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Institut für Experimentelle Kernphysik (IEKP)
AMS-02 UPD <> U-Crate Cabling
Assembly Procedure
Version 2.1 13th Apr. 2007
AMS-02 TRD Page 1 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
Written by Andreas Sabellek
Reviewed by Kai Gassmann
Approved by Alexandre Koulemzine (procedure)
Andrey Rhozkov (length verified)
AMS-02 TRD Page 2 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
Contents
Scope of the document 3
1. Assembly information 4
1.1 Cleaning of materials 4 1.2 Cable Assignment and List of Cablel 5 1.3 UPD<>U-Crate Electrical Connection Scheme 7 1.4 Cable Assembly Sheets 8 1.5 List of Wires 22
2. List of tools 26
2.1 Wire Cutter 26 2.2 Wire Stripper 26 2.3 Crimper Tool for Connector Pins 27 2.4 Connector Pin Insertion Tool 31 2.5 Criper Tool for Terminal Ring Lugs 32
3. Assembly Steps 34
3.1 Wire length 34 3.2 Connector Mounting 35 3.3 Twisting of Wires 37 3.4 Application of Sleeving 38 3.5 Crimping of Terminal Ring Lugs 40 3.6 Cable Installation 41
4. Bill of Materials (BOM) total 42
AMS-02 TRD Page 3 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
Scope of the document This document has been written to support the assembly of the TRD Electronics Cabling between TRD Power Distribution Box (UPD) and TRD-Electronics-Crate (U-Crate). Chapter 1 is preparation of materials and definition of cables containing a assembly sheet for each cable. In Chapter 2, tools and in chapter 3 working steps will be listed and explained for the assembly of cables. Chapter 4 a bill of materials for assembly of all cables is given and should be checked before starting assembly. The entire procedure should be read before starting assembly.
AMS-02 TRD Page 4 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
1. Assembly Information
1.1 Cleaning of materials Area for the UPD assembly must be maintained in a clean and orderly condition. The surface of working table must be cleaned by IPA (Isopropyl Alcohol). The subsequent objects need to be cleaned by IPA before assembly:
- all mechanical parts and cables - all assembly tools
During the assembly you must wear 100% natural rubber gloves. For a complete procedure the NASA technical standards for flight hardware workmanship should be followed.
AMS-02 TRD Page 5 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
1.2 UPD <> U-Crate Cable Assignment and Labeling
00U
DR
201
UP
SFE
02U
DR
203
UD
R2
04U
PS
FE05
UD
R2
06U
DR
207
UP
SFE
08U
DR
209
JINF
10U
HV
G
12U
HV
G
15U
HV
G14
UH
VG
13U
HV
G
11U
HV
G
Slot1Slot2 Slot3
Slot4
U0
UPD0
120/5V-U0-0120/5V-U0-1120/5V-U0-2
+/-2.5V-U0-0+/-2.5V-U0-1+/-2.5V-U0-2
3.3V-U0-0
+/-2.5 V+3.3 V+120/+5 V
00U
DR
201
UP
SFE
02U
DR
203
UD
R2
04U
PS
FE05
UD
R2
06U
DR
207
UP
SFE
08U
DR
209
JINF
10U
HV
G
12U
HV
G
15U
HV
G14
UH
VG
13U
HV
G
11U
HV
G
Slot1Slot2 Slot3
Slot4
U1
UPD1
120/5V-U1-0120/5V-U1-1120/5V-U1-2
+/-2.5V-U1-0+/-2.5V-U1-1+/-2.5V-U1-2
3.3V-U1-0
+/-2.5 V+3.3 V+120/+5 V
J22
J23
J25
J28J27J26
J21
J22
J23
J25
J28J27J26
J21
RA
M C
rates InterconnectionW
AK
E C
rates Interconnection
UPD<>U-Crate Cables Overview
J24
J201J202
LeCroy
LeCroy
J24
J201J202
+28V in
+28V in
Uni Karlsruhe, IEKP2007/Feb/20 A.Sabellek
see corresponding Cable Sheet for details
see corresponding Cable Sheet for details
Fig.1: Interconnection Scheme
AMS-02 TRD Page 6 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
Cable UPD UPD side U-Crate Cable ID Box No. Conn.ID Conn. Partno Crate No. Slot Length (mm)
120/5V-U0-0 UPD0 J26 MS27484E 10F35P U0 1 1400
120/5V-U0-1 UPD0 J27 MS27484E 10F35P U0 1 1350
120/5V-U0-2 UPD0 J28 MS27484E 10F35P U0 1 1350
120/5V-U1-0 UPD1 J26 MS27484E 10F35P U1 1 1900
120/5V-U1-1 UPD1 J27 MS27484E 10F35P U1 1 1850
120/5V-U1-2 UPD1 J28 MS27484E 10F35P U1 1 1800
+/-2.5V-U0-0 UPD0 J22 MS27484E 20F16P U0 4 1850
+/-2.5V-U0-1 UPD0 J23 MS27484E 20F16P U0 4 1800
+/-2.5V-U0-2 UPD0 J25 MS27484E 20F16P U0 3 1700
+/-2.5V-U1-0 UPD1 J22 MS27484E 20F16P U1 4 1500
+/-2.5V-U1-1 UPD1 J23 MS27484E 20F16P U1 4 1450
+/-2.5V-U1-2 UPD1 J25 MS27484E 20F16P U1 3 1450
3.3V-U0-0 UPD0 J21 MS27484E 16F6P U0 2 1500
3.3V-U1-0 UPD1 J21 MS27484E 16F6P U1 2 1850
LC-U0-0 UPD0 J201 M83513/04-B16N U0 / PC0 2 1350
LC-U0-1 UPD0 J202 M83513/04-B16N U0 / PC1 2 1500
LC-U1-0 UPD1 J201 M83513/04-B16N U1 / PC0 2 1800
LC-U1-1 UPD1 J202 M83513/04-B16N U1 / PC1 2 1800
Tab.1 List of Cables
In the following, unique label assignment for cables between UPD and U-Crate given in Fig.1 is used. Two set of Cables are needed. Each cable set consists of: 1 x 3.3V Cable to connect LV output of S9053 DCDC Converter with UBP 3 x +/-2.5V Cable to connect LV output of S9048 DCDC Converter to UBP/UPSFEs 3 x 120/5V Cable to connect LV output of S9056 DCDC Converter to UBP/UHVGs Position for Cable set x-U1-x (connecting UPD1 and U1) is the RAM-Radiator and position for Cable set x-U0-x (connecting UPD0 and U0) is the WAKE- Radiator. Lecroy cables (LC-Ux-x) connecting UBP to S9011AU Controller inside UPD are part of UBP (U-Backplane) and its BOM and excluded in this document.
