Applcaton Specfcaton 114-6039 AMPINNERGY* Modular Wrng System 25 JUL 11 Rev G All numercal values are n metrc unts [wth U.S. customary unts n brackets]. Dmensons are n mllmeters [and nches]. Unless otherwse specfed, dmensons have a tolerance of +0.13 [+.005] and angles have a tolerance of +2_. Fgures and llustratons are fordentfcaton only and are not drawn to scale. 1. INTRODUCTION Ths specfcaton covers the requrements for applcaton of AMPINNERGY modular wrng system. The system conssts of connectors and harness assembles. The system has the capablty of provdng electrcal servce outlets to both sdes of a workstaton wall panel by nstallng pluggable duplex receptacles nto a mounted juncton box assembly. When correspondng wth personnel, use the termnology provded n ths specfcaton to facltate your nqures for nformaton. Basc terms and features of ths product are provded n Fgure 1. Receptacle Wall Panel Installaton Wall Panel ThcknessD 51, 57.2, 63.5, 79.4, 82.6, or 88.9 [2, 2.25, 2.50. 3.12, 3.25, or 3.50] Metal Flexble Condut Power (Assembled to Stran Relef) Lne Rvets (Customer Suppled) Power Contact Lne Identfcaton Mark (See Note Below) Duplex Receptacle Snap -On Power Juncton Box Assembly Depth of ReceptacleD Lne Contact D Depth of Receptacle Selected on Bass of Desred Wall Panel Thckness Note: Lnes 1, 2, 3, and 4 duplex receptacles are marked by ether 1, 2, 3, or 4. Duplex receptacles wth the solated ground are marked 1G, 2G, 3G, 4G, or 5G wth an orange colored trangle (Y) under the desgnated lne markng ndcator number. Fgure 1 E2011 Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company TOOLING ASSISTANCE CENTER 1-800 -722-1111 All Rghts Reserved PRODUCT INFORMATION 1-800 -522-6752 TE Connectvty, TE connectvty (logo), and TE (logo) are trademarks. *Trademark. Other logos, product and/or Company names may be trademarks of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.te.com 1 of 9 LOC B
114-6039 The power juncton box assembly has two man functons at each workstaton: t provdes electrcal servce, and t supples feed--thru capabltes to and from other workstatons. The assembly uses power juncton box connector contacts, and t provdes four crcut optons. The duplex receptacles are pluggable modules that snap nto a power juncton box assembly and functon as Lne 1, 2, 3, or 4 receptacles or as Lne 1G, 2G, 3G, 4G, or 5G receptacle wth solated ground crcut. The receptacles are avalable n styles for sx wall panel thcknesses. The power contact and lne contact are desgned to be crmped onto wre sze 12 or 10 AWG havng stranded conductors. The two--pece, unassembled power housng accepts power contacts crmped to wres and functons as a power connector. It mates wth a lne connector or power juncton box assembly. The two--pece, unassembled lne housng accepts lne contacts crmped to wres and functons as a lne connector; t s compatble wth the power connector only. The unassembled stran relef s a metal component that s used wth both the power and lne connectors to provde stran relef when usng flexble condut. 2. REFERENCE MATERIAL 2.1. Revson Summary Revsons to ths applcaton specfcaton nclude: S Replaced company logo 2.2. Customer Assstance Reference Product Base Part Number 556124 and Product Code 2421 are representatve of AMPINNERGY modular wrng system. Use of these numbers wll dentfy the product lne and expedte your nqures through a servce network establshed to help you obtan product and toolng nformaton. Such nformaton can be obtaned through a local Representatve or, after purchase, by callng PRODUCT INFORMATION at the number at the bottom of page 1. 