and quality parts To ensure that the same level of quality is maintained VPC expects from its Interface System users that all components used in Operating servicing and adjusting meet certain guidelines These guidelines are available from VPC directly and are supplied with the Interface Systems VPC in its attempt to perfect its product lines takes field studies seriously Observations have revealed that some users are not fol lowing VPC s procedures and are not using VPC tools for the proper assembly of the VPC Contacts The user must strickly adhere to follow the Assembly Instruction Sheets that are available from and provided by VPC The following Assembly Instructions Sheets are available Description VPC P N CASS P N Hi Density Signal ID 610 110 108 1899AS287 01 610 103 140 2038AS396 01 610 103 140 2038A5396 01 610 104 142 2038A5397 01 Solder Sleeve Mini Coaxial Receiver for RG 178 610 104 142 2038AS397 01 Solder Sleeve Mini Coaxial ID for RG316 610 103 158 2038AS396 02 Solder Sleeve Mini Coaxial ID for RG178 610 103 158 2038AS396 02 Mini Coaxial Mini Coaxial Receiver Terminal 50 OHM for RG316 1899AS270 01 Mini Coaxial Receiver Terminal 50 OHM for RG178 1899AS270 02 Mini Coaxial ID Terminal 50 OHM for RG316 1899AS284 01 Mini Coaxial ID Terminal 50 O
47. r cable jacket 7 H 065 015 5 Smooth the braid ends flat against the cable dielectric 6 Slip the contact over the end of the prepared cable and carefully push the contact S A E onto the cable until it stops Rotating the contact slightly during cable insertion will ere help prevent the braid from catching INSPECTION A pI WINDOW 7 Inspect for proper insertion Fig B The center conductor must be visible through one of the forward inspection windows The distance from the rear of the contact He CONTACT outer body to the cable jacket insulation should be 065 015 a ADAPTER 8 _ Install the adapter onto the holding fixture Fig C Insert a contact in the adapter c o FORWARD side marked P for pin and setup the dimensions as shown in Figure C A Z INSPECTION DE 9 Insert the contact cable assembly into the adapter Clamp the cable in the holding Traen MARKED P fixture The cable must remain fully inserted in the contact and the contact must be fully inserted in the adapter for the adapter to actas a heat sink The cable must be straight between the contact and the cable clamp 10 Attach the appropriate reflector to the heating tool see separate Heat Gun instruction sheet included with tool for tool operation an
48. solder will wick away from the joint areas leaving no solder HOLDING FIXTURE fillets An overheated contact must be removed and a new contact installed ie 14 After the contact has cooled for at least 10 seconds remove the contact and cable Figure D from the holding fixture 15 Inspect the completed termination for correct assembly The cable shield must extend into the contact at least as far as the front edge of the rear inspection windows The center conductor must be visible through one of the forward inspection windows revised 2 06 02 12 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Instructions Section 5 VPC P N 610 104 142 CASS P N 2038AS397 01 RG316 PARTS REQUIRED Solder Kit for Mini Coax includes holding fixture and adapter P N 910 121 144 Adapter for those who already own a holding fixture P N 910 121 149 Steinel Heat Gun with Reflector P N 910 121 160 or Raychem MiniGun Heater with Reflector P N 910 121 148 Mini Coax Contact Receiver Solder Sleeve P N 610 104 142 INSTRUCTIONS 1 Prepare the coaxial cable to the dimensions shown Fig A 2 Straighten the center conductor making sure the stranded center conductor is twisted 7050157 7 ao EoI into its original lay i 115 4015 3 Pretin stranded center conductor with Sn63 solder per QQ S 571 Use RMA flux per S pases se pitas MIL F 14256 Alpha 611 or equivalent Figure A 4 Make sure the shield braid is tri
49. st and in Hex position C for the smaller section of the crimp ring of 1899AS270 02 Fig O To ensure proper crimp position slide shield conductor over pin on locator Fig P Wire must not be allowed to pull on center conductor during crimping for example long wire hanging down to floor CRIMP A POSITION RING j y e 2 i aI ES 89945270 02 c POSITION Fig O i con t page 24 Fig P revised 11 21 01 Virginia Panel Corporation 23 CASS USER S MANUAL Ver 2 7 Wiring Assembly Instructions Section 5 VPC P N 610 104 141 CASS P N 1899AS270 02 RG178 15 Repeat step 8 to verify 06 02 dimension with P N 910 121 156 16 During installation of contact into module listen for retaining clip ears to spring out then push on front of contact to ensure that it is locked into position 24 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Instructions Section 5 P N 610 103 115 CASS P N 1899AS284 01 RG316 P N 610 103 159 CASS P N 1899AS284 04 RG316 VPC Tools Required For the assembly of the Mini Coaxial Contact s VPC P N 610 103 115 CASS P N 1899AS284 01 and or P N 610 103 159 1899AS284 04 the following parts are required by VPC Tools P N Description 910 121 142 Outer shield conductor expanding tool for male mini coax contact 910 121 126 Outer shield conductor forming tool for male mini coax contact 910 101 115 Hex crimp tool kit
