Mini Coaxial User Manual - Equip-Test
Contents
1. ASSEMBLY INSTALLATION AND REMOVAL YPI CONTACTS AND MODULES FOR MINI COAXIAL CONTACTS AND MODULES TABLE OF CONTENTS SECTION 1 RECEIVER CONTACT ASSEMBLY INSTRUCTIONS SECTION 2 ITA CONTACT ASSEMBLY INSTRUCTIONS SECTION 3 WIRE WRAP CONTACT TERMINATION INSTRUCTIONS SECTION 4 CONTACT INSTALLATION AND REMOVAL INSTRUCTIONS SECTION 5 MODULE INSTALLATION AND REMOVAL INSTRUCTIONS SECTION 6 CROSS REFERENCE TABLES APPENDIX PRODUCT PERFORMANCE SPECIFICATIONS 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 1 VIRGINIA PANEL CORPORATION MINI COAXIAL RECEIVER CONTACT ASSEMBLY PART 610 104 114 FOR RG316 ee TOOLS REQUIRED Center Conductor Enlarging Tool Part 910 121 143 Weight Gauge Kit Part 910 121 131 Center Conductor Forming Tool Part 910 121 119 4 0 oz Weight Part 432 026 000 included in Part 910 121 131 Hex Crimp Tool Part 910 101 115 0 5 oz Weight Part 432 025 000 included in Part 910 121 131 Inspection Depth Gauge Part 910 121 156 E Calibration Plug Part 414 854 104 Included in Part 910 121 156 inches ASSEMBLY INSTRUCTIONS mem l Strip wire Figure 77 70 10 16 40 2 Slide the crimp ring onto the wire Figure 4 32 17 3 braid back over outer insulation Figure CENTER CONDUCTOR WIRE tA Solder center conductor wire into center conductor contact and clean Figure D VPC solders per IPC S J2. Check the minimum extraction force of 3 ounces with Part 414 852 000 Slide contact the weight gauge tip Insert approximately 0 15 3 81 mm into tip Take care not to insert chamfer of contact the weight gauge tip Figure M The weight gauge should remain mated with the contact as the contact is slowly lifted and suspended in the air If weight gauge remains mated move to step 12 If weight gauge falls off the extraction force is too low and the shield conductor needs to be opened up with the Outer Shield Conductor Expanding Tool Part 910 121 142 Figure N To enlarge the shield conductor genily 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 gauge can be held by contact Check the maximum extraction force of 20 ounces with Part 414 853 000 Slide contact the weight gauge tip Insert approximately 0 15 3 81 mm into tip Take care not to insert chamfer of contact the weight gauge tip Figure O The weight gauge should fall off the contact as the contact is slowly lifted and suspended in the air If the weight gauge falls off move to step 13 If weight gauge 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 Part 910 121 126 Figure P Squeezing the tool han
3. Re tighten retaining screw Adjust locating markers to 20 and 90 9 Check the 01 25 mm dimension Figure J with the inspection depth gauge Figure H Push the contact onto the pressure plunger of the gauge After attaining a positive stop and while holding firm pressure push the plunger on top of the dial to push collar over Teflon read the dial on the gauge If the pointer measures between 20 and 90 go to step 10 If the pointer is out of the range repeat steps 1 9 10 To ensure proper crimp position slide shield conductor over Figure H Inspection Depth Gauge Part 910 121 157 the locator pin Figure K Crimp using the Hex Crimp Tool Part 910 101 115 Figure L in hex position for the larger end px first and in hex position B for the smaller section of the crimp ring Wire must be allowed pull on the center conductor during crimping for example long wire hanging down to floor Continued on next page Figure J Check dimensions POSITION A LOCATOR POSITION B Figure K Slide shield conductor over pin on locator Figure L Hex Crimp Tool Part 910 102 115 222 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA CONTACT ASSEMBLY PART 610 103 115 FOR RG316 ASSEMBLY INSTRUCTIONS CONTINUED Fi
4. 144 Adapter for those who already own a holding fixture Part 910 121 149 Steinel Heat Gun with nozzle Part 910 121 160 110V or Part 910 121 167 220V inches ASSEMBLY INSTRUCTIONS 7 36 JT 290 015 3 81 l Strip wire Figure A 1 2 2 Straighten the center conductor making sure the stranded center conductor is twisted into its original lay E l DIELECTRIC 3 Tin stranded center conductor with 5 63 solder per QQ S 571 Use RMA flux per MIL F 14256 Aloha 611 or equivalent Figure Strip wire 4 Fold the center conductor back on itself Figure r 5 Make sure the shield braid is trimmed evenly and no loose strands extending CONDUCTOR out across the exposed dielectric or cable jacket CRE Figure B Fold center conductor 0 381 F 015 6 Smooth the braid ends flat against the cable jacket 7 Slide 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 REAR INSPECTION WINDOW FORWARD INSPECTION WINDOW CENTER CONDUCTOR 8 Inspect for proper insertion Figure 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 0 38 mm Figure
5. 5 ounce with Part 432 025 000 Slide female center conductor over approximately 4 the length of the tip in the weight gauge Figure G The weight gauge should remain mated with the center conductor as the center conductor is slowly lifted and suspended in the air If weight gauge remains mated move to step 10 If weight gauge falls off the extraction force is too low and the center conductor needs to be closed with the Center Conductor Forming Tool Part 910 121 119 Figure H Recheck the 0 5 ounce retention force Check maximum extraction force of 4 ounces with Part 432 026 000 Slide female center conductor over approximately of the length of the tip in the weight gauge Figure J The weight gauge should fall off the contact as the contact is slowly lifted and suspended in the air If weight gauge falls off move to step 10 If weight gauge remains mated with the contact the extraction force is too high and the center conductor needs to be opened with the Center Conductor Enlarging Tool Part 910 121 143 Figure K EXERCISE CAUTION WHEN USING THIS TOOL INSERT AND REMOVE TOOL IN LINE WITH CONTACT TO AVOID BREAKING TIP OF TOOL OR CONTACT To enlarge the center conductor gently insert the enlarging tool into the center conductor Pivot the enlarging tool to increase the diameter Recheck 0 5 and 4 ounce retention force as in step 9 Turn both braids back over the shield conductor Figure L If the braid extends beyond
6. C Contact on wire CONTACT FORWARD INSPECTION WINDOW 9 Install the Adapter Part 910 121 149 onto the Holding Fixture Part 910 121 144 Figure D Insert a contact in the adapter side marked P for pin and set up the SIDE MARKED P dimensions Figure D 10 Insert the contact cable assembly into the adapter Clamp the cable in the holding fixture The cable must remain fully inserted in the contact and the contact must be fully inserted in the adapter for adapter to act as a heat sink The cable must be straight between the contact and the cable clamp HOLDING FIXTURE 11 Attach the appropriate reflector to the heating tool See instruction sheet accompanying heat gun for instructions and safety precautions 12 Using the holding fixture position the contact in the heating tool reflector with the Figure D Solder fixture 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 13 If contact is UNDERHEATED there will be visible remnants of the original shapes of the solder preforms An underheated contact must be re heated If contact is OVERHEATED solder will wick away from the joint areas leaving no solder fillets An overheated con