2.3. Drawngs Customer Drawngs for product part numbers are avalable from the servce network. If there s a conflct between the nformaton contaned n the Customer Drawngs and ths specfcaton or wth any other techncal documentaton suppled, the nformaton contaned n the Customer Drawngs takes prorty. 2.4. Specfcatons Product Specfcaton 108--1234 provdes product performance requrements and test nformaton. 2.5. Instructonal Materal Instructon Sheets (408--seres) provde product assembly nstructons or toolng setup and operaton procedures and Customer Manuals (409--seres) provde machne setup and operatng procedures. There are no documents avalable that pertan to ths product. 408--3198 Inspecton of AMPINNERGY System Power Contacts 408--3210 Assembly and Installaton of AMPINNERGY System Components 408--8040 Heavy Duty Mnature Quck--Change Applcators (Sde--Feed Type) 409--5842 AMP--O--LECTRIC* Model G Termnatng Machnes 354500--[ ] 3. REQUIREMENTS 3.1. Wre A. Wre Selecton Each contact accepts stranded copper wre sze 12 or 10 AWG. B. Wre Preparaton Care must be exercsed to prevent cuttng or nckng of the wre strands. Care must also be used when handlng wre durng crmpng to prevent crackng or breakng of the wre strands and wre nsulaton. the wres must be strpped to the dmensons gven n Fgure 2. 2 of 9 Rev G
114-6039 Strpped Insulaton of Common Ground Wre Conductor Note: Not to Scale 38 [1 1 / 2 ] 38 [1 1 / 2 ] Strpped Insulaton of All Other Wres 6.4-7.1 [ 1 / 4-9 / 32 ] 6.4-7.1[ 1 / 4-9 / 32 ] Fgure 2 3.2. Crmped Contacts Crmpng procedures are outlned n the materal packaged wth the applcator and n nstructon sheet 408--3198. Inspect crmped contacts for condtons shown n Fgure 3. Crmp heght dmenson depends upon use of the proper selector settng on the applcator. See Secton 5 for avalable applcators. Applcator Adjusted to Obtan Rear Bellmouth Heght Wre Sze 12 AWG: 3.43 0.25 [.135.010] Wre Sze 10 AWG: 3.78 0.25 [.149.010 ] Wre Insulaton Does Not Enter Wre Barrel Crmp Heght (See Table) No Front Bellmouth WIRE SIZE (AWG) 10 12 CONTACT WIRE BARREL CRIMP HEIGHT 3.28 0.05 [.129.002] 2.92 0.05 [.115.002] No Ncked or Mssng Wre Strands End of Wre Flush to 1.52 [.060] (Max) fromendofwrebarrel 0.20 [.008] or 1 1 / 2 _ Max Upward Bend Allowed No Downward Bend Allowed Straght Edge Fgure 3 3.3. Contact Inserton Termnated power contacts must be loaded nto the power housng and lne contacts must be loaded nto the lne housng. The contacts wll clck nto place and be held there by a bult--n retenton feature. 3.4. Harness Assembles A power harness assembly conssts of two power connectors wth stran relef halves ftted around the connectors and condut ends. It s recommended that 305 [12] as the mnmum overall length for a double--ended fnshed harness assembly. Rev G 3 of 9
A. Dmensonal Consderatons 114-6039 There are three mportant dmensonal consderatons when makng a harness assembly: (1) the desred overall length of the harness assembly, whch becomes the dstance between the matng faces of attached connectors; (2) the length of the flexble metal condut and; (3) the length of wre for each ndvdual contact cavty. After crmpng contacts to the wres, the contact wth the approprate wre length must be nserted nto the predetermned cavty of the connector. Fgure 4 provdes an example for calculatng wre and condut lengths for a 616 [24 1 / 4 ] long power--to--power cable harness assembly. The wre lengths are for a typcal