50. sure that coaxial cable has been fully inserted into contact ensure that a gap is between shielding and contact when achieving positive stop Fig E Note Shield Conductor and Teflon insulator are supplied as an assembly SMALL GAP TO ENSURE THAT COAX CABLE HAS BEEN FULLY INSERTED INTO CONTAC p CENTER Fig E CONDUCTOR 7 Turn braid back toward the front of the shield conductor Fig F If braid extends beyond shoulder trim back to face of shoulder BRAID H SHOULDER CT 3881 Era s t 32 Fig F ROS cer 1 01 Virginia Panel Corporation 31 CASS USER S MANUAL Ver 2 7 Wiring Assembly Instructions Section 5 P N 610 103 130 CASS P N 1899AS284 02 RG178 P N 610 103 157 CASS P N 1899AS284 03 RG178 8 Calibrate gage P N 910 121 157 Fig G by loosening the dial face retaining screw until the dial face allows itself to be turned Insert the calibration plug P N 414 855 103 into base of gage While keeping constant pressure on the plug adjust the dial by rotating it such that the pointer points to 0 Re tighten retaining screw Adjust locating markers to 90 and 20 9 Check 01 01 02 dimensions Fig H by using Seji P N 910 121 157 Fig I Insert contact into gage and push contact into collar until contact stops If pointer is between the two markers go to step 10 If the pointer FA Fig G is out of the range of the two markers check dimensio
51. the locking tabs have col lapsed Damage can occur to the contacts if the Tool is not held parallel to the contacts CAUTION Never probe a contact without using a mating contact patchcord as a probe to avoid damaging the contact s being tested revised 11 20 01 4 VMCASSUS Ver 2 7 CASS USER S MANUAL General Operating Procedures and Precautions Section 3 Mounting an Enclosure on an ID The CASS specification requires stainless steel screws be used in certain IDs P N 410 113 111 410 113 117 and 410 113 118 which has been known to cause self locking helicoils to seize or pull out It is recommended when using heat treated unplated or stainless steel screws an anti seize compound e g molybden disulfide must be used in order to minimize galling and assure maximum cycle life CAUTION e When engaging the ID with the Receiver caution must be taken to ensure that the ID is parallel with the Receiver upon engagement and that the ID rollers are engaged at the same time All power supplies for the system should be properly disconnected prior to handling Caution should always be used when engaging making sure that all foreign objects are removed from the system Engaging ID with Receiver Listed below are the required steps to be taken prior to the engagement of the ID and Receiver 1 The handle of the Receiver has been designed in such a way as to provide maximum leverage by allowing the handle to exten
52. to 0 Re tighten retaining screw Adjust locating markers to 80 and 40 8 Check 06 02 dimensions Fig G Push the contact onto the pressure plunger of the gage Fig F After IK attaining positive stop and while holding firm pressure push plunger on top of dial to push collar over Teflon 4 s read the dial on the gage Fig F i j G6 O2 Xes v IJA ZZ i NX Fig G Go to step 9 if the indicator is between the two marker bands 80 amp 40 Repeat steps 1 6 should the range of dimensions not meet the criterion gt 9 Check minimum extraction force of 0 5 ounce with L 432025000 Assembly Fig H Slide female center S deo conductor over approximately 3 4 of the lengih of the S tip in the weight gage Fig I The weight gage should 5 remain mated with the center conductor as the center conductor is slowly lifted and suspended in the air 432025000 50 07 i 7 If weight gage remains mated move to step 10 FH FN y AY If weight gage falls off the extraction force is too low and the center conductor needs to be closed with the center conductor forming tool P N 910 121 119 Fig J Recheck 0 5 ounce retention force SI gt O E Fig Fig J con t page 23 revised 11 21 01 22 VMCASSUS Ver 2 7 CASS USER S MANUAL Wiring Assembly Instructions
53. urn braid back over outer insulation Fig C 4 Solder wire into center conductor and clean Fig C Note Center conductor and dielectric must touch Fig C 5 Slide the spacer tube over dielectric to edge of the braid Fig D Heat spacer tube with a heat gun until it has shrunk to hold on to dielectric FLUSH WITH EDGE AFTER SHRINKING TUBE ii JN CENTER CONDUCTOR f pet SOLDER Fig D 6 Slide shield conductor over center conductor until the center conductor stops in the Teflon shield To ensure that coaxial cable has been fully inserted into contact ensure that a gap is between shielding and contact when achieving positive stop Fig E Note Shield Conductor and Teflon insulator are supplied as an assembly SMALL GAP TO ENSURE THA COAX CABLE HAS BEEN FULLY INSERTED SHIELD CONDUCTOR A Zs Sos SST EE CENTER SE CONDUCTOR Fig E con t page 22 revised 11 21 01 Virginia Panel Corporation 21 CASS USER S MANUAL Ver 2 7 Wiring Assembly Instructions Section 5 VPC P N 610 104 141 CASS P N 1899AS270 02 RG178 7 Calibrate gage P N 910 121 156 Fig F by loosening the dial face retaining screw until the dial face allows itself to be turned l MESS Insert the calibration plug P N 414854104 into base of gage While NE keeping constant pressure on the plug adjust the dial by rotating it such that the pointer points
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