7. Depth Gauge part 910 121 157 POSITION lt Figure J Crimp positions Figure K Hex Crimp Tool part 910 101 115 2 9 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA CONTACT ASSEMBLY PART 610 103 152 FOR RG316 DOUBLE SHIELDED ASSEMBLY INSTRUCTIONS CONTINUED 12 Check the minimum extraction force of 3 ounces with Part 414 852 000 Slide contact into the weight gauge tip Insert approximately 0 15 3 81 mm into tip be careful not to insert chamfer of contact the weight gauge tip Figure L The weight gauge should remain mated with the contact as the contact is slowly lifted and suspendedi in the air If the weight gauge remains mated move to step 12 If the weight gauge falls off the extraction force is too low and the shield conductor needs to be opened up with the Outer Shield Conductor Expanding Tool Part 910 121 142 Figure 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 the 3 ounce weight gauge can be held by contact Check the maximum extraction force of 20 ounces with Part 414 853 000 Slide the contact into the weight gauge tip Insert approximately 0 15 3 81 mm
8. Part 910 ED CONDUCTOR 121 156 be used to verify the 06 02 dimension Figure SHOULDER Figure F Turn braid back over contact POSITION Figure G Crimp positions 1 524 0 508 060 020 Figure Verify dimension 1 9 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 1 VIRGINIA PANEL CORPORATION MINI COAXIAL RECEIVER SOLDER SLEEVE CONTACT ASSEMBLY PART 610 104 142 FOR RG316 TOOLS REQUIRED Solder Kit includes Holding Fixture and Adapter Part 910 121 144 Adapter for those who already own a holding fixture Part 910 121 149 Steinel Heat Gun with nozzle Part 910 121 160 110V or Part f 910 121 167 220V ASSEMBLY INSTRUCTIONS 1 Strip wire Figure 2 Straighten the center conductor making sure the stranded center conductor is twisted into its original lay 3 Tin stranded center conductor with 563 solder QQ S 571 Use RMA flux per MIL F 14256 Aloha 611 or equivalent 4 Make sure the shield braid is trimmed 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 6 Slide 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 th
9. STD 001 NOTE Center conductor contact and dielectric must touch Figure A wire DIELECTRIC OUTER INSULATION SHIELD BRAID 5 Slide shield conductor over center conductor until the center CRIMP RING conductor stops in the Teflon shield Figure E NOTE Shield conductor and Teflon insulator are supplied as an assembly Figure B Crimp ring Continued on next page TURN SHIELD BRAID BACK Figure C Turn braid back NO GAP PERMISSIBLE SOLDER CENTER CONDUCTOR Figure D Solder center conductor SHIELD CONDUCTOR ASSEMBLY SMALL GAP TO ENSURE AT COAX CABLE HAS BEEN FULLY INSERTED Figure E Slide shield conductor over center conductor When soldering care must be taken so as to not deform the center conductor tip If soldered properly steps 8 and 9 can be skipped 1 1 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 1 VIRGINIA PANEL CORPORATION MINI COAXIAL RECEIVER CONTACT ASSEMBLY PART 610 104 114 FOR RG316 ASSEMBLY INSTRUCTIONS CONTINUED 6 Calibrate the Inspection Depth Gauge Part 910 121 156 Figure F by loosening the dial face retaining screw until the dial face allows itself to be turned Insert the Calibration Plug Part 414 854 104 into the base of the gauge While keeping constant pressure on the plug adjust the dial by rotating it such that
10. cable must be straight between the contact and the cable clamp Attach the appropriate reflector to the heating tool See instruction sheet accompanying heat gun for instructions 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 Dimensions shown millimeters inches 7 37 290 3 56 140 BRAID DIELECTRIC Figure A Strip wire 5 46 r 215 5 WIRE Figure B Fold center conductor 1 65 dr 088 REAR INSPECTION WINDOW CENTER CONDUCTOR WIRE FORWARD INSPECTION WINDOW Figure Contact on wire CONTACT FORWARD INSPECTION WINDOW SIDE MARKED 5 HOLDING FIXTURE Figure D Holding fixture If contact is UNDERHEATED there will be visible remnants of the original shapes of the solder preforms An underheated contact must be re heated 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 After the contact has cooled for at least 10 seconds rem
11. is squared up with the corresponding module location Once in place pull the wire slightly to ensure that the contact is seated CONTACT REMOVAL INSTRUCTIONS l Remove the module from the receiver frame NOTE For more information concerning the process of removing the module from the receiver frame see module installation and removal instructions in Section 5 of this User s Manual 2 Use the appropriate tool to remove the module cap screws located at the top and bottom of the module Figure A Figure A Extraction Tool Part 910 112 104 MODULE CAP SCREW 3 Grasp the module halves and apply force in opposite directions rocking the ends of the module while slightly pulling the module cap away from f essa the mating bottom section Be sure to open both sides of the module simultaneously or contacts could be damaged 4 Place the Mini Power Mini Coaxial Extraction Tool part 910 112 104 hago te si Figure B over the contact to be removed replaced Use care to keep the tool perpendicular to the surface of the module otherwise the tool or contact could be damaged DETAIL A SCALE 2 1 5 Once the extraction tool is seated and the retaining ring tabs on the PRESS DOWN contact are compressed push the plunger The contact will be pushed out of the rear of the module 6 For19 and 76 position modules do not tighten screws Insert an ITA contact in positions 2 and 18 or 2A and 18A for 7
12. the dielectric to edge of the braid Figure D Use heat gun to shrink spacer to hold onto dielectric 5 Tin wire and solder into center conductor and clean Figure E VPC solders per IPC S J STD 001 NOTE Center conductor and dielectric must touch Solder should be visible in the hole 6 Slide shield conductor over center conductor until the center conductor stops in the Teflon shield To ensure that the coaxial cable has been fully inserted into the contact a gap between the shielding and the contact should exist after achieving positive stop Figure F NOTE Shield conductor and Teflon insulator are supplied as an assembly Continued on next page Weight Gauge Kit Part 910 121 131 4 0 oz Weight Part 432 026 000 included in Part 910 121 131 0 5 oz Weight Part 432 025 000 included in Part 910 121 131 Dimensions shown millimeters inches 16 51 0 65 9 90 r 0 39 4 32 0 17 m conbucron OUTER INSULATION Figure A Strip wire CRIMP RING Figure B Crimp ring Figure C Turn braid back SPACER FLUSH WITH EDGE AFTER ka BSHRIMKINCS TUBE CENTER CONDUCTOR Figure D Spacer tube NO GAP PERMISSIBLE SOLDER y f CENTER CONDUCTOR Figure E Ensure solder is visible in hole opan BEEN FULLY INSERTED SHIELD CONDUCTOR CENTER CONDUCTOR Figure F Shield conduc