AMS-02 TRD Page 7 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
1.3 Electrical Connection Scheme Overview
J1J22S9048-0
+2.5V0A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
BAN
DEC
JKS
HGR
GNDF0
-2.5V0
J2
J3
J4 +2.5V1
GNDF0
-2.5V1
J5
J6
J7J23S9048-1
+2.5V2A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
BAN
DEC
JKS
HGR
GNDF1
-2.5V2
J8
J9
J10 +2.5V3
GNDF1
-2.5V3
J11
J12
J13
Cable +/-2.5V-U
x-0
J25S9048-2+2.5V4
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
BAN
DEC
JKS
HGR
GNDF2
-2.5V4
J14
J15
J16 +2.5V5
GNDF2
-2.5V5
J17
J18
J37J21S9053-0
+3.3VRTN+3.3
+3.3RTN
AB
DE
DGNDJ38
J19S9056-0
+5.0V0A +5.0A RTNA +120
B +5.0B RTNB +120
A +5.0A RTNA +120
B +5.0B RTNB +120
2111
4512
7613
8109
GNDH0
+120V0
J20
J21
J22
J23
J24
J25J27S9056-1 A +5.0
A RTNA +120
B +5.0B RTNB +120
A +5.0A RTNA +120
B +5.0B RTNB +120
J26
J27
J28
J29
J30
J31
Cable +/-2.5V-U
x-1
J28S9056-2 A +5.0A RTNA +120
B +5.0B RTNB +120
A +5.0A RTNA +120
B +5.0B RTNB +120
J32
J33
J34
J35
J36
UPDx<>Ux Interconnection Schematics (see Cable Sheets for details)
UPDx Ux
Cable 3.3V-U
x-0C
able +/-2.5V-Ux-2
Cable 120/5V-U
x-0C
able120/5V-Ux-1
Cable 120/5V-U
x-2J26
2111
4512
7613
8109
2111
4512
7613
8109
+5.0V1
GNDH0
+120V1
+5.0V2
GNDH1
+120V2
+5.0V3
GNDH1
+120V3
+5.0V4
GNDH2
+120V4
+5.0V5
GNDH2
+120V5
J1
J1
J1
J1
J1
J1
J1
J1
J3J2
J4
J3J5J2
J6J4J7
J9J11J8
J12J10J13
J3J5J2
J6J4J7
J9J11J8
J12J10J13
J3J5J2
J6J4J7
J9J11J8
J12J10J13
J3J5J2
J6J4J7
J9J11J8
J12J10J13
J3J5J2
J6J4J7
J9J11J8
J12J10J13
J3J5J2
J6J4J7
J9J11J8
J12J10J13
Fig.2 UPD<>U-Crate Electrical Interconnection Schematics
AMS-02 TRD Page 8 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
1.4 Cable Assembly Sheets
J37
J38
UPD0 Cable 3.3V-U0-0 U0
J21 J1 J2J3
J4J5
S9053-0
+3.3V
DGND
RTN+3.3
+3.3RTN
Cable Assembly 3.3V-U0-0
Assem
bly Draw
ing and BO
MInterconnection S
cheme
Wires Tw
isting
AB
DE
AB
DE
AB
DE
NC
M22759/44-12-0M22759/44-12-2
M22759/44-12-2M22759/44-12-0
100mm
C
NCF
J2
J3
J4
J5
J1
LL1
J1
J2/J5J3/J4
1,2 3,4,6 8
Qty1 connector MS27484E16F6P pc 12 shell MS27506F16-2 pc 13 wire M22759/44-12-0 mm L 24 wire M22759/44-12-2 mm L 25 heat shrinkRW-175 mm 50 36 sleeve DM686 ¼” mm L1 17 lacing tapeA-A-52084-PTH-5 pc 28 ring lug AMP 1-332433-0 pc 4
Cable ID L1 L3.3V-U0-0 1350 1500
5,7 5,7
[mm]
AMS-02 TRD Page 9 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
J37
J38
UPD1 Cable 3.3V-U1-0 U1
J21 J1 J2J3
J4J5
S9053-0
+3.3V
DGND
RTN+3.3
+3.3RTN
Cable Assembly 3.3V-U1-0
Assem
bly Draw
ing and BO
MInterconnection S
cheme
Wires Tw
isting
AB
DE
AB
DE
AB
DE
NC
M22759/44-12-0M22759/44-12-2
M22759/44-12-2M22759/44-12-0
100mm
C
NCF
J2
J3
J4
J5
J1
LL1
J1
J2/J5J3/J4
1,2 3,4,6 8
Qty1 connector MS27484E16F6P pc 12 shell MS27506F16-2 pc 13 wire M22759/44-12-0 mm L 24 wire M22759/44-12-2 mm L 25 heat shrinkRW-175 mm 50 36 sleeve DM686 ¼” mm L1 17 lacing tapeA-A-52084-PTH-5 pc 28 ring lug AMP 1-332433-0 pc 4
Cable ID L1 L3.3V-U1-0 1700 1850
5,7 5,7
[mm]
AMS-02 TRD Page 10 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
J1
J2
J3
100mm
L
J2J3J4J5
J1
L1 L2
J1J2/J5J3/J6J4/J7J8/J11J9/J12J10/J13
1,2 3,4,5,6,7,8,10 12
Cable ID L1 L2 L+/-2.5V-U0-0 1700 70 1850
J6J7J8J9J10J11J12J13
9,11 9,11
[mm]
UPD0 Cable +/-2.5V-U0-0 U0
J22 J1J2J3J4J5J6J7J8J9J10J11J12J13
S9048-0
J4
J5
J6
+2.5V0
GNDF0
-2.5V0
+2.5V1
GNDF0
-2.5V1
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
Cable Assembly +/-2.5V-U0-0
Assem
bly Draw
ing and BO
MInterconnection Schem
eW
ires Twisting
BAN
DEC
JKS
HGR
F,L,M,P NC
M22759/44-16-2M22759/44-16-0M22759/44-16-6
M22759/44-16-2M22759/44-16-0M22759/44-16-6
