VIRGINIA PANEL CORPORATION HIGH POWER CONTACTS AND MODULES USER’S MANUAL: SECTION 1 HIGH POWER RECEIVER CONTACT ASSEMBLY PART # 610 149 101 FRONT PLATE TOOLS REQUIRED Wire Cutter Jacket Stripper Pneumatic Crimp Tool Kit, Part # 910 102 116, (Figure A) includes: • High Power Pneumatic Crimper • High Power Contact Locator • High Power Contact Die Set Point Micrometer Heat Gun Figure A. Pneumatic crimper. HIGH POWER PNEUMATIC CRIMPER CRIMP TOOL SETUP HIGH POWER CONTACT LOCATOR 1. Disconnect airline. HIGH POWER CONTACT DIE SET 2. Install locator into locator cavity (Figure B). 3. Install die set into pneumatic crimper (Figure B). 4. Ensure front plate is installed on crimper (Figure A). 5. Re-connect airline. Figure B. Exploded view of pneumatic crimper. INSPECTION HOLE ASSEMBLY INSTRUCTIONS 1. Figure C. Crimped contact. Cut wire to length. 2. Strip wire 0.75" (19.05 mm). 3. Carefully insert wire into the wire end of the contact. NOTE: Be careful not to disturb the natural lay of the individual wire strands, this could make it difficult to insert the strands into the contact. 4. Place the contact into the crimper cavity until it completely bottoms out against the end of the locator. 5. Depress button to crimp and then remove the crimped wire and contact from the crimp cavity (Figure C). 6. Inspect the location of crimp indentions. Indentions should be located between the wire end of the crimp barrel and the wire inspection hole. The wire should be visible in the inspection hole (Figure C). 7. Use a point micrometer to measure the crimp height across the crimp indentions. Measure across the crimp indentions, rotate the contact 90° and measure across remaining crimp indentions. The measurement should be 0.279" ± 0.005" [7.087 ± 0.127 mm] (Figure D). 8. Slide a 2" piece of Ø0.5" shrink tubing over the contact up to the first shoulder from the wire end of the contact covering the inspection hole and shrink in place with heat gun (Figure E). NOTE: Contact tested and designed for specific use with Cooner Wire CW6044-14(UL Rated), AS 105-14(Non-UL), or equivalent. If using a wire other than prescribed, reference “5.3.5 Machined Contacts - CMA buildup” of the IPC/WHMA-A-620A standard. NOTE: Recommended CMA range for this contact falls between 63,206 and 66,499 with a max conductor Ø of .340" [8.636 mm] and a min conductor Ø of .315" [8.001 mm]. To calculate CMA please reference Figure F. Figure D. Measuring crimp. Figure E. Applied shrink tubing. Stranded Wire AWG D D Number of Strands Metric Dimensions CMA = D2 x N x 1550.003 CMA = Circular Mil Area D = Diameter of Single Strand in millimeters N = Number of Strands U.S. Customary Dimensions CMA = D2 x N CMA = Circular Mil Area D = Diameter of Single Strand in mils N = Number of Strands Figure F. Calculate circular mil area. 1-1 For more information visit vpc.com 11/25/2014