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FCI OCTIS 10135748-101LF Application Specification Download Page 14

NUMBER 

GS-20-0454 

TYPE 

APPLICATION SPECIFICATION 

                                      

 

TITLE 

PAGE 

REVISION

 

 

OCTIS PLUG KIT ASSEMBLY 

– HYBRID, SIGNAL & POWER 

14 of 30 

D 

AUTHORIZED BY 

DATE

 

Stalin Alosius

 

2019-09-12

 

 

CLASSIFICATION

 

UNRESTRICTED 

 

Copyright   FCI  
 
Form E-3334  
Rev F   

 
Form E-3334  
Rev F   

 

9  APPLICATION TOOLING 

 

Product number

 

Tool description

 

10137182-001 

Semi automatic IDC Cable Terminator (Fig 6) 

10135856-001 

IDC table top pistol for Metral HDXS Octis Cable Connector 
(Fig 7) 

10135701-001 

Octis Power Profile Crimping Tool (Fig 8) 

10141086-001

 

Octis Signal Crimping Tool (Fig 9)

 

Cable stripper

 

General available cable stripper

 

 

 

  

 

 

 

   

 

 

 

    

Figure 6: 10137182-001

  

 

     

 

 

 

Figure 7: 10135856-001

 

 
 
 
 

 

 

 

 

 

 

 
 
 

  

 

 

Figure 8: 10135701-001 

 

     

Figure 9: 10141086-001 

 

 

PDS: Rev :D

STATUS:Released

Printed:  Sep 18, 2019

Summary of Contents for OCTIS 10135748-101LF

Page 1: ...ype 7 2 OBJECTIVE 8 3 SCOPE 8 4 GENERAL 8 5 DRAWINGS AND APPLICABLE DOCUMENTS 8 6 APPLICATION REQUIREMENTS 8 7 RECOMMENDED WIRE SIZES AND INSULATIONS 8 7 1 Wire insulation materials 8 7 2 Maximum insulation diameters and wire sizes 9 7 2 1 Signal Contact 9 7 2 2 Power Contact 9 7 2 3 Crimp on Wire Power Contact 10 8 ACCEPTABLE WIRE TERMINATION 11 8 1 Termination requirements visual 11 8 1 1 Wire L...

Page 2: ...4 Rev F Form E 3334 Rev F 10 3 Cable IDC 19 10 3 1 Crimping Process Method 1 19 10 3 2 Crimping Process Method 2 23 10 4 OCTIS Assembly 24 10 4 1 Assembling Hybrid Signal Power Combo Connector 24 10 4 2 Assembling Signal Metral HDXS Connector 29 10 4 3 Assembling Power Profile connector 2 and 3 position power connector 29 10 5 OCTIS EMI cap assembly 30 11 REVISION RECORD 30 PDS Rev D STATUS Releas...

Page 3: ...f 30 D AUTHORIZED BY DATE Stalin Alosius 2019 09 12 CLASSIFICATION UNRESTRICTED Copyright FCI Form E 3334 Rev F Form E 3334 Rev F 1 ASSEMBLING OF OCTIS KITS USER INSTRUCTION 1 1 CRIMPED TYPE Hybrid Signal Power Combo connector interface Plug Kit Part Number 10135748 101LF PDS Rev D STATUS Released Printed Sep 18 2019 ...

Page 4: ...Y HYBRID SIGNAL POWER 4 of 30 D AUTHORIZED BY DATE Stalin Alosius 2019 09 12 CLASSIFICATION UNRESTRICTED Copyright FCI Form E 3334 Rev F Form E 3334 Rev F 1 2 CRIMPED TYPE Signal Metral HDXS connector interface Plug kit Part Number 10135750 101LF PDS Rev D STATUS Released Printed Sep 18 2019 ...

