assembly, installation, and removal of contacts and modules

ASSEMBLY, INSTALLATION, AND REMOVAL OF
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
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 1
MINI COAXIAL RECEIVER CONTACT ASSEMBLY
PART # 610 104 114 FOR RG316
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)
*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]
ASSEMBLY INSTRUCTIONS
inches
17.78
.70
1.
Strip wire (Figure A).
2.
Slide the crimp ring onto the wire (Figure B).
3.
Turn braid back over outer insulation (Figure C).
10.16
.40
4.32
.17
CENTER CONDUCTOR WIRE
*4. Solder center conductor wire into center conductor contact and
clean (Figure D). VPC solders per IPC’S J-STD-001.
NOTE: Center conductor contact and dielectric must touch.
5.
Slide shield conductor over center conductor until the center
conductor stops in the Teflon® shield (Figure E).
NOTE: Shield conductor and Teflon insulator are supplied as an
assembly.
DIELECTRIC
OUTER INSULATION
SHIELD BRAID
Figure A. Strip wire.
CRIMP RING
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
THAT 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
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MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 1
MINI COAXIAL RECEIVER CONTACT ASSEMBLY
PART # 610 104 114 FOR RG316
ASSEMBLY INSTRUCTIONS, CONTINUED
6.
7.
[1.52]
.06
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 the pointer points to “0.” Re-tighten the retaining
screw. Adjust locating markers to “40” and “80.”
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
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.
DETAIL A
Figure F. Inspection Depth Gauge, Part # 910 121 156.
*8. Check the minimum extraction force of 0.5 ounce with
Part # 432 025 000. Slide female center conductor over
approximately 3/4 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
suspended 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 properly, steps 8 and 9 can be skipped.
1-2
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VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 1
MINI COAXIAL RECEIVER CONTACT ASSEMBLY
PART # 610 104 114 FOR RG316
ASSEMBLY INSTRUCTIONS, CONTINUED
*9. 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 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, 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 8.
Figure J. Check maximum
weight with Part # 432 026
000.
10. 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.
11. Slide the crimp ring into position over the braid and crimp using the
Hex Crimp Tool, Part # 910 101 115 (Figure M), in hex position “A” for
the larger 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).
Figure K. Center
Conductor Enlarging
Tool, Part # 910 121
143.
BRAID
SHOULDER
Figure L. Braid turned over shield conductor.
12. Use the inspection depth gauge to verify the .06” [1.52 mm]
dimension. See step 7.
Figure M. Hex Crimp Tool, Part # 910 101 115.
CRIMP RING
POSITION “A”
POSITION “C”
Figure N. Crimp positions.
*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.
1-3
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VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 1
MINI COAXIAL RECEIVER CONTACT ASSEMBLY
PART # 610 104 141 FOR RG178
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)
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]
ASSEMBLY INSTRUCTIONS
[16.51]
0.65
[9.90]
0.39
1.
Strip wire (Figure A).
2.
Slide the crimp ring onto the wire (Figure B).
3.
Turn braid back over outer insulation (Figure C).
4.
Slide the spacer tube over 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.
OUTER INSULATION
BRAID
DIELECTRIC
inches
[4.32]
0.17
CONDUCTOR
WIRE
Figure A. Strip wire.
Figure B. Crimp ring.
Figure C. Turn braid back.
Continued on next page...
Figure D. Spacer tube.
Figure E. Ensure solder is visible in hole.
Figure F. Shield conductor.
1-4
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VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 1
MINI COAXIAL RECEIVER CONTACT ASSEMBLY
PART # 610 104 141 FOR RG178
ASSEMBLY INSTRUCTIONS, CONTINUED
7.
8.
Calibrate the Inspection Depth Gauge, Part # 910 121 156 (Figure
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.”
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.
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). 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 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.
[1.52]
.06
DETAIL A
A
Figure G. Inspection Depth Gauge, Part # 910 121 156.
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.
1-5
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VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 1
MINI COAXIAL RECEIVER CONTACT ASSEMBLY
PART # 610 104 141 FOR RG178
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).
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.