M22759/44-16-1M22759/44-16-9M22759/44-16-7
M22759/44-16-1M22759/44-16-9M22759/44-16-7
1 connector MS27484E20F16P pc 12 shell MS27506F20-2 pc 13 wire M22759/44-16-0 mm L-L2 24 wire M22759/44-16-1 mm L-L2 25 wire M22759/44-16-2 mm L-L2 26 wire M22759/44-16-6 mm L 27 wire M22759/44-16-7 mm L 28 wire M22759/44-16-9 mm L 29 heat shrinkRW-175 mm 50 3
10 sleeve DM686 ¼” mm L1 111 lacing tapeA-A-52084-PTH-5 pc 212 ring lug AMP 332453 pc 12
BAN
DEC
JKS
HGR
BAN
DEC
JKS
HGR
AMS-02 TRD Page 11 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
J7
J8
J9
100mm
L
J2J3J4J5
J1
L1 L2
J1J2/J5J3/J6J4/J7J8/J11J9/J12J10/J13
1,2 3,4,5,6,7,8,10 12
Cable ID L1 L2 L+/-2.5V-U0-1 1650 70 1800
J6J7J8J9J10J11J12J13
9,11 9,11
[mm]
UPD0 Cable +/-2.5V-U0-1 U0
J23 J1J2J3J4J5J6J7J8J9J10J11J12J13
S9048-1
J10
J11
J12
+2.5V2
GNDF1
-2.5V2
+2.5V3
GNDF1
-2.5V3
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
Cable Assembly +/-2.5V-U0-1
Assem
bly Draw
ing and BO
MInterconnection S
cheme
Wires Tw
isting
BAN
DEC
JKS
HGR
F,L,M,P NC
M22759/44-16-2M22759/44-16-0M22759/44-16-6
M22759/44-16-2M22759/44-16-0M22759/44-16-6
M22759/44-16-1M22759/44-16-9M22759/44-16-7
M22759/44-16-1M22759/44-16-9M22759/44-16-7
Qty1 connector MS27484E20F16P pc 12 shell MS27506F20-2 pc 13 wire M22759/44-16-0 mm L-L2 24 wire M22759/44-16-1 mm L-L2 25 wire M22759/44-16-2 mm L-L2 26 wire M22759/44-16-6 mm L 27 wire M22759/44-16-7 mm L 28 wire M22759/44-16-9 mm L 29 heat shrinkRW-175 mm 50 3
10 sleeve DM686 ¼” mm L1 111 lacing tapeA-A-52084-PTH-5 pc 212 ring lug AMP 332453 pc 12
BAN
DEC
JKS
HGR
BAN
DEC
JKS
HGR
AMS-02 TRD Page 12 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
J13
J14
J15
100mm
L
J2J3J4J5
J1
L1 L2
J1J2/J5J3/J6J4/J7J8/J11J9/J12J10/J13
1,2 3,4,5,6,7,8,10 12
Cable ID L1 L2 L+/-2.5V-U0-2 1550 70 1700
J6J7J8J9J10J11J12J13
9,11 9,11
[mm]
UPD0 Cable +/-2.5V-U0-2 U0
J25 J1J2J3J4J5J6J7J8J9J10J11J12J13
S9048-2
J16
J17
J18
+2.5V4
GNDF2
-2.5V4
+2.5V5
GNDF2
-2.5V5
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
Cable Assembly +/-2.5V-U0-2
Assem
bly Draw
ing and BO
MInterconnection S
cheme
Wires Tw
isting
BAN
DEC
JKS
HGR
F,L,M,P NC
M22759/44-16-2M22759/44-16-0M22759/44-16-6
M22759/44-16-2M22759/44-16-0M22759/44-16-6
M22759/44-16-1M22759/44-16-9M22759/44-16-7
M22759/44-16-1M22759/44-16-9M22759/44-16-7
Qty1 connector MS27484E20F16P pc 12 shell MS27506F20-2 pc 13 wire M22759/44-16-0 mm L-L2 24 wire M22759/44-16-1 mm L-L2 25 wire M22759/44-16-2 mm L-L2 26 wire M22759/44-16-6 mm L 27 wire M22759/44-16-7 mm L 28 wire M22759/44-16-9 mm L 29 heat shrinkRW-175 mm 50 3
10 sleeve DM686 ¼” mm L1 111 lacing tapeA-A-52084-PTH-5 pc 212 ring lug AMP 332453 pc 12
BAN
DEC
JKS
HGR
BAN
DEC
JKS
HGR
AMS-02 TRD Page 13 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
J1
J2
J3
100mm
L
J2J3J4J5
J1
L1 L2
J1J2/J5J3/J6J4/J7J8/J11J9/J12J10/J13
1,2 3,4,5,6,7,8,10 12
Cable ID L1 L2 L+/-2.5V-U1-0 1350 70 1500
J6J7J8J9J10J11J12J13
9,11 9,11
[mm]
UPD1 Cable +/-2.5V-U1-0 U1
J22 J1J2J3J4J5J6J7J8J9J10J11J12J13
S9048-0
J4
J5
J6
+2.5V0
GNDF0
-2.5V0
+2.5V1
GNDF0
-2.5V1
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
Cable Assembly +/-2.5V-U1-0
Assem
bly Draw
ing and BO
MInterconnection S
cheme
Wires Tw
isting
BAN
DEC
JKS
HGR
F,L,M,P NC
M22759/44-16-2M22759/44-16-0M22759/44-16-6
M22759/44-16-2M22759/44-16-0M22759/44-16-6
M22759/44-16-1M22759/44-16-9M22759/44-16-7
M22759/44-16-1M22759/44-16-9M22759/44-16-7
Qty1 connector MS27484E20F16P pc 12 shell MS27506F20-2 pc 13 wire M22759/44-16-0 mm L-L2 24 wire M22759/44-16-1 mm L-L2 25 wire M22759/44-16-2 mm L-L2 26 wire M22759/44-16-6 mm L 27 wire M22759/44-16-7 mm L 28 wire M22759/44-16-9 mm L 29 heat shrinkRW-175 mm 50 3