applcaton; however, the applcaton may requre more wre. Adequate wre MUST BE ENSURED to prevent stress on the wres and contacts durng handlng. Notce that specfc elements have a mnus factor. Ths factor s subtracted from the overall harness assembly dmenson to obtan the length of the tem (condut or wre). The mnus factor remans the same for all harness assembles. Overall Length of Harness Assembly (616 [24 1 / 4 ]Max) Flexble Condut Wres Matng Face (Ref) Condut Length (495 [19 1 / 2 ]) ITEM ELEMENT MINUS FACTOR PER END DIMENSION ITEM LENGTH Condut 2 s 60.3 [2 3 / 8 ] 495.3 [19 1 / 2 ] Wre HARNESS ASSEMBLY OVERALL LENGTH Contact Cavty Identty (Refer to Fgure 5 for 4 and IG 1 and N4 25.4 [1] 22.2 [ 7 / 8 ] 565.2 [22 1 / 4 ] 571.5 [22 1 / 2 ] 616 [24 1 / 4 4] Locaton; Markngs Do Not Appear on 2 and N 20.6 [ 13 / 16 ] 574.7 [22 5 / 8 ] Housng) 3 and G 19.8 [ 25 / 32 ] 576.3 [22 11 / 16 ] Fgure 4 4 of 9 Rev G
114-6039 Cavty Identfcaton Power Housng 1 2 3 4 5 6 7 8 Lne Housng G Ground = No. 1 N Neutral (Shared) = No. 2 N4 Neutral = No. 3 IG Isolated Ground = No. 4 4 Lne = No. 5 1 Lne = No. 6 2 Lne = No. 7 3 Lne = No. 8 Cavty Markng on Base Keyway 3 Lne 2 Lne 1 Lne 4 Lne IG Isolated Ground N4 Neutral N Neutral (Shared) G Ground Base Fgure 5 B. Requred Tools and Materals In addton to the harness connectors (consstng of housngs, contacts, and wres), the followng materals are requred to assemble a power--to--power harness assembly: two rght stran relef halves two left stran relef halves eght rvets (customer suppled) It s recommended that 3.18 [.125] dameter by 12.7 [.500] long sem -tubular steel rvets be used to assemble the stran relef halves to the power harness. sutable rvet stakng equpment (customer suppled) flexble condut, requred length: 12.7 [ 1 / 2 ] trade sze (for 5--wre) and havng a nomnal 16.5 [.65] outer dameter (OD) or 14.3 [ 9 / 16 ] trade sze (for 8--wre) and havng a nomnal 18.29 [.720] OD (customer suppled) It s recommended that the flexble condut be purchased from: Internatonal Metal Hose Co. 520 Goodrch Road, Bellevue, OH 44811 (Part No. AFLS -1/2 n. for 12.7 [1/2]; AFLS -9/16 n. for 14.3 [9/16]) It s recommended that a flexble condut cuttng tool be purchased from: Seatek Company, Inc. 392 -T Pacfc Street, Stamford, CT 06902 (Roto Splt Tool) two nsulatng bushngs (one for each cable end) (customer suppled) stranded wre sze 12 and stranded wre sze 10 AWG (customer suppled) Rev G 5 of 9
C. Assembly 114-6039 Generally, the steps requred to complete a fnshed assembly are somewhat detaled and should be followed n sequence. They nclude wre cuttng and strppng, crmpng the contacts, sldng the flexble condut over the crmped contacts, matchng each crmped contact wth the correct housng cavty, and assemblng the stran relefs to the power harness. The length of the fnshed harness assembly should be determned by usng the nformaton contaned n Fgure 4. Wre sze 10 AWG s used n the neutral poston (second slot from the top). There s a dfference n slot wdth for the stran relef n the second poston to compensate for ths. 3.5. Installaton Some of the varous ways AMPINNERGY modular wrng system can be used s llustrated n Fgure 6. The power juncton box assembly can also be used as a pass--through assembly n applcatons where outlet servce s not needed or prohbted. A. Flexble Condut A power connector usng flexble metal condut s shown n Fgure 6, Detal A. B. Multple Juncton Box The multple juncton box s desgned to provde power n modular furnture walls. See Fgure 6, Detal B. C. Raceway