Figure K. Check maximum
extraction force with Part #
432 026 000.
BRAID
11. Turn the braid back toward the front of the shield conductor
(Figure M). 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.
Figure L. Center
Conductor Enlarging
Tool, Part # 910 121 143.
SHOULDER
Figure M. Turn braid back over shield conductor.
Figure N. Hex Crimp Tool, Part # 910 101 115.
CRIMP RING
POSITION "A"
POSITION"C"
Figure O. Crimp positions.
1-6
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VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 1
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 # 910 121 119
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)
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]
ASSEMBLY INSTRUCTIONS
16.76
.66
1.
Strip wire (Figure A).
2.
Slide the crimp ring onto the wire (Figure B).
3.
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).
4.
Insert the center conductor of the wire into the center conductor
contact, solder and clean (Figure C). VPC solders per IPC’S
J-STD-001.
NOTE: Center conductor contact and dielectric must touch.
5.
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.
9.4
.37
BRAID
DIELECTRIC
Check to ensure that the center conductor is flush with the Teflon
insulator (Figure E).
7.
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.”
8.
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 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 9. If the pointer is out of the range, repeat
steps 1-8.
[4.31]
.17
CONDUCTOR
WIRE
Figure A. Strip wire.
CRIMP RING
FOLD BRAID BACK
Figure B. Crimp ring.
NO GAP PERMISSIBLE
SOLDER
6.
inches
CENTER CONDUCTOR
CONTACT
Figure C. Assemble wire into contact.
SHIELD CONDUCTOR
Figure D. Slide shield conductor over center conductor.
TEFLON INSULATOR
1.52±0.51
.06±.02
CENTER CONDUCTOR
CONTACT
Figure E. Ensure center conductor is flush with Teflon
insulator.
[1.52]
.06
0
DETAIL A
Continued on next page...
A
INSPECTION DEPTH GAUGE
Figure F. Inspection Depth Gauge, Part # 910 121 156.
1-7
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MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 1
MINI COAXIAL RECEIVER CONTACT ASSEMBLY
PART # 610 104 149 FOR RG316 DOUBLE SHIELDED
ASSEMBLY INSTRUCTIONS, CONTINUED
9.
Check minimum extraction force of 0.5 ounce with Part # 432
025 000. Slide female center conductor over approximately 3/4
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.
10. Check maximum extraction force of 4 ounces with Part # 432 026
000. Slide female center conductor over approximately 3/4 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 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).
Figure G. Check minimum
extraction force with Part #
432 025 000.
Figure H. Center Conductor
Forming Tool, Part # 910
121 119.
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.
11. Turn both braids back over the shield conductor (Figure L). If the
braid extends beyond the shoulder, trim the braid back to the
face of the shoulder.
12. Slide the crimp ring over the braid and shield conductor (Figure
M) and crimp using the Hex Crimp Tool, Part # 910 101 115, in
hex position “A”. To ensure proper crimp position, slide the shield
conductor over the dowel pin on the hex crimp tool. The wire
must not be allowed to pull on the center conductor during
crimping (For example, long wire hanging down to floor).
13. Use the inspection depth gauge to verify the .06” [1.52 mm]
dimension. See step 8.
Figure J. Check maximum
extraction force with Part # 432
026 000.
Figure K. Center
Conductor Enlarging
Tool, Part # 910 121 143.
BRAID
SHOULDER
Figure L. Turn braids back over shield conductor.
CRIMP RING
CRIMP POSITION "A"
Figure M. Slide the crimp ring over the braid and crimp.
1-8
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MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 1
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]
ASSEMBLY INSTRUCTIONS
1.
25.40
1.00
Strip outer jacket (Figure A).
2.Cut 3/16 tubing 1.75” long and slide over jacket (Figure A).
3.
Slide crimp ring over braid (Figure B).
4.
Turn braid over crimp ring and cut .125” off dielectric and strip
center conductor (Figure C).
5.
Solder wire into center contact and clean. Make sure contact
touches dielectric (Figure D). VPC solders per IPC’S J-STD-001.
6.