13. the pointer points to 0 Re tighten the retaining screw Adjust locating markers to 40 and 80 7 Check the 06 1 52 mm dimensions with the inspection depth gauge Figure F Push the contact onto the pressure plunger of the gauge After attaining a positive stop and Figure F Inspection Depth Gauge Part 910 121 156 while holding firm pressure push the plunger on top of the dial to push collar over Teflon read the dial on the gauge If the pointer measures between 40 and 80 go to step 8 If the pointer is out of range repeat steps 1 6 8 Check the minimum extraction force of 0 5 ounce with Part 432 025 000 Slide female center conductor over approximately of the length of the tip in the weight gauge Figure G The weight gauge should remain mated with the center conductor as the center conductor is slowly lifted and suspendedi in the air If the weight gauge remains mated move to step 9 If the weight gauge falls off the extraction force is too low and the center conductor needs to be closed with the Center Conductor Forming Tool Part 910 121 119 Figure H Recheck the 0 5 ounce retention force Continued on next page Figure G Check minimum weight with Part 432 025 000 Figure H Center Conductor Forming Tool Part 910 121 119 When soldering care must be taken so as to not deform the center conductor tip If soldered properl
14. the shoulder trim the braid back to the face of the shoulder Figure H Center Conductor Forming Tool Part 910 121 119 Figure G Check minimum extraction force with Part 432 025 000 Figure K Center Conductor Enlarging i Tool Part 910 121 143 12 Slide the crimp ring over the braid and shield conductor Figure jos d PEL 432 M and crimp using the Hex Crimp Tool Part 910 101 115 in We TP M 026 000 hex position A To ensure proper crimp position slide the shield conductor over the dowel pin on the hex crimp tool The wire BRAID must not be allowed to pull on the center conductor during crimping For example long wire hanging down to floor ATA 13 Use the inspection depth gauge to verify the 06 1 52 mm Figure L Turn braids back over shield conductor dimension See step 8 CRIMP i led POSITION A Figure M Slide the crimp ring over the braid and crimp 1 8 For more information visit vpc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 1 VIRGINIA PANEL CORPORATION MINI COAXIAL RECEIVER CONTACT ASSEMBLY PART 610 104 154 FOR RG58 TOOLS REQUIRED Hex Crimp Tool Part 910 101 115 Inspection Depth Gauge Part 910 121 156 Dimensions shown millimeters inches ASSEMBLY INSTRUCTIONS 25 40 l Strip outer jacket Figure E 1 00 TI 2 Cut is tubing 1 75
15. the wire Figure 4 32 17 3 Turn braid back over outer insulation Figure C OUTER ON BRAID E l DIELECTRIC 4 Slide the spacer tube over dielectric to edge of the braid Figure D Heat spacer tube until soacer shrinks to hold onto dielectric Figure A Strip wire 5 Slide the center conductor wire into the center conductor contact and solder Clean solder joint Figure D VPC solders per IPC S J STD 001 NOTE Center conductor and dielectric must touch Figure B Crimp ring 6 Slide the shield conductor over the center conductor until the FOLD BRAID BACK center conductor stops in the Teflon shield To ensure that coaxial J cable has been fully inserted into contact ensure that a gap is between shielding and contact when achieving positive stop Figure E NOTE Shield conductor and teflon insulator are supplied as an assembly SPACER TUBE CENTER CONDUCTOR 7 braid back over the shield conductor Figure F If braid SONASI extends beyond shoulder trim back to face of shoulder SOLDER NO GAP PERMISSIBLE Figure C Turn braid back Continued on next page Figure D Install center conductor contact SMALL A SHOULDER Figure E Install shield conductor FOLD BRAID OVER SHIELD CONDUCTOR SHOULDER Figure F Turn braid over contact 2 4 For more information visit voc com 9 24 10 MINI COAXIAL CON
16. 15 3 81 mm into tip Take care not to insert chamfer of contact the weight gauge tip Figure M The weight gauge should fall off the contact as the contact is slowly lifted and suspended in the air If weight gauge falls off move to step 14 If weight gauge 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 Part 910 121 126 Figure N Squeezing the tool handles will reposition the contact legs This procedure should be done in three different locations approximately 120 apart on the same shield to obtain proper sizing Repeat steps 12 and 13 Use the inspection depth gauge to verify the 01 25 mm dimension See step 10 CHAMFER Figure K Check minimum extraction force with Part 414 852 000 Figure L Outer Shield Conductor Expanding Tool Part 910 121 142 CHAMFER Figure M Check maximum extraction force with Part 414 853 000 Figure N Shield Conductor Forming Tool Part 910 121 126 2 6 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA CONTACT ASSEMBLY PART f 610 103 136 FOR 24 AWG PART 610 103 166 FOR 24 AWG 26 AWG PART 610 103 172 FOR 22 AWG TOOLS REQUIRED Crimp Tool Part 910 101 118 Crimp Locator Part 910 104 128 in
17. 19 Hex Crimp Tool Part 910 101 115 Inspection Depth Gauge Part 910 121 156 Calibration Plug Part 414 855 104 Included in Part 910 121 156 ASSEMBLY INSTRUCTIONS Is 2 Strip wire Figure Slide the crimp ring onto the wire Figure B Turn both the inner and outer braid back over the outer insulation Turn the outer braid back and smooth then turn the inner braid back Figure B Insert the center conductor of the wire into the center conductor contact solder and clean Figure VPC solders per IPC S J SID OOI NOTE Center conductor contactand dielectric must touch Slide the shield conductor over the center conductor until the center conductor stops in the Teflon insulator Figure D NOTE Shield conductor and Teflon insulator are supplied as an assembly Check to ensure that the center conductor is flush with the Teflon insulator Figure E Calibrate the Inspection Depth Gauge Part 910 121 156 Figure F by loosening the dial face retaining screw until the dial face can be turned Insert the Calibration Plug Part 414 855 104 into the base of the gauge While keeping constant pressure on the plug adjust the dial by rotating it so that the pointer points to 0 Re tighten the retaining screw Adjust the locating markers to 40 and 80 Check the 06 1 52 mm dimension with the inspection depth gauge Figure F Push the contact onto the pressure plunger of the gauge After a
18. 6 position modules to properly align the module cap With the ITA contacts in place tighten the module MINI COAX _ cap screws Do not over tighten screws screw torque limit is 13 1 in oz Figure B Be sure to keep the tool perpendicular so as to For all other modules replace the module cap Figure C using both hands avoid bent pins to push the separated halves together Replace and tighten the module screws to maximum torque of 2 in lbs 0 23 Nm MINI COAX ITA CONTACT 7 MODULE CAP SCREW F MODULECAP DO NOT PUSH THE TOOL INTO THE MODULE UNTIL THE TIP OF THE EXTRACTION TOOL HAS BEEN FULLY SEATED INTO THE MODULE AND COMPRESSED THE RETAINING RING TABS ON THE CONTACT NOTE The process shown here uses standard 90 series modules The same process is used for modules from other series V MINI COAX RECEIVER CONTACT NOTE If you are using a hybrid module you may need to reference the User s Manual for the other contact type for extraction instructions Figure C Module Cap Alignment Diagram 4 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 4 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA CONTACT INSTALLATION AND REMOVAL TOOLS REQUIRED Mini Coaxial Extraction Tool Part 910 112 104 CONTACT INSTALLATION INSTRUCTIONS 1 Assemble the contact to the respective wire NOTE For more information concerning the conta