Confguraton The raceway provdes a means of mechancal support, electrcal groundng, and locatng for the modular wrng system. The raceway should be mounted to the structure or panel wth the power connector nstalled. See Fgure 6, Detal C. It s recommended that the raceway confguraton be grounded to the wrng by usng a self--mountng wre nsulaton dsplacement clp. The clps are commercally avalable from sprng--clp manufacturers. D. Lne to Power Usng Flexble Condut Ths arrangement shown n Fgure 6, Detal C conssts of a lne connector assembly matng wth a power connector assembly usng flexble metal condut. It s desgned to serve as a quck--dsconnect, power feed--thru connector assembly. These arrangements are normally used where the power juncton box assembly s not needed. Typcal Installaton Confguratons Detal A Flexble Condut Juncton Box Detal B Multple Juncton Box Detal C Lne to Power AMPINNERGY Lne AMPINNERGY Power AMPINNERGY Power Multplex Juncton Box Fgure 6 6 of 9 Rev G
3.6. Duplex Receptacles 114-6039 Any of the duplex receptacles are compatble wth the power juncton box assembly. No toolng s needed for nserton. Two flat--bladed screwdrvers should be used to extract a duplex receptacle from a power juncton box assembly. 3.7. Panel Cutout A. Panel Thckness The power juncton box requres a panel thckness range of 1.27 through 2.03 [.050 through.080]. B. Mountng Cutout No mountng hardware s requred for mountng the power juncton box. The mountng cutout s shown n Fgure 7. Mountng Cutout Snap In Power Juncton Box 16.76+0.10 [.660+.004] 28.96+0.13 [1.140+.005] 123.95 [4.880] Mn 16.76+0.10 [.660+.004] 14.48+0.13 [.570+.005] 12.7 [.500] Mn R 1.27 [.050] (4 Plc) 2.54+0.10 [.100+.004] 56.13+0.13 [2.210+.005] 1.27+0.13 [.050+.005] (4 Plc) 16.76+0.10 [.660+.004] 39.12+0.13 [1.540+.005] 19.56+0.13 [.770+.005] 16.76+0.10 [.660+.004] 12.7 [.500] Mn Multplex Power Juncton Box 28.96+0.13 [1.140+.005] (2 Plc) 250.96 [9.880] Mn 127.00 [5.000] 61.98 [2.44] 14.48+0.13 [.570+.005] (2 Plc) 1.27+0.13 [.050+.005] (8 Plc) 12.70 [.500] Mn R 1.27 [.050] (4 Plc) 56.13+0.13 [2.210+.005] Of Assy 19.56+0.13 [.770+.005] (2 Plc) 39.12+0.13 [1.540+.005] (2 Plc) 16.76+0.13 [.660+.005] (4 Plc) 1.27+0.13 [.050+.005] (8 Plc) 12.70 [.500] Mn Fgure 7 Rev G 7 of 9
4. QUALIFICATIONS 114-6039 The connectors for AMPINNERGY modular wrng system are Lsted by Underwrters Laboratores Inc. (UL) under Fle E132626 and UL183 and Certfed by Canadan Standards (CSA) under Fle LR 7189. 5. TOOLING Toolng part numbers and nstructonal materal packaged wth the toolng are shown n Fgure 8. For hgh--volume producton, a sem--automatc machne ftted wth an applcator s avalable. Heavy -Duty Mnature Applcator 567256-3 (408-8040) AMP -O -LECTRIC Model G Termnatng Machne 354500-1 (409-5842) Fgure 8 8 of 9 Rev G
114-6039 6. VISUAL AID The llustraton below shows a typcal applcaton of AMPINNERGY modular wrng system. Ths llustraton should be used by producton personnel to ensure a correctly appled product. Applcatons whch DO NOT appear correct should be nspected usng the nformaton n the precedng pages of ths specfcaton and n the nstructonal materal shpped wth the product or toolng. THE WORD UP SHOULD BE ORIENTED WITH THE TOP MARKING ON JUNCTION BOX STRAIN RELIEF HALVES SHOULD BE BOTTOMED ON EACH OTHER AND NO WIRES SHOULD PROTRUDE FROM SEAM CONNECTOR MUST BE LATCHED TO POWER JUNCTION BOX ASSEMBLY WIRE CONDUCTOR ENDS SHOULD BE HELD FIRMLY BY SHIELD HALVES CONNECTOR EMBOSSMENTS SHOULD BE SEATED IN SHIELD SLOTS FIGURE 9. VISUAL AID Rev G 9 of 9