7.
inches
BRAID
SHRINK TUBING
Figure A. Strip outer jacket.
CRIMP RING
Figure B. Slide crimp ring over braid.
Slide shield assembly over center conductor (Figure E). NOTE: Make sure the Teflon® in the shield assembly touches wire
dielectric.
Turn braid back toward the front of the shield conductor (Figure
F). If braid extends beyond shoulder, trim back to face of
shoulder.
FOLD BRAID
OVER CRIMP RING
2.54
.100
DIELECTRIC
CONDUCTOR
WIRE
Figure C. Fold braid back.
NO GAP PERMISSIBLE
8.
9.
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
center conductor during crimping (Example: Long wire hanging
down to floor).
Slide tubing to back of shoulder and shrink into place. Make sure
that the tubing does not extend over the shoulder of the shield
conductor.
SOLDER
Figure D. Solder center conductor.
NO GAP PERMISSIBLE
SHIELD CONDUCTOR
Figure E. Install shield conductor.
10. It is recommended that the Inspection Depth Gauge, Part # 910
121 156, be used to verify the .06 +/- .02 dimension (Figure H).
FOLD BRAID OVER
SHIELD CONDUCTOR
SHOULDER
Figure F. Turn braid back over contact.
CRIMP POSITION "A"
Figure G. Crimp positions.
1.524±0.508
.060±.020
Figure H. Verify dimension.
1-9
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MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 1
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 # 910 121 167 - 220V
Dimensions shown: [millimeters]
9.14±0.38
.360±.015
ASSEMBLY INSTRUCTIONS
1.
Strip wire (Figure A).
2.
Straighten the center conductor making sure the stranded center conductor is
twisted into its original lay.
3.
Tin stranded center conductor with Sn63 solder per QQ-S-571. Use RMA flux per
MIL-F-14256 (Alpha #611 or equivalent).
4.
inches
Make sure the shield braid is trimmed evenly and no loose strands are extending
out across the exposed dielectric or cable jacket.
4.83±0.38
.190±.015
2.92±0.38
.115±.015
BRAID
DIELECTRIC
CONDUCTOR
WIRE
Figure A. Strip wire.
1.65
.065
REAR INSPECTION WINDOW
CENTER CONDUCTOR WIRE
FORWARD INSPECTION WINDOW
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 the braid from catching.
7.
8.
9.
Figure B. Contact on wire.
CONTACT
1.52
.06
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].
SIDE MARKED "S"
ADAPTER
Install the Adapter, Part # 910 121 149, onto the Holding Fixture, Part # 910 121 144
(Figure C). Insert contact in the adapter side marked “S” for socket, and set up
the dimensions (Figure C).
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.
FORWARD INSPECTION
WINDOW
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 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.
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
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VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 1
MINI COAXIAL RECEIVER, SOLDER SLEEVE® , CONTACT ASSEMBLY
PART # 610 104 142 FOR RG178 AND JOY CABLE (TYPE 033, 93 OHMS)
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 # 910 121 167 - 220V
Dimensions shown: [millimeters]
ASSEMBLY INSTRUCTIONS
7.37
.290
1.
Strip wire (Figure A).
2.
Straighten the center conductor making sure the stranded center conductor
is twisted into its original lay.
3.
Tin stranded center conductor with Sn63 solder per QQ-S-571. Use RMA flux
per MIL-F-14256 (Alpha #611 or equivalent).
4.
Fold the center conductor back on itself (Figure B).
5.
Make sure the shield braid is trimmed evenly and no loose strands are
extending out across the exposed dielectric or cable jacket.
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
contact onto the cable until it stops. Rotating the contact slightly during
cable insertion will help prevent the braid from catching.
8.
9.
inches
BRAID
DIELECTRIC
Figure A. Strip wire.
5.46
.215
CONDUCTOR
WIRE
Figure B. Fold center conductor.
1.65
.065
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 D).
3.56
.140
REAR INSPECTION WINDOW
CENTER CONDUCTOR WIRE
FORWARD INSPECTION WINDOW
Figure C. Contact on wire.
CONTACT
1.52
.06
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.