10 sleeve DM686 ¼” mm L1 111 lacing tapeA-A-52084-PTH-5 pc 212 ring lug AMP 332453 pc 12
BAN
DEC
JKS
HGR
BAN
DEC
JKS
HGR
AMS-02 TRD Page 14 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
J7
J8
J9
100mm
L
J2J3J4J5
J1
L1 L2
J1J2/J5J3/J6J4/J7J8/J11J9/J12J10/J13
1,2 3,4,5,6,7,8,10 12
Cable ID L1 L2 L+/-2.5V-U1-1 1300 70 1450
J6J7J8J9J10J11J12J13
9,11 9,11
[mm]
UPD1 Cable +/-2.5V-U1-1 U1
J23 J1J2J3J4J5J6J7J8J9J10J11J12J13
S9048-2
J10
J11
J12
+2.5V2
GNDF1
-2.5V2
+2.5V3
GNDF1
-2.5V3
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
Cable Assembly +/-2.5V-U1-1
Assem
bly Draw
ing and BO
MInterconnection Schem
eW
ires Twisting
BAN
DEC
JKS
HGR
F,L,M,P NC
M22759/44-16-2M22759/44-16-0M22759/44-16-6
M22759/44-16-2M22759/44-16-0M22759/44-16-6
M22759/44-16-1M22759/44-16-9M22759/44-16-7
M22759/44-16-1M22759/44-16-9M22759/44-16-7
Qty1 connector MS27484E20F16P pc 12 shell MS27506F20-2 pc 13 wire M22759/44-16-0 mm L-L2 24 wire M22759/44-16-1 mm L-L2 25 wire M22759/44-16-2 mm L-L2 26 wire M22759/44-16-6 mm L 27 wire M22759/44-16-7 mm L 28 wire M22759/44-16-9 mm L 29 heat shrinkRW-175 mm 50 3
10 sleeve DM686 ¼” mm L1 111 lacing tapeA-A-52084-PTH-5 pc 212 ring lug AMP 332453 pc 12
BAN
DEC
JKS
HGR
BAN
DEC
JKS
HGR
AMS-02 TRD Page 15 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
J13
J14
J15
100mm
L
J2J3J4J5
J1
L1 L2
J1J2/J5J3/J6J4/J7J8/J11J9/J12J10/J13
1,2 3,4,5,6,7,8,10 12
Cable ID L1 L2 L+/-2.5V-U1-2 1300 70 1450
J6J7J8J9J10J11J12J13
9,11 9,11
[mm]
UPD1 Cable +/-2.5V-U1-2 U1
J25 J1J2J3J4J5J6J7J8J9J10J11J12J13
S9048-2
J16
J17
J18
+2.5V4
GNDF2
-2.5V4
+2.5V5
GNDF2
-2.5V5
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
A +2.5A RTNA -2.5
B +2.5B RTNB -2.5
Cable Assembly +/-2.5V-U1-2
Assem
bly Draw
ing and BO
MInterconnection S
cheme
Wires Tw
isting
BAN
DEC
JKS
HGR
F,L,M,P NC
M22759/44-16-2M22759/44-16-0M22759/44-16-6
M22759/44-16-2M22759/44-16-0M22759/44-16-6
M22759/44-16-1M22759/44-16-9M22759/44-16-7
M22759/44-16-1M22759/44-16-9M22759/44-16-7
Qty1 connector MS27484E20F16P pc 12 shell MS27506F20-2 pc 13 wire M22759/44-16-0 mm L-L2 24 wire M22759/44-16-1 mm L-L2 25 wire M22759/44-16-2 mm L-L2 26 wire M22759/44-16-6 mm L 27 wire M22759/44-16-7 mm L 28 wire M22759/44-16-9 mm L 29 heat shrinkRW-175 mm 50 3
10 sleeve DM686 ¼” mm L1 111 lacing tapeA-A-52084-PTH-5 pc 212 ring lug AMP 332453 pc 12
BAN
DEC
JKS
HGR
BAN
DEC
JKS
HGR
AMS-02 TRD Page 16 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
J19
J20
J21
2111
M22759/44-22-2M22759/44-22-0M22759/44-22-3
50mm
L
J2J3J4J5
J1
L1 L2
J1J2/J5J3/J6J4/J7J8/J11J9/J12J10/J13
1,2 3,4,5,6,7,8,10 12
Qty1 connector MS27484E10F35P pc 12 shell MS27506F10-2 pc 13 wire M22759/44-22-0 mm L 24 wire M22759/44-22-1 mm L-L2 25 wire M22759/44-22-2 mm L 26 wire M22759/44-22-3 mm L 27 wire M22759/44-22-4 mm L-L2 28 wire M22759/44-22-9 mm L-L2 29 heat shrinkRW-175 mm 50 3
10 sleeve DM686 ¼” mm L1 111 lacing tapeA-A-52084-PTH-5 pc 212 ring lug AMP 1-332446-1 pc 12
Cable ID L1 L2 L
120/5V-U0-0 1200 120 1400
J6J7J8J9J10J11J12J13
M22759/44-22-2M22759/44-22-0M22759/44-22-3
M22759/44-22-1M22759/44-22-9M22759/44-22-4
M22759/44-22-1M22759/44-22-9M22759/44-22-4
4512
7613
8109
9,11 9,11
[mm]
UPD0 Cable 120/5V-U0-0 U0
J26 J12111
4512
7613
8109
J2J3J4J5J6J7J8J9J10J11J12J13
2111
4512
7613
8109
S9056-0
J22
J23
J24
+5.0V0
GNDH0
+120V0
+5.0V1
GNDH0
+120V1
A +5.0A RTNA +120
B +5.0B RTNB +120
A +5.0A RTNA +120
B +5.0B RTNB +120
Cable Assembly 120/5V-U0-0
Assem
bly Draw
ing and BO
MInterconnection S
cheme
Wires Tw
isting