Page 5: ...LY HYBRID SIGNAL POWER 5 of 30 D AUTHORIZED BY DATE Stalin Alosius 2019 09 12 CLASSIFICATION UNRESTRICTED Copyright FCI Form E 3334 Rev F Form E 3334 Rev F 1 3 CRIMPED TYPE Power Pwr Profile connector interface Plug Kit Part Number 10135752 101LF PDS Rev D STATUS Released Printed Sep 18 2019 ...

Page 6: ...BRID SIGNAL POWER 6 of 30 D AUTHORIZED BY DATE Stalin Alosius 2019 09 12 CLASSIFICATION UNRESTRICTED Copyright FCI Form E 3334 Rev F Form E 3334 Rev F 1 4 SCREW TYPE 2 position Power Pwr Profile connector interface Plug Kit Part Number 10143760 101NLF PDS Rev D STATUS Released Printed Sep 18 2019 ...

Page 7: ...BRID SIGNAL POWER 7 of 30 D AUTHORIZED BY DATE Stalin Alosius 2019 09 12 CLASSIFICATION UNRESTRICTED Copyright FCI Form E 3334 Rev F Form E 3334 Rev F 1 5 SCREW TYPE 3 position Power Pwr Profile connector interface Plug Kit Part Number 10143759 101NLF PDS Rev D STATUS Released Printed Sep 18 2019 ...

Page 8: ...en the product drawings and this specification the drawings take precedence 5 DRAWINGS AND APPLICABLE DOCUMENTS FCI product drawings and specifications are available by accessing the FCI website or contacting the FCI Technical Service In the event of a conflict between this specification and the product drawing the drawing takes precedence Customers should refer to the latest revision level of FCI...

Page 9: ...m inch 26 gauge solid 0 74 0 0291 0 4mm solid 0 74 0 0291 24 gauge 1 00 0 0394 0 5mm solid 1 00 0 0394 Certain wire sizes other than those recommended above can be inserted in the contact IDC but must be qualified individually The specification of the cable using the stranded wire must have the wire insulation type wire insulation thickness number of strands size of strands and twist of strands co...

Page 10: ...VISION OCTIS PLUG KIT ASSEMBLY HYBRID SIGNAL POWER 10 of 30 D AUTHORIZED BY DATE Stalin Alosius 2019 09 12 CLASSIFICATION UNRESTRICTED Copyright FCI Form E 3334 Rev F Form E 3334 Rev F 7 2 3 CRIMP ON WIRE POWER CONTACT PDS Rev D STATUS Released Printed Sep 18 2019 ...

Page 11: ...hields on shielded connectors The automatic wire terminators will set all the unused contacts unless the machine cycle is interrupted When using hand tools the operator must index the connector subassembly to all unused positions and activate the hand tool 8 1 Termination Requirements Visual Requirements for an acceptable termination as well as non destructive visual inspection methods to ensure s...

Page 12: ...The dimension ab is based on the diameter of the wire being used Conductor Size Insulation Diameter mm Dimension ab mm 26 gauge wire 0 74 0 42 0 12 24 gauge wire 1 00 0 36 0 12 The measurement should be done when the insertion equipment is set up If the measurement is less than specified reduce the depth of insertion until it meet Contact your FCI representative if the wire you selected cannot mee...

Page 13: ...imum of 0 1 millimeter 0 004 inched during wire insertion 8 1 5 Wire Damage There shall be no breaks in the wire insulation to expose the center conductor below surface E In fig 4 view C Marks and dents in the insulation caused by the insertion equipment that do not expose the conductor in this area are permitted 8 2 Tool Set up and Destructive Inspection Techniques Techniques to verify proper too...

Page 14: ...TION TOOLING Product number Tool description 10137182 001 Semi automatic IDC Cable Terminator Fig 6 10135856 001 IDC table top pistol for Metral HDXS Octis Cable Connector Fig 7 10135701 001 Octis Power Profile Crimping Tool Fig 8 10141086 001 Octis Signal Crimping Tool Fig 9 Cable stripper General available cable stripper Figure 6 10137182 001 Figure 7 10135856 001 Figure 8 10135701 001 Figure 9 ...