FORWARD INSPECTION
WINDOW
SIDE MARKED "S"
ADAPTER
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 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.
HOLDING FIXTURE
Figure D. Holding fixture.
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 contact
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 should be visible through one of the forward inspection windows.
1-11
For more information visit vpc.com
9/24/10
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 2
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)
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]
ASSEMBLY INSTRUCTIONS
1.
Strip wire (Figure A).
2.
Slide the crimp ring onto the wire (Figure B).
3.
Turn braid back over outer insulation (Figure C).
4.
Solder wire into center conductor and clean (Figure D). VPC
solders per IPC’S J-STD-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.
[17.01]
.67
Turn the braid back toward the front of the shield conductor
(Figure F). If braid extends beyond shoulder, trim back to face
of shoulder.
OUTER
INSULATION
inches
[8.38]
.33
[3.81]
.15
CONDUCTOR
WIRE
DIELECTRIC
BRAID
Figure A. Strip wire.
CRIMP RING
Figure B. Crimp ring.
BRAID
Figure C. Fold braid back.
Continued on next page...
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.
BRAID
SHOULDER
Figure F. Fold braid over.
2-1
For more information visit vpc.com
9/24/10
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 2
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.” Re-tighten retaining screw. Adjust locating
markers to “20” and “90.”
9.
Figure G. Slide crimp ring over braid.
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
the locator pin (Figure K). Crimp using the Hex Crimp Tool, Part
# 910 101 115 (Figure L) in hex position “A” for the larger end
first, and in hex position “B” 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...
DETAIL A
A
Figure H. Inspection Depth Gauge, Part # 910 121 157.
[0.254]
.010
Figure J. Check dimensions.
POSITION "A"
LOCATOR
POSITION "B"
Figure K. Slide shield conductor over pin on locator.
Figure L. Hex Crimp Tool, Part # 910 101 115.
2-2
For more information visit vpc.com
9/24/10
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 2
MINI COAXIAL ITA CONTACT ASSEMBLY
PART # 610 103 115 FOR RG316
ASSEMBLY INSTRUCTIONS, CONTINUED
11. 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, 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.
12. 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 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 11 and 12. Do not pass slotted end of contact.
Figure M. Check minimum
extraction force with Part #
414 852 000.
Figure N. Outer Shield
Conductor Expanding
Tool, Part # 910 121 142.
13. Use the inspection depth gauge to verify the .01” [.25
mm] dimension. See step 9.
Figure O. Check maximum
extraction force with Part #
414 853 000.
2-3
For more information visit vpc.com
Figure P. Outer Shield
Conductor Forming Tool,
Part # 910 121 126.
9/24/10
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 2
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
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)
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]
ASSEMBLY INSTRUCTIONS
17.27
.68
1.
Strip wire (Figure A).
2.
Slide the crimp ring onto the wire (Figure B).
3.
Turn braid back over outer insulation (Figure C).
4.
Slide the spacer tube over dielectric to edge of the braid (Figure
D). Heat spacer tube until spacer shrinks to hold onto dielectric.
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.
6.
7.
9.14
.36
4.32
.17
Slide the shield conductor over the 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
(Figure E).
NOTE: Shield conductor and teflon insulator are supplied as an
assembly.
OUTER
INSULATION
CONDUCTOR
WIRE
DIELECTRIC
BRAID
Figure A. Strip wire.
CRIMP RING
Figure B. Crimp ring.
CRIMP RING
FOLD BRAID BACK
Figure C. Turn braid back.
SPACER TUBE
CENTER CONDUCTOR
CONTACT
Turn braid back over the shield conductor (Figure F). If braid
extends beyond shoulder, trim back to face of shoulder.
Continued on next page...
inches
SOLDER
NO GAP PERMISSIBLE
Figure D. Install center conductor contact.
SMALL GAP
SHOULDER
Figure E. Install shield conductor.
FOLD BRAID OVER
SHIELD CONDUCTOR
SHOULDER
Figure F. Turn braid over contact.