19. Alpha 611 or equivalent REAR INSPECTION WINDOW CENTER CONDUCTOR 4 Make sure the shield braid is trimmed evenly and no loose strands are extending out across the exposed dielectric or cable jacket Figure B Contact on wire 5 Smooth the braid ends flat against the cable dielectric CONTACT FORWARD INSPECTION 6 Slide 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 7 ADAPTER 7 Inspect for proper insertion Figure 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 015 0 38 mm 8 Install the Adapter Part 910 121 149 onto the Holding fixture Part 910 121 HOLDING FIXTURE 144 Figure C Insert a contact in the adapter side marked P for pin and set up the dimensions Figure C 9 Insert the contact cable assembly into the adapter Clamp the cable in the ugue Capote holding 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 10 Attach the appropriate reflector to the heating tool See instruction sheet accompanying heat gun for instr
20. ND Crimp Tool Part 910 101 118 LOCKING SCREW Crimp Tool Part 910 101 115 p Crimp Locator Part 910 104 128 INDENTER CRIMP TOOL SETUP 27 1 Setup the Crimp Tool Part 910 101 118 Figure A by loosening the latch locking screw counter clockwise until turning stops Remove any previously used locator MICROCRIMP ADJUSTING KNOB MICROCRIMP INDICATOR 2 Insert the open end of the Crimp Contact Locator Part 910 104 128 Figure B into the locator retainer Slide the retaining latch toward the Figure A Crimp Tool Part 910 101 118 locator until it is securely locked into place The locator may have to be twisted to allow the latch to retain it Tighten the latch locking screw 2 T ASSEMBLY INSTRUCTIONS memi l Select correct crimp setting for gauge wire to be used See Table WP below While in closed position check diameter of the crimp tool with Figure B Locator Part 910 104 128 gauge pins to be sure setting is correct This should be done periodically during use to compensate for wear For more information about gauge ava Eu Hd pins visit vpc com gaugepins See calibration instructions for Part 910 m EE 101 102 103 for pin gauge verification instructions 2 00 REF 2 Untwist 2 50 8 mm of twisted wire Cut 0 5 12 7 mm off the white E wire and strip white wire 0 160 4 06 mm Figure C Figure C Cur and strip wire C G 3 Sl
21. OR RG316 DOUBLE SHIELDED ASSEMBLY INSTRUCTIONS CONTINUED 8 Slide the crimp ring over the braid and shield conductor Figure G Do not crimp Calibrate the Inspection Depth Gauge Part 910 121 157 Figure H by loosening the dial face retaining screw until the dial face allows itself to be turned Insert the Calibration Plug Part 414 855 103 into base of gauge 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 20 and 90 Check the 01 25 mm dimension Figure H with the inspection depth gauge Push the contact onto the pressure plunger of the gauge After attaining a positive stop and while holding firm pressure push the plunger on top of the dial to push collar over Teflon read the dial on the gauge If the pointer measures between 20 and 90 go to step 11 If the pointer is out of the range repeat steps 1 10 To ensure proper crimp position slide shield conductor over the locator pin Figure J Crimp using the Hex Crimp Tool Part 910 101 115 Figure K in hex position A Figure J Wire must not be allowed to pull on the center conductor during crimping for example long wire hanging down to floor Continued on next page CRIMP POSITION A Figure G Crimp ring 25 01 DETAIL A INSPECTION DEPTH GAUGE Figure H Inspection
22. TACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA CONTACT ASSEMBLY PART 610 103 130 FOR RGI78 PART st 610 103 157 FOR RG178 ASSEMBLY INSTRUCTIONS CONTINUED 8 Slide crimp ring into position over the braid Figure G Do not crimp Calibrate the Inspection Depth Gauge Part 910 121 157 Figure H by loosening the dial face retaining screw until the dial face allows itself to be turned Insert the Calibration Plug Part 414 855 103 into base of gauge 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 20 and 90 Check the 01 25 mm dimension Figure H by using Part 910 121 157 Figure H Insert contact into the gauge and push contact into collar until contact stops If pointer is between the two markers go to step 11 If the pointer is out of the range of the two markers repeat steps 1 10 To ensure proper crimp position slide the shield conductor over the locator pin Figure G Crimp using the Hex Crimp Tool Part 910101 115 Figure J in hex position A for the larger end first and in hex position C for the smaller section of the crimp ring Wire must not be allowed to pull on the center conductor during crimping for example long wire hanging down to floor Continued on next page POSITION A POSITION C Fi
23. TD 001 NOTE Center conductor and dielectric must touch 5 Slide the shield conductor over the center conductor until the center conductor stops in the Teflon shield Figure D NOTE Shield conductor and Teflon insulator are supplied as an assembly 6 Check to ensure that the Teflon insulator is flush with the tip of the shield conductor Figure E 7 Turn both braids back over the shield conductor Figure F If the braid extends beyond shoulder trim braid back to face of shoulder Continued on next page Weight Gauge Kit Part 910 121 155 3 oz weight Part 414 852 000 included in kit Part 910 121 155 20 oz weight Part 414 853 000 included in kit Part 910 121 155 Dimensions shown millimeters inches 16 76 66 9 4 37 431 17 OUTER BRAID INSULATION DIELECTRIC Figure A Strip wire CRIMP RING FOLD BRAID BACK Figure Fold braid back NO GAP PERMISSIBLE CENTER CONDUCTOR POLDER CONTACT Figure C Install center conductor SMALL GAP a SHIELD CONDUCTOR Figure D Install shield conductor 00 DETAIL A Figure E Check 5 dimension Figure F Turn braid over contact 2 8 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA CONTACT ASSEMBLY PART 610 103 152 F
24. atically releases CRIMP LOCATION 6 Contact should be crimped in correct position with no fractures or loose crimp 7 Gently pull wire to check crimp CONTACT 8 Slide tubing into position and shrink Figure E Fi D Contact in igure D Contact locator CRIMP SETTINGS WIRE STRIP LENGTH MAX MIN PULLOUT FORCE GAUGE IN MM IN MM IN MM LBS N 0 160 4 06 0 034 8 63 0 031 7 87 2 8 89 Figure E Shrink tubing must cover crimp 24 0400 4 06 0 039 9 91 0 035 8 89 2 8 89 22 0400 4 06 0 037 9 39 0 033 8 38 2 8 89 2 7 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA CONTACT ASSEMBLY PART 610 103 152 FOR RG316 DOUBLE SHIELDED TOOLS REQUIRED Outer Shield Conductor Expanding Tool Part 910 121 142 Outer Shield Conductor Forming Tool Part 910 121 126 Hex Crimp Tool Part 910 101 115 Inspection Depth Gauge Part 910 121 157 Calibration Plug Part 414 855 103 included in Part 910 121 157 ASSEMBLY INSTRUCTIONS l Strip wire Figure 2 Slide the crimp ring onto the wire Figure 3 Fold the outer braid back and smooth then fold the inner braid back Figure B 4 Insert the center conductor of the wire into the center conductor contact and solder Figure C VPC solders per IPC S J S