Page 15: ...D Copyright FCI Form E 3334 Rev F Form E 3334 Rev F 10 APPLICATION PROCEDURE 10 1 Cable Preparation for Power Profile Contact Step 1 Strip the outer jacket Fig 9 Do not cut any wire on braid Figure 9 Step 2 Unweave and fold back the braid Fig 10 The braid should be equally distributed No Bundles Figure 10 Step 3 Cut the braid to 9mm Fig 11 Figure 11 PDS Rev D STATUS Released Printed Sep 18 2019 ...

Page 16: ... E 3334 Rev F Form E 3334 Rev F Step 4 Attach copper tape 1 5 turn Fig 12 Figure 12 Step 5 Remove the foil Fig 13 When cutting away the foil make sure that no wires of the braid are being damaged Figure 13 Step 6 Remove the two fillers Fig 14 When cutting away the fillers make sure that no wires of the braid or the individual wire insulation are being damaged Figure 14 PDS Rev D STATUS Released Pr...

Page 17: ...7 Remove the individual wire insulation Fig 15 Make sure that the wires are not damaged Figure 15 Step 8 Crimp the contacts Fig 16 By using 10135701 001 Octis Power Profile Crimping Tool Make sure the cables are positioned side by side as flat as possible no twisting allowed Figure 16 Black wire on top Crimp position on top no rotation allowed Crimp position on top no rotation allowed Grey wire on...

Page 18: ...ION UNRESTRICTED Copyright FCI Form E 3334 Rev F Form E 3334 Rev F 10 2 Cable Preparation for Signal Contact Step 1 Strip the outer jacket Fig 17 Do not cut any wire of the braid Figure 17 Step 2 Unweave the braid Step 3 Fold back the braid The braid should be equally distributed No Bundles Step 4 Cut the braid to 9mm Fig 18 Figure 18 PDS Rev D STATUS Released Printed Sep 18 2019 ...

Page 19: ...ng away the foil make sure that no wires of the braid are being damaged Figure 20 Step 7 Remove the plastic foil When cutting away the foil make sure that no wires of the braid are being damaged 10 3 Cable IDC General Tooling Setup For application tooling see Chapter 9 Read the manual before setting up 10 3 1 Crimping Process Method 1 by using 10135856 001 IDC table top pistol for Metral HDXS Octi...

Page 20: ...334 Rev F Form E 3334 Rev F Figure 22 Step 2 Place the nest or positioning body into the insertion head Move the nest by hand until the first insertion position is reached Fig 23 Figure 23 Step 3 Fix the cable by means of a cable clamp This will ensure a correct positioning of the cable and guarantees a correct length of the individual wires for easy cover mounting Fig 24 PDS Rev D STATUS Released...

Page 21: ...Figure 24 Step 4 Bring the individual wire to be crimped via the wire slot into to the insertion head Make sure the wire is positioned after the little hook on top of the insertion head Fig 25 Figure 25 Step 5 Straighten the wire by a slight pulling force and activate simultaneously the tool by pulling down the hand lever till the end position The wire is now crimped and excess wire is cut off Fig...

Page 22: ...il the whole contact row is inserted Afterwards the inserted process can always be restarted by placing the nest again in the correct start position After the first contact row is installed pull out the positioning body and turn it over 180 The empty contact row is now facing the wire guiding gap Repeat all different steps as described above After crimping all the contacts the required terminal bl...

Page 23: ... 23 of 30 D AUTHORIZED BY DATE Stalin Alosius 2019 09 12 CLASSIFICATION UNRESTRICTED Copyright FCI Form E 3334 Rev F Form E 3334 Rev F 10 3 2 Crimping Process Method 2 by using 10141086 001 Octis Signal Crimping Tool Cable preparation See 10 2 IDC termination process PDS Rev D STATUS Released Printed Sep 18 2019 ...