2-4
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9/24/10
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 2
MINI COAXIAL ITA CONTACT ASSEMBLY
PART # 610 103 130 FOR RG178, PART # 610 103 157 FOR RG178
ASSEMBLY INSTRUCTIONS, CONTINUED
8.
Slide crimp ring into position over the braid (Figure G). Do not
crimp.
CRIMP RING
9.
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.”
POSITION “C”
10. 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.
11. To ensure proper crimp position, slide the shield conductor over
the locator pin (Figure G). Crimp using the Hex Crimp Tool, Part
# 910 101 115 (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).
POSITION “A”
Figure G. Crimp locations.
[.25]
.01- .
DETAIL A
A
Figure H. Inspection Depth Gauge, Part # 910 121 157.
Continued on next page...
Figure J. Hex Crimp Tool, Part # 910 101 115.
2-5
For more information visit vpc.com
9/24/10
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 2
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.
13. 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 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.
CHAMFER
Figure K. Check minimum
extraction force with Part #
414 852 000.
Figure L. Outer Shield
Conductor Expanding
Tool, Part # 910 121 142.
14. Use the inspection depth gauge to verify the .01” [.25 mm]
dimension. See step 10.
CHAMFER
Figure M. Check maximum
extraction force with Part #
414 853 000.
2-6
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Figure N. Shield Conductor
Forming Tool, Part # 910
121 126.
9/24/10
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 2
MINI COAXIAL ITA CONTACT ASSEMBLY
PART # 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
Dimensions shown: [millimeters]
CRIMP TOOL SETUP
1.
2.
Set up Crimp Tool, Part # 910 101 118 (Figure A), by loosening the
latch locking screw (counter-clockwise, until turning stops). Remove
any previously used locator.
Insert the open end of the Locator, Part # 910 104 128 (Figure B),
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.
inches
LATCH ASSEMBLY AND
LOCKING SCREW
LOCATOR DIE
INDENTER
OPENING
MICROCRIMP
ADJUSTING KNOB
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.
See calibration instructions for Part # 910 101 102/103 for pin gauge
verification instructions.
2.
Strip wire (Figure C).
3.
Slide tubing onto wire (Figure C).
4.
Insert contact with wire in place to the depth allowed by die
(Figure D).
5.
Close crimp tool completely until it automatically releases.
6.
Contact should be crimped in correct position with no fractures or
loose crimp.
7.
Gently pull wire to check crimp.
8.
Slide tubing into position and shrink (Figure E).
Figure B. Locator, Part # 910 104 128.
SHRINK TUBING
[4.06]
.16
Figure C. Stripped wire with tubing.
LOCATOR
CRIMP LOCATION
CONTACT
Figure D. Contact in locator.
SHRINK TUBING
CRIMP SETTINGS
WIRE
GAUGE
STRIP LENGTH
(IN [MM])
MAX.
(IN [MM])
MIN.
(IN [MM])
PULLOUT FORCE
(LBS [N])
26
0.160 [4.06]
0.034 [8.63]
0.031 [7.87]
2 [8.89]
24
0.160 [4.06]
0.039 [9.91]
0.035 [8.89]
2 [8.89]
22
0.160 [4.06]
0.037 [9.39]
0.033 [8.38]
2 [8.89]
2-7
Figure E. Shrink tubing must cover crimp.
For more information visit vpc.com
9/24/10
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 2
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)
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]
ASSEMBLY INSTRUCTIONS
[16.76]
.66
1.
Strip wire (Figure A).
2.
Slide the crimp ring onto the wire (Figure B).
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-STD-001.
NOTE: Center conductor and dielectric must touch.
5.
6.
7.
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.
OUTER
INSULATION
inches
[9.4]
.37 [4.31]
.17
CONDUCTOR
WIRE
DIELECTRIC
BRAID
Figure A. Strip wire.
CRIMP RING
FOLD BRAID BACK
Figure B. Fold braid back.
NO GAP PERMISSIBLE
Teflon®
Check to ensure that the
insulator is flush with the tip of
the shield conductor (Figure E).
Turn both braids back over the shield conductor (Figure F). If
the braid extends beyond shoulder, trim braid back to face of
shoulder.