AMS-02 TRD Page 17 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
J25
J26
J27
2111
M22759/44-22-2M22759/44-22-0M22759/44-22-3
50mm
L
J2J3J4J5
J1
L1 L2
J1J2/J5J3/J6J4/J7J8/J11J9/J12J10/J13
1,2 3,4,5,6,7,8,10 12
Qty1 connector MS27484E10F35P pc 12 shell MS27506F10-2 pc 13 wire M22759/44-22-0 mm L 24 wire M22759/44-22-1 mm L-L2 25 wire M22759/44-22-2 mm L 26 wire M22759/44-22-3 mm L 27 wire M22759/44-22-4 mm L-L2 28 wire M22759/44-22-9 mm L-L2 29 heat shrinkRW-175 mm 50 3
10 sleeve DM686 ¼” mm L1 111 lacing tapeA-A-52084-PTH-5 pc 212 ring lug AMP 1-332446-1 pc 12
Cable ID L1 L2 L
120/5V-U0-1 1150 120 1350
J6J7J8J9J10J11J12J13
M22759/44-22-2M22759/44-22-0M22759/44-22-3
M22759/44-22-1M22759/44-22-9M22759/44-22-4
M22759/44-22-1M22759/44-22-9M22759/44-22-4
4512
7613
8109
9,11 9,11
[mm]
UPD0 Cable 120/5V-U0-1 U0
J27 J12111
4512
7613
8109
J2J3J4J5J6J7J8J9J10J11J12J13
2111
4512
7613
8109
S9056-1
J28
J29
J30
+5.0V2
GNDH1
+120V2
+5.0V3
GNDH1
+120V3
A +5.0A RTNA +120
B +5.0B RTNB +120
A +5.0A RTNA +120
B +5.0B RTNB +120
Cable Assembly 120/5V-U0-1
Assem
bly Draw
ing and BO
MInterconnection S
cheme
Wires Tw
isting
AMS-02 TRD Page 18 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
J31
J32
J33
2111
M22759/44-22-2M22759/44-22-0M22759/44-22-3
50mm
L
J2J3J4J5
J1
L1 L2
J1J2/J5J3/J6J4/J7J8/J11J9/J12J10/J13
1,2 3,4,5,6,7,8,10 12
Qty1 connector MS27484E10F35P pc 12 shell MS27506F10-2 pc 13 wire M22759/44-22-0 mm L 24 wire M22759/44-22-1 mm L-L2 25 wire M22759/44-22-2 mm L 26 wire M22759/44-22-3 mm L 27 wire M22759/44-22-4 mm L-L2 28 wire M22759/44-22-9 mm L-L2 29 heat shrinkRW-175 mm 50 3
10 sleeve DM686 ¼” mm L1 111 lacing tapeA-A-52084-PTH-5 pc 212 ring lug AMP 1-332446-1 pc 12
Cable ID L1 L2 L
120/5V-U0-2 1150 120 1350
J6J7J8J9J10J11J12J13
M22759/44-22-2M22759/44-22-0M22759/44-22-3
M22759/44-22-1M22759/44-22-9M22759/44-22-4
M22759/44-22-1M22759/44-22-9M22759/44-22-4
4512
7613
8109
9,11 9,11
[mm]
UPD0 Cable 120/5V-U0-2 U0
J28 J12111
4512
7613
8109
J2J3J4J5J6J7J8J9J10J11J12J13
2111
4512
7613
8109
S9056-2
J34
J35
J36
+5.0V4
GNDH2
+120V4
+5.0V5
GNDH2
+120V5
A +5.0A RTNA +120
B +5.0B RTNB +120
A +5.0A RTNA +120
B +5.0B RTNB +120
Cable Assembly 120/5V-U0-2
Assem
bly Draw
ing and BO
MInterconnection S
cheme
Wires Tw
isting
AMS-02 TRD Page 19 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
J19
J20
J21
2111
M22759/44-22-2M22759/44-22-0M22759/44-22-3
50mm
L
J2J3J4J5
J1
L1 L2
J1J2/J5J3/J6J4/J7J8/J11J9/J12J10/J13
1,2 3,4,5,6,7,8,10 12
1 connector MS27484E10F35P pc 12 shell MS27506F10-2 pc 13 wire M22759/44-22-0 mm L 24 wire M22759/44-22-1 mm L-L2 25 wire M22759/44-22-2 mm L 26 wire M22759/44-22-3 mm L 27 wire M22759/44-22-4 mm L-L2 28 wire M22759/44-22-9 mm L-L2 29 heat shrinkRW-175 mm 50 3
10 sleeve DM686 ¼” mm L1 111 lacing tapeA-A-52084-PTH-5 pc 212 ring lug AMP 1-332446-1 pc 12
Cable ID L1 L2 L
120/5V-U1-0 1700 120 1900
J6J7J8J9J10J11J12J13
M22759/44-22-2M22759/44-22-0M22759/44-22-3
M22759/44-22-1M22759/44-22-9M22759/44-22-4
M22759/44-22-1M22759/44-22-9M22759/44-22-4
4512
7613
8109
9,11 9,11
[mm]
UPD1 Cable 120/5V-U1-0 U1
J26 J12111
4512
7613
8109
J2J3J4J5J6J7J8J9J10J11J12J13
2111
4512
7613
8109
S9056-0
J22
J23
J24
+5.0V0
GNDH0
+120V0
+5.0V1
GNDH0
+120V1
A +5.0A RTNA +120
B +5.0B RTNB +120
A +5.0A RTNA +120
B +5.0B RTNB +120
Cable Assembly 120/5V-U1-0
Assem
bly Draw
ing and BO
MInterconnection S
cheme
Wires Tw
isting
AMS-02 TRD Page 20 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
J25
J26
J27
2111
M22759/44-22-2M22759/44-22-0M22759/44-22-3
50mm
L
J2J3J4J5
J1
L1 L2
J1J2/J5J3/J6J4/J7J8/J11J9/J12J10/J13