25. ches CRIMP TOOL SETUP LATCH ASSEMBLY AND 1 Setup Crimp Tool Part 4 910 101 118 Figure by loosening the latch locking screw counter clockwise until turning stops Remove LOCATOR DIE any previously used locator INDENTER OPENING MICROCRIMP ADJUSTING KNOB 2 Insert the open end of the Locator Part f 910 104 128 Figure into the crimp tool contact locator retainer Slide the retaining latch toward the locator until the locator is securely locked into place The locator may have to be twisted to allow the latch to retain it Tighten the latch locking screw MICROCRIMP INDICATOR Figure A Crimp Tool Part 910 101 118 ASSEMBLY INSTRUCTIONS 1 Select correct crimp setting for gauge of wire and contact to be used See Table below While in closed position check diameter of crimp tool with gauge pins to be sure setting is correct This should be done periodically during use to compensate for wear For more information about gauge pins visit vpc com gaugepins Figure B Locator Part 910 104 128 See calibration instructions for Part 910 101 102 103 for pin gauge verification instructions SHRINK TUBING 2 Strip wire Figure C RH 3 Slide tubing onto wire Figure C 4 06 16 Figure C Stripped wire with tubing 4 Insert contact with wire in place to the depth allowed by die Figure D 5 Close crimp tool completely until it autom
26. ct assembly process see contact assembly instructions in Section 2 of this User s Manual 2 Insert the assembled contact into the back wiring side of the module Push the contact forward until the crimp is inside the module housing Once in place pull the wire slightly to ensure the contact is seated CONTACT REMOVAL INSTRUCTIONS 1 Remove the module from the ITA frame NOTE For more information concerning the process of removing the module from the ITA frame see module installation and removal instructions in Section 5 of this User s Manual 2 Place the Mini Power Mini Coaxial Extraction Tool part 910 112 104 Figure A over the contact to be removed replaced Use care to keep the tool perpendicular to the surface of the module otherwise the tool or contact could be damaged Rotate the tool slightly while pushing it into the counter bore on the mating side of the module Figure A Extraction Tool Part 910 112 104 3 Once the extraction tool is seated properly and the retaining ring tabs on the contact are compressed push the tool into the module The contact will be pushed out of the rear of the module Figure B PRESS DOWN TO EXTRACT CONTACT DO NOT PUSH THE TOOL INTO THE MODULE UNTIL THE TIP OF THE EXTRACTION TOOL HAS BEEN FULLY SEATED INTO THE MODULE AND COMPRESSED THE RETAINING RING TABS ON THE CONTACT RETAINING TAB DETAIL B SCALE 2 1 PRESS DOWN UNTIL FULLY SEATED NOTE The process sho
27. d Figure J Wire must not be allowed to pull on the center conductor Figure G Apply crimp ring during crimping for example long wire hanging down to floor CRIMP SETTINGS QUIE n immp Ibs INI Figure H Crimp tool Part 910 101 115 0 032 8 12 0 028 7 11 2 8 89 0 039 9 91 0 035 8 89 2 8 89 POSITION POSITION 6 4 22 0 044 11 17 0 039 9 91 2 8 89 Acceptable Stranding 1 x 22 7 x 30 Figure J Crimp locations 2 11 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA SOLDER SLEEVE CONTACT ASSEMBLY PART 610 103 140 FOR RG316 PART 610 103 158 FOR RG316 TOOLS REQUIRED Dimensions shown millimeters Solder Kit includes Holding Fixture and Adapter Part f 910 121 144 inches Adapter for those who already own a holding fixture Part 910 121 149 Steinel Heat Gun with nozzle Part 910 121 160 110V or Part f 910 121 167 220V scia NW ASSEMBLY INSTRUCTIONS gee 1 WIRE Strip wire Figure A TE ie DIELECTRIC 2 Straighten the center conductor making sure the stranded center conductor is Figure A Strip wire twisted into its original lay 0 381 3 Tinstranded center conductor with Sn63 solder per QQ S 571 Use RMA flux per o MIL F 14256
28. dles will reposition the contact legs This procedure should be done in three different locations approximately 120 apart on the same shield to obtain proper sizing Repeat steps 11 and 12 Do not pass slotted end of contact Use the inspection depth gauge to verify the 01 25 mm dimension See step 9 Figure M Check minimum extraction force with Part 414 852 000 Figure Outer Shield Conductor Expanding Tool Part 910 121 142 Figure O Check maximum extraction force with Part 414 853 000 Figure P Outer Shield Conductor Forming Tool Part 910 121 126 2 2 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA CONTACT ASSEMBLY PART 610 103 130 FOR RG178 PART 610 103 157 FOR RG178 TOOLS REQUIRED Outer Shield Conductor Expanding Tool Part 910 121 142 Weight Gauge Kit Part 910 121 155 Outer Shield Conductor Forming Tool Part 910 121 126 3 oz weight Part 414 852 000 included in kit Part 910 121 155 Hex Crimp Tool Part 910 101 115 20 oz weight Part 414 853 000 included in kit Part 910 121 155 Inspection Depth Gauge Part 910 121 157 Calibration Plug Part 414 855 103 included in Part 910 121 157 inches ASSEMBLY INSTRUCTIONS m l Strip wire Figure A 68 9 14 36 2 Slide the crimp ring onto
29. e braid from catching 7 Inspect for proper insertion Figure 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 0 065 1 65 mm 8 Install the Adapter Part 910 121 149 onto the Holding Fixture Part 910 121 144 Figure Insert contact in the adapter side marked 5 for socket and set up the dimensions Figure C 9 Insert the contact cable assembly into the adapter Clamp the cable in the holding 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 Dimensions shown millimeters inches 9 14 0 38 360 015 4 83 0 38 190 015 2 92 0 38 1155018 TE DIELECTRIC WIRE Figure A Strip wire 1 65 REAR INSPECTION WINDOW CENTER CONDUCTOR WIRE FORWARD INSPECTION WINDOW Figure B Contact on wire CONTACT FORWARD INSPECTION WINDOW SIDE MARKED S HOLDING FIXTURE Figure C Holding fixture 10 Attach the appropriate reflector to the heating tool See instruction sheet accompanying heat gun for instructions and safety precautions 11 Using the holding fixture position the contact in the heating tool reflector with the forward inspection wi
30. e way through the wire slot until it goes out of the cutting window The simplified sleeve of the manual tool has no notch Hold the wire in place by hand Figure Position the terminal hole of the wire wrap gun on the post to be wrapped The wire wrap gun should be parallel with the contact The wire must continue to be held in place by hand Engage the wire wrap gun to wrap the wire During the wrapping operation gently press the tool forward onto the wire wrap post The turns of the connection have to be nicely wrapped against the other Do not push too hard Do not pull backwards Figure A Wire wrap gun with wire Figure B Completed wrapped wire 3 1 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 4 VIRGINIA PANEL CORPORATION MINI COAXIAL RECEIVER CONTACT INSTALLATION AND REMOVAL TOOLS REQUIRED 0 050 Allen Wrench MODULE CAP SCREWS MODULE CAP Flat Head Screwdriver Phillips Screwdriver for iCon modules Mini Power Mini Coaxial Extraction Tool Part 910 112 104 CONTACT INSTALLATION INSTRUCTIONS 1 Assemble the contact to the respective wire NOTE For more information concerning the contact assembly process see contact assembly instructions in Section 1 of this User s Manual 2 Insert the assembled contact into the back wiring side of the assembled module The contact can only go into one side Ensure that the contact