SOLDER
CENTER CONDUCTOR
CONTACT
Figure C. Install center conductor.
Continued on next page...
SMALL GAP
SHIELD CONDUCTOR
Figure D. Install shield conductor.
A
.00
DETAIL A
Figure E. Check flush dimension.
BRAID
SHOULDER
Figure F. Turn braid over contact.
2-8
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9/24/10
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 2
MINI COAXIAL ITA CONTACT ASSEMBLY
PART # 610 103 152 FOR RG316 DOUBLE SHIELDED
ASSEMBLY INSTRUCTIONS, CONTINUED
8.
Slide the crimp ring over the braid and shield conductor (Figure G).
Do not crimp.
9.
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.”
10. 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.
CRIMP RING
Figure G. Crimp ring.
[.25]
.01
DETAIL A
A
INSPECTION DEPTH GAUGE
Figure H. Inspection Depth Gauge, part # 910 121 157.
11. 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"
POSITION "A"
LOCATOR
Figure J. Crimp positions.
Figure K. Hex Crimp Tool, part # 910 101 115.
2-9
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9/24/10
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 2
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 suspended 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.
13. 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] 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 #
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.
Figure M. Outer
Figure L. Check minimum
extraction force with Part # Shield Conductor
Expanding Tool,
414 852 000.
Part # 910 121 142.
14. Use the inspection depth gauge to verify the .01” [.25
mm] dimension. See step 10.
Figure N. Check maximum
extraction force with Part #
414 853 000.
2-10
For more information visit vpc.com
Figure O. Outer
Shield Conductor
Forming Tool, Part #
910 121 126.
9/24/10
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 2
MINI COAXIAL ITA CONTACT ASSEMBLY
PART # 610 103 161 FOR 24 & 26 AWG TWISTED PAIR
Dimensions shown: [millimeters]
TOOLS REQUIRED
Crimp Tool, Part # 910 101 118
Crimp Tool, Part # 910 101 115
Crimp Locator, Part # 910 104 128
inches
LATCH ASSEMBLY AND
LOCKING SCREW
CONTACT
LOCATOR DIE
INDENTER
OPENING
CRIMP TOOL SETUP
1.
Set up 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.
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
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.
MICROCRIMP
ADJUSTING KNOB
MICROCRIMP INDICATOR
Figure A. Crimp Tool, Part # 910 101 118.
ASSEMBLY INSTRUCTIONS
1.
2.
Select correct crimp setting for gauge wire to be used. See Table
below. While in closed position, check diameter of the 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. See calibration instructions for Part # 910
101 102/103 for pin gauge verification instructions.
Untwist 2” [50.8 mm] of twisted wire. Cut 0.5” [12.7 mm] off the white
wire and strip white wire 0.160” [4.06 mm] (Figure C).
Figure B. Locator, Part # 910 104 128.
[50.8]
2.00 REF.
Figure C. Cut and strip wire.
CRIMP RING
3.Slide 1/16 [1.58 mm] shrink tubing 0.25” [6.35 mm] long over white wire.
Slide crimp ring over both wires (smaller end first) (Figure D).
4.
Insert 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.
5.
Slide shield conductor over center conductor until it stops (Figure E).
6.
Slide shrink tubing over crimped area so that it covers all exposed areas
of center conductor and touches dielectric. Heat to shrink (Figure F).
7.
Re-twist black wire around white conductor and shield. Trim excess wire
that extends beyond the shoulder of the shield conductor. Strip black
wire such that insulation still covers shrink tubing but not crimp area on
shield. Unravel and flare strands around shield (Figure G).
8.
To ensure proper crimp position, slide shield conductor over the locator
pin. Crimp using the Hex Crimp Tool, Part # 910 101 115 (Figure H) in hex
position “A” for the larger side and hex position “B” for the smaller end
(Figure J). Wire must not be allowed to pull on the center conductor
during crimping (for example, long wire hanging down to floor).
[12.7]
.50
[4.06]
.16
SHRINK TUBING
Figure D. Crimp ring and shrink tubing.
SHIELD CONDUCTOR
CRIMP LOCATION
Figure E. Install shield conductor.