Page 24: ...334 Rev F Form E 3334 Rev F 10 4 OCTIS ASSEMBLY 10 4 1 Assembling Hybrid Signal Power Combo connector 1 Make the cable assembly by crimping the two terminal block assemblies power contacts Fig 28 Figure 28 2 Insert the gland nut through the other end of the cable Fig 29 Figure 29 3 Insert the housing sub set kit combo power signal through the front end of the cable Fig 30 PDS Rev D STATUS Released...

Page 25: ...BY DATE Stalin Alosius 2019 09 12 CLASSIFICATION UNRESTRICTED Copyright FCI Form E 3334 Rev F Form E 3334 Rev F Figure 30 4 Insert the holder kit combo power signal as shown in fig 31 Figure 31 5 Insert the crimped cable assembly into the cable connector housing as shown in Fig 32 Figure 32 PDS Rev D STATUS Released Printed Sep 18 2019 ...

Page 26: ...3334 Rev F 6 Push the cable assembly into the cable connector housing till it gets fixed inside the housing Fig 33 Figure 33 7 Push the cable connector into holder kit combo power signal till the latch of the housing gets locked inside the respective slot of holder kit Fig 34 Figure 34 8 Tighten the holder kit combo power signal against the cable using clamp screw and nut Fig 35 Figure 35 PDS Rev ...

Page 27: ...019 09 12 CLASSIFICATION UNRESTRICTED Copyright FCI Form E 3334 Rev F Form E 3334 Rev F 9 Open the lever of housing sub set kit combo power signal and push it against the cable assembly so that it gets fixed as a unit Fig 36 Figure 36 10 Place the split rubber gland onto the cable Fig 37 Fig 38 Figure 37 Figure 38 PDS Rev D STATUS Released Printed Sep 18 2019 ...

Page 28: ...TION UNRESTRICTED Copyright FCI Form E 3334 Rev F Form E 3334 Rev F 11 Place the tightening cone onto the split rubber gland Fig 39 Fig 40 Figure 39 Figure 40 12 Tighten the gland nut close the lever and close the secondary lock button Kit assembly is ready now Fig 41 Tighten the nut using Wrench 21mm flat Torque 2 to 2 5N Figure 41 PDS Rev D STATUS Released Printed Sep 18 2019 ...

Page 29: ...sary use the protection cap optional Fig 42 Fig 43 Figure 43 Figure 42 10 4 2 Assembling Signal Metral HDXS connector All the procedure is same as that of the assembly of combo connector There is change only in the cable connector 10 4 3 Assembling Power Pwr Profile connector 2 and 3 position power connector All the procedure is same as that of the assembly of combo connector Only change in the ca...

Page 30: ...UTHORIZED BY DATE Stalin Alosius 2019 09 12 CLASSIFICATION UNRESTRICTED Copyright FCI Form E 3334 Rev F Form E 3334 Rev F 10 5 OCTIS EMI CAP 10 5 1 OCTIS EMI cap Assembly 10 5 2 OCTIS EMI cap with strap Assembly 1 2 3 1 2 Connect the strap Unscrew the bottom 3 Lock cap in bulkhead PDS Rev D STATUS Released Printed Sep 18 2019 ...

Page 31: ...19 09 12 CLASSIFICATION UNRESTRICTED Copyright FCI Form E 3334 Rev F Form E 3334 Rev F 11 REVISION RECORD REV PAGE DESCRIPTION EC DATE A All Pre release xxx 2015 10 19 B All Modified ELX I 27924 2017 08 22 C D 9 30 Texts moved to close 7 2 1 Adding EMI cap user manual ELX I 32440 ELX I 348331 2019 01 11 2019 09 12 PDS Rev D STATUS Released Printed Sep 18 2019 ...

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