31. er end first and in hex position B for the small section of the crimp ring Figure N To ensure proper crimp position slide the shield conductor over the the locator pin The wire must not be allowed to pull on center conductor during crimping for example long wire hanging down to floor Use the inspection depth gauge to verify the 06 1 52 mm dimension See step 7 When soldering care must be taken so as to not deform the center conductor tip If soldered properly steps 8 and 9 can be skipped Figure J Check maximum weight with Part 432 026 000 a Figure K Center Conductor Enlarging Tool Part 910 121 143 POSITION C POSITION A Figure N Crimp positions 1 3 For more information visit vpc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 1 VIRGINIA PANEL CORPORATION MINI COAXIAL RECEIVER CONTACT ASSEMBLY PART 610 104 141 FOR RGI78 TOOLS REQUIRED Center Conductor Enlarging Tool Part 910 121 143 Center Conductor Forming Tool Part 910 121 119 Hex Crimp Tool Part 910 101 115 Inspection Depth Gauge Part 910 121 156 Calibration Plug Part 414 854 104 Included in Part 910 121 156 ASSEMBLY INSTRUCTIONS 1 Strip wire Figure 2 Slide the crimp ring onto the wire Figure 3 braid back over outer insulation Figure 4 Slide the spacer tube over
32. gure G Crimp locations 20 01 DETAIL A Figure H Inspection Depth Gauge Part 910 121 157 Figure J Hex Crimp Tool Part 910 101 115 2 9 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA CONTACT ASSEMBLY PART 610 103 130 FOR RG 178 610 103 157 FOR RG 178 ASSEMBLY INSTRUCTIONS CONTINUED 12 Check the minimum extraction force of 3 ounces with Part 414 852 000 Slide contact the weight gauge tip Insert approximately 0 15 3 81 mm into tip Take care not to insert the chamfer of contact the weight gauge tip Figure K The weight gauge should remain mated with the contact as the contact is slowly lifted and suspended in the air If the weight gauge remains mated move to step 13 If weight gauge falls off the extraction force is too low and the shield conductor needs to be opened up with the Outer Shield Conductor Expanding Tool Part 910 121 142 Figure L 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 gauge can be held by contact Check the maximum extraction force of 20 ounces with Part 414 853 000 Slide contact the weight gauge tip Insert approximately 0
33. ide 4 1 58 mm shrink tubing 0 25 6 35 mm long over white wire in v Slide crimp ring over both wires smaller end first Figure D 4 nsert wire with center conductor in place at depth allowed by die into Crimp Tool Part 910 101 118 Figure B and close crimp tool handles completely until handles release Remove crimped center conductor and wire Gently pull on wire to ensure proper crimp CRIMP SI GONBUSJON 5 Slide shield conductor over center conductor until it stops Figure 6 Slide shrink tubing over crimped area so that it covers all exposed areas Figure E Install shield conductor of center conductor and touches dielectric Heat to shrink Figure F SHRINK TUBING E 7 Re twist black wire around white conductor and shield Trim excess wire i a T that extends beyond the shoulder of the shield conductor Strip black wire such that insulation still covers shrink tubing but not crimp area on Figure D Crimp ring and shrink tubing Figure F Shrink tubing shield Unravel and flare strands around shield Figure G UNRAVEL STRANDS TO FLARE CUT BLACK WIRE HERE AND AROUND SHIELD TRIM STRANDS AFTER UNRAVELING 8 To ensure proper crimp position slide shield conductor over the locator pin Crimp using the Hex Crimp Tool Part 910 101 115 Figure in hex SHOULDER A position A for the larger side and hex position B for the smaller en
34. into tip be careful not to insert chamfer of contact the weight gauge tip Figure N The weight gauge should fall off as the contact is slowly lifted and suspended in the air If the weight gauge falls off move to step 13 If the weight gauge 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 Part f 910 121 126 Figure O Squeezing the tool handles will reposition the contact legs This procedure should be done in three different locations approximately 120 apart on the same shield to obtain proper sizing Repeat steps 12 and 13 Do not pass slotted end of contact Use the inspection depth gauge to verify the 01 25 mm dimension See step 10 CHAMFER WEIGHT GAUGE Figure L Check minimum Figure M Outer extraction force with Part Shield Conductor 414 852 000 Expanding Tool Part 910 121 142 CHAMFER WEIGHT GAUGE Figure O Outer Shield Conductor Forming Tool Part Figure N Check maximum 910 121 126 extraction force with Part 414 853 000 2 10 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA CONTACT ASSEMBLY PART 610 103 161 FOR 24 amp 26 AWG TWISTED PAIR Dimensions shown millimeters inches TOOLS REQUIRED LATCH ASSEMBLY A
35. long and slide over jacket Figure SHRINK TUBING BRAID 3 Slide crimp ring over braid Figure Figure A Strip outer jacket 4 Turn braid over crimp ring and cut 125 off dielectric and strip CRIMP RING See Sten Wee 5 Solder wire into center contact and clean Make sure contact touches dielectric Figure D VPC solders per IPC S J STD 001 Figure B Slide crimp ring over braid 6 Slide shield assembly over center conductor Figure FOLD BRAID NOTE Make sure the Teflon in the shield assembly touches wire AS 2 54 dielectric aml P i ees 7 Turn braid back toward the front of the shield conductor Figure WIRE F If braid extends beyond shoulder trim back to face of Figure Fold braid back shoulder NO GAP PERMISSIBLE 8 Slide the crimp ring into position over braid and crimp using Hex Crimp Tool Part 910 101 115 in hex position A Figure G To ensure proper crimp position slide shield conductor over dowel pin in the crimp locator Wire must not be allowed to pull on the Figure D Solder center conductor 9 Slide tubing to back of shoulder and shrink into place Make sure that the tubing does not extend over the shoulder of the shield dide di conductor Figure E Install shield conductor 10 It is recommended that the Inspection Depth Gauge
36. ndow 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 12 If contact is UNDERHEATED there will be visible remnants of the original shapes of the solder preforms An underheated contact must be re heated 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 1 10 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 1 VIRGINIA PANEL CORPORATION MINI COAXIAL RECEIVER SOLDER SLEEVE CONTACT ASSEMBLY PART 610 104 142 FOR RG178 AND JOY CABLE 033 93 OHMS TOOLS REQUIRED Solder Kit includes Holding Fixture and Adapter Part f 910 121 144 Adapter for those who already own a holding fixture Part 910 121 149 Steinel Heat Gun with
37. nozzle Part 910 121 160 110V or Part 910 121 167 220V ASSEMBLY INSTRUCTIONS ls ZA Strio wire Figure A Straighten the center conductor making sure the stranded center conductor is twisted into its original lay Tin stranded center conductor with Sn63 solder per QQ S 571 Use RMA flux MIL F 14256 Aloha 611 or equivalent Fold the center conductor back on itself Figure B Make sure the shield braid is trimmed evenly and no loose strands are extending 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 Figure 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 edge of the braid should be 0 015 0 38 mm Install the Adapter Part 910 121 149 onto the Holding Fixture Part 910 121 144 Figure D Insert a contact in the adapter side marked S for socket and set up the dimensions Figure DJ Insert the contact cable assembly into the adapter Clamp the cable in the holding fixture The cable must remain fully inserted in the contact and the contact must be fully inserted in the adapter for adapter to act as a heat sink The