SHRINK TUBING
Figure F. Shrink tubing.
UNRAVEL STRANDS TO FLARE
AROUND SHIELD
CUT BLACK WIRE HERE AND
TRIM STRANDS AFTER UNRAVELING
SHOULDER
Figure G. Apply crimp ring.
CRIMP SETTINGS
WIRE
GAUGE
MAX.
(in [mm])
MIN.
(in [mm])
PULLOUT FORCE
(lbs [N])
26
0.032 [8.12]
0.028 [7.11]
2 [8.89]
24
0.039 [9.91]
0.035 [8.89]
2 [8.89]
22*
0.044 [11.17]
0.039 [9.91]
2 [8.89]
*Acceptable Stranding: 1 x 22; 7 x 30
2-11
Figure H. Crimp tool, Part # 910 101 115.
POSITION "B"
POSITION "A"
Figure J. Crimp locations.
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9/24/10
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 2
MINI COAXIAL ITA, SOLDER SLEEVE® , CONTACT ASSEMBLY
PART # 610 103 140 FOR RG316, PART # 610 103 158 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 # 910 121 167 - 220V
Dimensions shown: [millimeters]
inches
9.144
.360
4.826
.190
ASSEMBLY INSTRUCTIONS
2.921
.115
1.
Strip wire (Figure A).
2.
Straighten the center conductor making sure the stranded center conductor is
twisted into its original lay.
3.
Tin stranded center conductor with Sn63 solder per QQ-S-571. Use RMA flux per
MIL-F-14256 (Alpha #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.
BRAID
DIELECTRIC
Figure A. Strip wire.
0.381
.015
REAR INSPECTION WINDOW
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.
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
144 (Figure C). Insert a contact in the adapter side marked “P” for pin, and set
up the dimensions (Figure C).
9.
CONDUCTOR
WIRE
CENTER CONDUCTOR
FORWARD INSPECTION WINDOW
Figure B. Contact on wire.
CONTACT
1.52
.06
FORWARD INSPECTION
WINDOW
SIDE MARKED "P"
ADAPTER
HOLDING FIXTURE
Figure C. Solder fixture.
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.
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 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
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9/24/10
VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 2
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 # 910 121 144
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
Dimensions shown: [millimeters]
ASSEMBLY INSTRUCTIONS
7.36
.290±.015
1.
Strip wire (Figure A).
2.
Straighten the center conductor making sure the stranded center conductor is
twisted into its original lay.
3.
Tin stranded center conductor with Sn63 solder per QQ-S-571. Use RMA flux per
MIL-F-14256 (Alpha #611 or equivalent).
4.
Fold the center conductor back on itself (Figure B).
5.
Make sure the shield braid is trimmed evenly and no loose strands are extending
out across the exposed dielectric or cable jacket.
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.
8.
9.
inches
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].
3.81
.150±.015
BRAID
DIELECTRIC
Figure A. Strip wire.
5.46±0.38
.215±.015
CONDUCTOR
WIRE
Figure B. Fold center conductor.
0.381
.015
REAR INSPECTION WINDOW
CENTER CONDUCTOR
FORWARD INSPECTION WINDOW
Figure C. Contact on wire.
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
dimensions (Figure D).
CONTACT
1.52
.06
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.
11. Attach the appropriate reflector to the heating tool. See instruction sheet
accompanying heat gun for instructions and safety precautions.
FORWARD INSPECTION
WINDOW
SIDE MARKED "P"
ADAPTER
HOLDING FIXTURE
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 contact
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
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VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 3
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
work for wire wrapping. VPC recommends 26 to 30 AWG wire.
1.
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 to the user manual of your wire-wrap gun to determine in which
fashion your tool operates.
2.
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 the way through the wire
slot until it goes out of the cutting window. The simplified sleeve of the
manual tool has no notch.
3.
Hold the wire in place by hand (Figure A).
Figure A. Wire wrap gun with wire.
4. 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.
5.
3-1
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 B. Completed wrapped wire.