1,2 3,4,5,6,7,8,10 12
Qty1 connector MS27484E10F35P pc 12 shell MS27506F10-2 pc 13 wire M22759/44-22-0 mm L 24 wire M22759/44-22-1 mm L-L2 25 wire M22759/44-22-2 mm L 26 wire M22759/44-22-3 mm L 27 wire M22759/44-22-4 mm L-L2 28 wire M22759/44-22-9 mm L-L2 29 heat shrinkRW-175 mm 50 3
10 sleeve DM686 ¼” mm L1 111 lacing tapeA-A-52084-PTH-5 pc 212 ring lug AMP 1-332446-1 pc 12
Cable ID L1 L2 L
120/5V-U1-1 1650 120 1850
J6J7J8J9J10J11J12J13
M22759/44-22-2M22759/44-22-0M22759/44-22-3
M22759/44-22-1M22759/44-22-9M22759/44-22-4
M22759/44-22-1M22759/44-22-9M22759/44-22-4
4512
7613
8109
9,11 9,11
[mm]
UPD1 Cable 120/5V-U1-1 U1
J27 J12111
4512
7613
8109
J2J3J4J5J6J7J8J9J10J11J12J13
2111
4512
7613
8109
S9056-1
J28
J29
J30
+5.0V2
GNDH1
+120V2
+5.0V3
GNDH1
+120V3
A +5.0A RTNA +120
B +5.0B RTNB +120
A +5.0A RTNA +120
B +5.0B RTNB +120
Cable Assembly 120/5V-U1-1
Assem
bly Draw
ing and BO
MInterconnection S
cheme
Wires Tw
isting
AMS-02 TRD Page 21 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
J31
J32
J33
2111
M22759/44-22-2M22759/44-22-0M22759/44-22-3
50mm
L
J2J3J4J5
J1
L1 L2
J1J2/J5J3/J6J4/J7J8/J11J9/J12J10/J13
1,2 3,4,5,6,7,8,10 12
Qty1 connector MS27484E10F35P pc 12 shell MS27506F10-2 pc 13 wire M22759/44-22-0 mm L 24 wire M22759/44-22-1 mm L-L2 25 wire M22759/44-22-2 mm L 26 wire M22759/44-22-3 mm L 27 wire M22759/44-22-4 mm L-L2 28 wire M22759/44-22-9 mm L-L2 29 heat shrinkRW-175 mm 50 3
10 sleeve DM686 ¼” mm L1 111 lacing tapeA-A-52084-PTH-5 pc 212 ring lug AMP 1-332446-1 pc 12
Cable ID L1 L2 L
120/5V-U1-2 1600 120 1800
J6J7J8J9J10J11J12J13
M22759/44-22-2M22759/44-22-0M22759/44-22-3
M22759/44-22-1M22759/44-22-9M22759/44-22-4
M22759/44-22-1M22759/44-22-9M22759/44-22-4
4512
7613
8109
9,11 9,11
[mm]
UPD1 Cable 120/5V-U1-2 U1
J28 J12111
4512
7613
8109
J2J3J4J5J6J7J8J9J10J11J12J13
2111
4512
7613
8109
S9056-2
J34
J35
J36
+5.0V4
GNDH2
+120V4
+5.0V5
GNDH2
+120V5
A +5.0A RTNA +120
B +5.0B RTNB +120
A +5.0A RTNA +120
B +5.0B RTNB +120
Cable Assembly 120/5V-U1-2
Assem
bly Draw
ing and BO
MInterconnection S
cheme
Wires Tw
isting
AMS-02 TRD Page 22 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
1.5.1 List of Wires RAM Radiator (UPD1 <> U1) [Units in Centimeters]
Cable Wire in Wire UPD side to UBP twisted (L1) free (L-L1) total wire (L)Identifier pin id Twist PartNo Color Conn/Pin Pad Net length[cm] length[cm] length[cm]
120/5V-U1-0 J2 1 M22759/44-22-2 red J26 / 2 J19 +5.0V0 170 8 178J3 1 M22759/44-22-0 black J26 / 1 J20 GNDH0 170 8 178J4 1 M22759/44-22-3 orange J26 / 11 J21 +120V0 170 8 178
J5 2 M22759/44-22-2 red J26 / 4 J19 +5.0V0 170 8 178J6 2 M22759/44-22-0 black J26 / 5 J20 GNDH0 170 8 178J7 2 M22759/44-22-3 orange J26 / 12 J21 +120V0 170 8 178
J8 3 M22759/44-22-1 brown J26 / 7 J22 +5.0V1 170 20 190J9 3 M22759/44-22-9 white J26 / 6 J23 GNDH0 170 20 190
J10 3 M22759/44-22-4 yellow J26 / 13 J24 +120V1 170 20 190
J11 4 M22759/44-22-1 brown J26 / 8 J22 +5.0V1 170 20 190J12 4 M22759/44-22-9 white J26 / 10 J23 GNDH0 170 20 190J13 4 M22759/44-22-4 yellow J26 / 9 J24 +120V1 170 20 190
120/5V-U1-1 J2 1 M22759/44-22-2 red J27 / 2 J25 +5.0V2 165 8 173J3 1 M22759/44-22-0 black J27 / 1 J26 GNDH1 165 8 173J4 1 M22759/44-22-3 orange J27 / 11 J27 +120V2 165 8 173
J5 2 M22759/44-22-2 red J27 / 4 J25 +5.0V2 165 8 173J6 2 M22759/44-22-0 black J27 / 5 J26 GNDH1 165 8 173J7 2 M22759/44-22-3 orange J27 / 12 J27 +120V2 165 8 173
J8 3 M22759/44-22-1 brown J27 / 7 J28 +5.0V3 165 20 185J9 3 M22759/44-22-9 white J27 / 6 J29 GNDH1 165 20 185
J10 3 M22759/44-22-4 yellow J27 / 13 J30 +120V3 165 20 185