38. or optimum performance and system longevity distribute the contact load evenly throughout the module Figure B ITA Module 5 9 For more information visit vpc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 6 VIRGINIA PANEL CORPORATION RECEIVER CONTACTS ITA CONTACTS STANDARD 90 SERIES RECEIVER MODULES ada l be son jejeje e omae l be be so l be mien STANDARD 90 SERIES ITA MODULES 510 108 111 ms EBENEN EBENEN EBENEN EBENEN EBNNN BEGREB 510 161 102 ICON RECEIVER MODULES CROSS REFERENCE TABLES ICON ITA MODULES 510 161 103 510 161 104 CASS 80 SERIES RECEIVER MODULES CRIMP TOOL EXTRACTION 910115 12 SIO TTS 122 910 101 115 910 112 104 910 121 119 210 121 131 210 121 143 210 121 144 910 121 149 210 121 156 210 121 160 210 121 167 CASS 80 SERIES ITA MODULES EXTRACTION 510114108 510114109 910101115 910 101 118 910 112 104 710 121 126 910 121 142 910 121 144 910 121 149 710 121 155 ZIOTZA T57 910 121 160 910 121 167 gt ooa EBENEN EERDE EERDER EBENEN te EE l EHE EERDE 6 1 For more information visit voc com 9 24 10
39. ove 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 should be visible through one of the forward inspection windows For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA CONTACT ASSEMBLY PART 610 103 115 FOR RG316 TOOLS REQUIRED Outer Shield Conductor Expanding Tool Part 910 121 142 Outer Shield Conductor Forming Tool Part 910 121 126 Hex Crimp Tool Part 910 101 115 Inspection Depth Gauge Part 910 121 157 Calibration Plug Part 414 855 103 included in Part 910 121 157 ASSEMBLY INSTRUCTIONS 1 Strip wire Figure 2 Slide the crimp ring onto the wire Figure 3 braid back over outer insulation Figure 4 Solder wire into center conductor and clean Figure D VPC solders per IPC S 5 001 NOTE Center conductor and dielectric must touch 5 Slide the shield conductor over the center conductor until the center conductor stops in the Teflon shield Figure E NOTE Shield conductor and teflon insulator are supplied as an assembly 6 Turn the braid back toward the front of the shield conductor Figure F If braid extends beyond shoulder trim back to face of shoulder Continued on next
40. owly lifted and suspended in the air If weight gauge remains mated move to step 10 If the weight gauge falls off the extraction force is too low and the center conductor needs to be closed with the Center Conductor Forming Tool Part 910 121 119 Figure J Recheck the 0 5 ounce retention force Continued on next page Figure H Check minimum extraction force with Part 432 025 000 Figure J Center Conductor Forming Tool Part 910 121 119 l 5 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 1 VIRGINIA PANEL CORPORATION MINI COAXIAL RECEIVER CONTACT ASSEMBLY PART 610 104 141 FOR RGI78 ASSEMBLY INSTRUCTIONS CONTINUED 10 Check the maximum extraction force of 4 ounces with Part 432 026 000 Slide the female center conductor over approximately 3 4 of the length of the tip in the weight gauge Figure K The weight gauge should fall off the contact as the contact is slowly lifted and suspended in the air If the weight gauge falls off move to step 11 If the weight gauge remains mated with contact the extraction force is too high and the center conductor needs to be opened with the Center Conductor Enlarging Tool Part 910 121 143 Figure L 4 6 atm EXERCISE CAUTION WHEN USING THIS TOOL INSERT AND REMOVE TOOL IN LINE WITH CONTACT TO AVOID BREAKING TIP OF TOOL OR CONTACT To enlarge the cen
41. page Weight Gauge Kit Part 910 121 155 3 oz weight Part 414 852 000 included in kit Part 910 121 155 20 oz weight Part 414 853 000 included in kit Part 910 121 155 Dimensions shown millimeters inches 17 01 67 8 38 33 3 81 15 7 5 N CONDUCTOR OUTER INSULATION BRAID WIRE DIELECTRIC Figure A Strip wire CRIMP Figure Crimp ring Figure C Fold braid back NO GAP PERMISSIBLE SOLDER CENTER CONDUCTOR Figure D Solder center conductor wire SMALL GAP TO ENSURE THAT COAX CABLE HAS BEEN FULLY INSERTED INTO CONTACT SHIELD CONDUCTOR CENTER CONDUCTOR Figure E Slide shield conductor on _ SHOULDER Figure F Fold braid over 2 1 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA CONTACT ASSEMBLY PART 610 103 115 FOR RG316 ASSEMBLY INSTRUCTIONS CONTINUED 7 Slide crimp ring into position over the braid Figure G Do not crimp 8 Calibrate the Inspection Depth Gauge Part 910 121 157 Figure H by loosening the dial face retaining screw until the dial face allows itself to be turned Insert the Calibration Plug Part 414 855 103 into base of gauge While keeping constant pressure on the plug adjust the dial by rotating it such that the pointer points to 0
42. rformance and system longevity distribute the contact load evenly throughout the module Figure A Receiver Module Figure B ITA Module 5 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 5 VIRGINIA PANEL CORPORATION MINI COAXIAL ICON MODULE INSTALLATION AND REMOVAL TOOLS REQUIRED Phillips Head Screwdriver INSTALLATION INSTRUCTIONS NOTE The receiver strain relief plate or the ITA cover may need to be removed prior to installing or removing an iCon module Please refer to the appropriate User s Manual for instructions on how to perform these steps l Place the module in the receiver or ITA until the upper and lower module screws touch the mating holes in the inner frame Install modules such that Position 1 is located at the top of the ITA receiver frame 2 Using a Phillips head screwdriver tighten the top screw 1 to 2 full revolutions while pushing lightly against the face of the module 3 Maintain this pressure while tightening the bottom screw 1 to 2 full revolutions 4 Repeat this sequence until the module is seated Torque the screw to 1 5 in lbs 0 16 Nm REMOVAL INSTRUCTIONS Figure A Receiver Module 1 Toremove loosen the top screw 1 to 2 full revolutions Loosen bottom screw 1 to 2 full revolutions 2 Repeat this sequence until the module is separated from the receiver or ITA NOTE F
43. tact must be removed and a new contact installed 14 After the contact has cooled for at least 10 seconds remove the contact and cable 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 2 13 For more information visit vpc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 3 VIRGINIA PANEL CORPORATION MINI COAXIAL WIRE WRAP CONTACT TERMINATION PART 610 104 140 RECEIVER 610 103 129 ITA TOOLS REQUIRED Wire Stripping Tool Wire wrap gun Wire wrap bit ASSEMBLY INSTRUCTIONS NOTE VPC performs wire wrap terminations in accordance with IPC A 620 standards NOTE Wire wraps must be performed with solid wire Stranded wire will not he work for wire wrapping VPC recommends 26 to 30 AWG wire Cut and strip the wire Depending on the style of wire wrap gun and bit used the wire is either stripped during the wrapping process or needs to be stripped before the wrapping process NOTE Refer fo the user manual of your wire wrap gun to determine in which fashion your tool operates Insert the wire into the wire slot on the wire wrap gun With modified and standard bits insert the wire in the wire slot as deep as possible With C S W bits the wire has to be inserted all th