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VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 4
MINI COAXIAL RECEIVER CONTACT INSTALLATION AND REMOVAL
TOOLS REQUIRED
0.050” Allen Wrench
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 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
1.
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).
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
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
(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.
5.
Once the extraction tool is seated and the retaining ring tabs on the
contact are compressed, push the plunger. The contact will be pushed out
of the rear of the module.
6.
For 19 and 76 position modules, do not tighten screws. Insert an ITA contact
in positions 2 and 18 or 2A and 18A (for 76 position modules) to properly
align the module cap. With the ITA contacts in place, tighten the module
cap screws. Do not over-tighten screws; screw torque limit is 13 +/- 1 in-oz.
For all other modules, replace the module cap (Figure C) using both hands
to push the separated halves together. Replace and tighten the module
cap screws to a maximum torque of 2 in-lbs [0.23 Nm].
Figure A. Extraction Tool, Part # 910 112 104.
Figure B. Be sure to keep the tool perpendicular so as to
avoid bent pins.
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.
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.
4-1
Figure C. Module Cap Alignment Diagram.
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VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 4
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 contact 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.
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).
Figure A. Extraction Tool, Part # 910 112 104.
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.
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 B. Be sure to keep the tool perpendicular to
avoid bent pins.
4-2
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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
/32 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].
POSITION 1
REMOVAL INSTRUCTIONS
1.
To remove, 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.
Figure A. Receiver Module.
NOTE: For optimum performance and system longevity, distribute
the contact load evenly throughout the module.
Figure B. ITA Module.
5-1
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VIRGINIA PANEL CORPORATION
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 5
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.
1.
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].
Figure A. Receiver Module.
REMOVAL INSTRUCTIONS
1. To remove, 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 performance and system longevity, distribute the
contact load evenly throughout the module.
Figure B. ITA Module.
5-2
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6-1
510 108 210
510 161 102
510 161 103
510 161 104
510 114 108
510 114 109
910 101 115
910 121 155
910 121 157
610 103 115
X
X
X
X
X
X
X
X
X
X
X
610 103 130
X
X
X
X
X
X
X
X
X
X
X
X
X
X
610 103 136
X
X
X
X
X
X
X
X
X
X
X
610 103 140
X
X
X
X
X
X
X
X
X
X
X
610 103 152
X
X
X
X
X
X
X
X
X
X
X
X
610 103 157
X
X
X
X
X
X
X
X
X
X
X
610 103 158
X
X
X
X
610 103 161
X
X
X
610 103 166
X
X
610 103 172
X
610 113 146
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
910 121 142
910 112 104
910 121 119
910 121 131
910 121 143
X
X
X
X
X
X
610 104 140
X
X
X
X
X
X
X
X
610 104 141
X
X
X
X
X
X
X
X
610 104 142
X
X
X
X
X
X
X
X
610 104 149
X
X
X
X
X
X
610 104 154
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
For more information visit vpc.com
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
910 121 156
910 121 149
910 121 167
X
910 121 160
X
X
X
X
X
X
X
X
X
X
X
X
910 121 167
910 101 115
X
910 121 160
510 113 122
X
910 121 149
510 113 121
X
910 121 144
510 160 104
X
X
MISC.
910 121 126
510 160 103
X
910 121 144
EXTRACTION
910 112 104
EXTRACTION
510 160 102
X
X
LOCATOR
CRIMP TOOL
510 104 243
X
MISC.
CASS/
80 SERIES
RECEIVER
MODULES
ICON
RECEIVER
MODULES
510 104 150
STANDARD/
90 SERIES
RECEIVER
MODULES
510 104 120
610 104 114
X
910 104 128
CRIMP
TOOLS
CASS/ 80
SERIES ITA
MODULES
ICON ITA
MODULES
STANDARD/
90 SERIES
ITA
MODULES
RECEIVER
CONTACTS
910 101 118
510 108 132
ITA
CONTACTS
510 108 111
MINI COAXIAL CONTACTS AND MODULES USER’S MANUAL: SECTION 6
VIRGINIA PANEL CORPORATION
CROSS REFERENCE TABLES
X
X
X
X
9/24/10