J11 4 M22759/44-22-1 brown J27 / 8 J28 +5.0V3 165 20 185J12 4 M22759/44-22-9 white J27 / 10 J29 GNDH1 165 20 185J13 4 M22759/44-22-4 yellow J27 / 9 J30 +120V3 165 20 185
120/5V-U1-2 J2 1 M22759/44-22-2 red J28 / 2 J31 +5.0V4 160 8 168J3 1 M22759/44-22-0 black J28 / 1 J32 GNDH2 160 8 168J4 1 M22759/44-22-3 orange J28 / 11 J33 +120V4 160 8 168
J5 2 M22759/44-22-2 red J28 / 4 J31 +5.0V4 160 8 168J6 2 M22759/44-22-0 black J28 / 5 J32 GNDH2 160 8 168J7 2 M22759/44-22-3 orange J28 / 12 J33 +120V4 160 8 168
J8 3 M22759/44-22-1 brown J28 / 7 J34 +5.0V5 160 20 180J9 3 M22759/44-22-9 white J28 / 6 J35 GNDH2 160 20 180
J10 3 M22759/44-22-4 yellow J28 / 13 J36 +120V5 160 20 180
J11 4 M22759/44-22-1 brown J28 / 8 J34 +5.0V5 160 20 180J12 4 M22759/44-22-9 white J28 / 10 J35 GNDH2 160 20 180J13 4 M22759/44-22-4 yellow J28 / 9 J36 +120V5 160 20 180
AMS-02 TRD Page 23 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
Cable Wire in Wire UPD side to UBP twisted (L1) free (L-L1) total wire (L)Identifier pin id Twist PartNo Color Conn/Pin Pad Net length[cm] length[cm] length[cm]
+/-2.5V-U1-0 J2 1 M22759/44-16-2 red J22 / B J1 +2.5V0 135 8 143J3 1 M22759/44-16-0 black J22 / A J2 GNDF0 135 8 143J4 1 M22759/44-16-6 blue J22 / N J3 -2.5V0 135 15 150
J5 2 M22759/44-16-2 red J22 / D J1 +2.5V0 135 8 143J6 2 M22759/44-16-0 black J22 / E J2 GNDF0 135 8 143J7 2 M22759/44-16-6 blue J22 / C J3 -2.5V0 135 15 150
J8 3 M22759/44-16-1 brown J22 / H J4 +2.5V1 135 8 143J9 3 M22759/44-16-9 white J22 / G J5 GNDF0 135 15 150
J10 3 M22759/44-16-7 violet J22 / R J6 -2.5V1 135 15 150
J11 4 M22759/44-16-1 brown J22 / J J4 +2.5V1 135 8 143J12 4 M22759/44-16-9 white J22 / K J5 GNDF0 135 15 150J13 4 M22759/44-16-7 violet J22 / S J6 -2.5V1 135 15 150
+/-2.5V-U1-1 J2 1 M22759/44-16-2 red J23 / B J7 +2.5V2 130 8 138J3 1 M22759/44-16-0 black J23 / A J8 GNDF1 130 8 138J4 1 M22759/44-16-6 blue J23 / N J9 -2.5V2 130 15 145
J5 2 M22759/44-16-2 red J23 / D J7 +2.5V2 130 8 138J6 2 M22759/44-16-0 black J23 / E J8 GNDF1 130 8 138J7 2 M22759/44-16-6 blue J23 / C J9 -2.5V2 130 15 145
J8 3 M22759/44-16-1 brown J23 / H J10 +2.5V3 130 8 138J9 3 M22759/44-16-9 white J23 / G J11 GNDF1 130 15 145
J10 3 M22759/44-16-7 violet J23 / R J12 -2.5V3 130 15 145
J11 4 M22759/44-16-1 brown J23 / J J10 +2.5V3 130 8 138J12 4 M22759/44-16-9 white J23 / K J11 GNDF1 130 15 145J13 4 M22759/44-16-7 violet J23 / S J12 -2.5V3 130 15 145
+/-2.5V-U1-2 J2 1 M22759/44-16-2 red J25 / B J13 +2.5V4 130 8 138J3 1 M22759/44-16-0 black J25 / A J14 GNDF2 130 8 138J4 1 M22759/44-16-6 blue J25 / N J15 -2.5V4 130 15 145
J5 2 M22759/44-16-2 red J25 / D J13 +2.5V4 130 8 138J6 2 M22759/44-16-0 black J25 / E J14 GNDF2 130 8 138J7 2 M22759/44-16-6 blue J25 / C J15 -2.5V4 130 15 145
J8 3 M22759/44-16-1 brown J25 / H J16 +2.5V5 130 8 138J9 3 M22759/44-16-9 white J25 / G J17 GNDF2 130 15 145
J10 3 M22759/44-16-7 violet J25 / R J18 -2.5V5 130 15 145
J11 4 M22759/44-16-1 brown J25 / J J16 +2.5V5 130 8 138J12 4 M22759/44-16-9 white J25 / K J17 GNDF2 130 15 145J13 4 M22759/44-16-7 violet J25 / S J18 -2.5V5 130 15 145
Cable Wire in Wire UPD side to UBP twisted (L1) free (L-L1) total wire (L)Identifier pin id Twist PartNo Color Conn/Pin Pad Net length[cm] length[cm] length[cm]
3.3V-U1-0 J2 1 M22759/44-12-0 black J21 / A J38 DGND 170 15 185J3 1 M22759/44-12-2 red J21 / B J37 +3.3V 170 15 185
J4 2 M22759/44-12-2 red J21 / D J37 +3.3V 170 15 185J5 2 M22759/44-12-0 black J21 / E J38 DGND 170 15 185
AMS-02 TRD Page 24 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