44. ter conductor gently insert the enlarging tool Figure K Check maximum Figure L Center into the center conductor Pivot the enlarging tool to increase the extraction force with Part Conductor Enlarging diameter Recheck 0 5 and 4 ounce retention force as in step 9 432 026 000 Tool Part 910 121 143 11 Turn the braid back toward the front of the shield conductor Figure If the braid extends beyond shoulder trim braid back to face of shoulder 12 Slide the crimp ring into position over the braid and crimp using the Hex Crimp Tool Part 910 101 115 Figure N in hex position A for the larger end first and in hex position C for the smaller section of the crimp ring Figure O To ensure proper crimp position slide the shield conductor over pin on locator attached to hex crimp tool Wire must not be allowed to pull on center conductor during crimping for example long wire hanging down to floor 15 Use the inspection depth gauge to verify the 06 1 52 mm dimension See step 8 POSITION C Figure O Crimp positions 1 6 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 1 VIRGINIA PANEL CORPORATION MINI COAXIAL RECEIVER CONTACT ASSEMBLY PART 610 104 149 FOR RG316 DOUBLE SHIELDED TOOLS REQUIRED Center Conductor Enlarging Tool Part 910 121 143 Center Conductor Forming Tool Part 910 121 1
45. tor 1 4 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 1 VIRGINIA PANEL CORPORATION MINI COAXIAL RECEIVER CONTACT ASSEMBLY PART 610 104 141 FOR RGI78 ASSEMBLY INSTRUCTIONS CONTINUED 7 Calibrate the Inspection Depth Gauge Part 910 121 156 Figure ee G by loosening the dial face retaining screw until the dial face allows itself to be turned Insert the Calibration Plug Part 414 854 104 into base of gauge 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 40 and 80 DETAIL A 8 Check the 06 1 52 mm dimensions with the inspection depth gauge Figure G Push the contact onto the pressure plunger of the gauge After attaining a positive stop and while holding firm pressure push the plunger on top of the dial to push collar over Teflon read the dial on the gauge If the pointer measures between 40 and 80 go to step 8 If the pointer is out of range repeat steps 1 6 Figure G Inspection Depth Gauge Part 910 121 156 9 Check the minimum extraction force of 0 5 ounce with Part 432 025 000 Slide the female center conductor over approximately 3 4 of the length of the tip in the weight gauge Figure H weight gauge should remain mated with the center conductor as the center conductor is sl
46. ttaining a positive stop and while holding firm pressure push the plunger on top of the dial to push collar over Teflon read the dial on the gauge If the pointer measures between 40 and 80 go to step 9 If the pointer is out of the range repeat steps 1 8 Continued on next page Weight Gauge Kit Part 910 121 131 0 5 oz weight Part 432 025 000 included in Part 910 121 131 4 oz weight Part 432 026 000 included in Part 910 121 131 Dimensions shown millimeters inches ar TANT CONDUCTOR DIELECTRIC WIRE Figure A Strip wire RING n BRAID BACK Figure B Crimp ring 16 76 66 NO GAP PERMISSIBLE CENTER CONDUCTOR SOLDER CONTACT Figure C Assemble wire into contact CONDUCTOR Figure D Slide shield conductor over center conductor TEFLON INSULATOR CENTER CONDUCTOR CONTACT 1 5240 51 06 02 Figure Ensure center conductor is flush with Teflon insulator 1 52 06 j 1 1 r DETAIL A INSPECTION DEPTH GAUGE Figure F Inspection Depth Gauge Part 910 121 156 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 1 VIRGINIA PANEL CORPORATION MINI COAXIAL RECEIVER CONTACT ASSEMBLY PART 610 104 149 FOR RG316 DOUBLE SHIELDED ASSEMBLY INSTRUCTIONS CONTINUED 7 Check minimum extraction force of 0
47. uctions and safety precautions 11 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 ear 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 re heated 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 2 12 For more information visit vpc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATION MINI COAXIAL ITA SOLDER SLEEVE CONTACT ASSEMBLY PART 610 103 140 FOR RG178 PART 610 103 158 FOR RG178 TOOLS REQUIRED Solder Kit includes Holding Fixture and Adapter Part 910 121
48. wn here uses standard 90 series modules The same process is used for modules from other series NOTE If you are using a hybrid module you may need to reference the User s Manual for the other contact type for extraction instructions MINI COAX CONTACT Figure B Be sure to keep the tool perpendicular to avoid bent pins 4 2 For more information visit voc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 5 VIRGINIA PANEL CORPORATION MINI COAXIAL STANDARD 90 SERIES MODULE INSTALLATION AND REMOVAL TOOLS REQUIRED 3 35 Allen Wrench INSTALLATION INSTRUCTIONS 1 Place the module in the receiver or ITA until the Upper and lower module screws touch the mating holes in the inner frame Ensure that Position 1 is located at the top for systems in which the modules are oriented vertically or to the left for systems in which the modules are oriented horizontally 2 Using a 3 32 Allen wrench tighten the top screw 1 to 2 full revolutions while pushing lightly against the face of the module 3 Maintain this pressure while tightening the bottom screw 1 to 2 full revolutions 4 Repeat this sequence until the module is seated Torque the screw to 4 in lbs 0 45 Nm REMOVAL INSTRUCTIONS 1 Toremove loosen the top screw 1 to 2 full revolutions Loosen bottom screw 1 to 2 full revolutions 2 Repeat this sequence until the module is separated from the receiver or ITA NOTE For optimum pe
49. y steps 8 and 9 can be skipped 12 For more information visit vpc com 9 24 10 MINI COAXIAL CONTACTS AND MODULES USER S MANUAL SECTION 1 VIRGINIA PANEL CORPORATION MINI COAXIAL RECEIVER CONTACT ASSEMBLY PART 610 104 114 FOR RG316 ASSEMBLY INSTRUCTIONS CONTINUED 10 Check the maximum extraction force of 4 ounces with Part 432 026 000 Slide the female center conductor over approximately 4 of the length of the tip in the weight gauge Figure J The weight gauge should fall off the contact as the contact is slowly lifted and suspended in the air If the weight gauge falls off move to step 10 If weight gauge remains mated with the contact the extraction force is too high and the center conductor needs to be opened with the Center Conductor Enlarging Tool Part 910 121 143 Figure K EXERCISE CAUTION WHEN USING THIS TOOL INSERT AND REMOVE TOOL IN LINE WITH CONTACT TO AVOID BREAKING TIP OF TOOL OR CONTACT To enlarge the center conductor genily insert the enlarging tool into the center conductor Pivot the enlarging tool to increase the diameter Recheck 0 5 and 4 ounce retention force as in step 8 Turn the braid back toward the front of the shield conductor Figure L If the braid extends beyond the shoulder trim the braid back to the face of the shoulder Slide the crimp ring into position over the braid and crimp using the Hex Crimp Tool Part 910 101 115 Figure in hex position A for the larg
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