1.5.2 List of Wires WAKE Radiator (UPD0 <> U0) [Units in Centimeters] Cable Wire in Wire UPD side to UBP twisted (L1) free (L-L1) total wire (L)Identifier pin id Twist PartNo Color Conn/Pin Pad Net length[cm] length[cm] length[cm]
120/5V-U0-0 J2 1 M22759/44-22-2 red J26 / 2 J19 +5.0V0 120 8 128J3 1 M22759/44-22-0 black J26 / 1 J20 GNDH0 120 8 128J4 1 M22759/44-22-3 orange J26 / 11 J21 +120V0 120 8 128
J5 2 M22759/44-22-2 red J26 / 4 J19 +5.0V0 120 8 128J6 2 M22759/44-22-0 black J26 / 5 J20 GNDH0 120 8 128J7 2 M22759/44-22-3 orange J26 / 12 J21 +120V0 120 8 128
J8 3 M22759/44-22-1 brown J26 / 7 J22 +5.0V1 120 20 140J9 3 M22759/44-22-9 white J26 / 6 J23 GNDH0 120 20 140
J10 3 M22759/44-22-4 yellow J26 / 13 J24 +120V1 120 20 140
J11 4 M22759/44-22-1 brown J26 / 8 J22 +5.0V1 120 20 140J12 4 M22759/44-22-9 white J26 / 10 J23 GNDH0 120 20 140J13 4 M22759/44-22-4 yellow J26 / 9 J24 +120V1 120 20 140
120/5V-U0-1 J2 1 M22759/44-22-2 red J27 / 2 J25 +5.0V2 115 8 123J3 1 M22759/44-22-0 black J27 / 1 J26 GNDH1 115 8 123J4 1 M22759/44-22-3 orange J27 / 11 J27 +120V2 115 8 123
J5 2 M22759/44-22-2 red J27 / 4 J25 +5.0V2 115 8 123J6 2 M22759/44-22-0 black J27 / 5 J26 GNDH1 115 8 123J7 2 M22759/44-22-3 orange J27 / 12 J27 +120V2 115 8 123
J8 3 M22759/44-22-1 brown J27 / 7 J28 +5.0V3 115 20 135J9 3 M22759/44-22-9 white J27 / 6 J29 GNDH1 115 20 135
J10 3 M22759/44-22-4 yellow J27 / 13 J30 +120V3 115 20 135
J11 4 M22759/44-22-1 brown J27 / 8 J28 +5.0V3 115 20 135J12 4 M22759/44-22-9 white J27 / 10 J29 GNDH1 115 20 135J13 4 M22759/44-22-4 yellow J27 / 9 J30 +120V3 115 20 135
120/5V-U0-2 J2 1 M22759/44-22-2 red J28 / 2 J31 +5.0V4 115 8 123J3 1 M22759/44-22-0 black J28 / 1 J32 GNDH2 115 8 123J4 1 M22759/44-22-3 orange J28 / 11 J33 +120V4 115 8 123
J5 2 M22759/44-22-2 red J28 / 4 J31 +5.0V4 115 8 123J6 2 M22759/44-22-0 black J28 / 5 J32 GNDH2 115 8 123J7 2 M22759/44-22-3 orange J28 / 12 J33 +120V4 115 8 123
J8 3 M22759/44-22-1 brown J28 / 7 J34 +5.0V5 115 20 135J9 3 M22759/44-22-9 white J28 / 6 J35 GNDH2 115 20 135
J10 3 M22759/44-22-4 yellow J28 / 13 J36 +120V5 115 20 135
J11 4 M22759/44-22-1 brown J28 / 8 J34 +5.0V5 115 20 135J12 4 M22759/44-22-9 white J28 / 10 J35 GNDH2 115 20 135J13 4 M22759/44-22-4 yellow J28 / 9 J36 +120V5 115 20 135
AMS-02 TRD Page 25 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
Cable Wire in Wire UPD side to UBP twisted (L1) free (L-L1) total wire (L)Identifier pin id Twist PartNo Color Conn/Pin Pad Net length[cm] length[cm] length[cm]
+/-2.5V-U0-0 J2 1 M22759/44-16-2 red J22 / B J1 +2.5V0 170 8 178J3 1 M22759/44-16-0 black J22 / A J2 GNDF0 170 8 178J4 1 M22759/44-16-6 blue J22 / N J3 -2.5V0 170 15 185
J5 2 M22759/44-16-2 red J22 / D J1 +2.5V0 170 8 178J6 2 M22759/44-16-0 black J22 / E J2 GNDF0 170 8 178J7 2 M22759/44-16-6 blue J22 / C J3 -2.5V0 170 15 185
J8 3 M22759/44-16-1 brown J22 / H J4 +2.5V1 170 8 178J9 3 M22759/44-16-9 white J22 / G J5 GNDF0 170 15 185
J10 3 M22759/44-16-7 violet J22 / R J6 -2.5V1 170 15 185
J11 4 M22759/44-16-1 brown J22 / J J4 +2.5V1 170 8 178J12 4 M22759/44-16-9 white J22 / K J5 GNDF0 170 15 185J13 4 M22759/44-16-7 violet J22 / S J6 -2.5V1 170 15 185
+/-2.5V-U0-1 J2 1 M22759/44-16-2 red J23 / B J7 +2.5V2 165 8 173J3 1 M22759/44-16-0 black J23 / A J8 GNDF1 165 8 173J4 1 M22759/44-16-6 blue J23 / N J9 -2.5V2 165 15 180
J5 2 M22759/44-16-2 red J23 / D J7 +2.5V2 165 8 173J6 2 M22759/44-16-0 black J23 / E J8 GNDF1 165 8 173J7 2 M22759/44-16-6 blue J23 / C J9 -2.5V2 165 15 180
J8 3 M22759/44-16-1 brown J23 / H J10 +2.5V3 165 8 173J9 3 M22759/44-16-9 white J23 / G J11 GNDF1 165 15 180
J10 3 M22759/44-16-7 violet J23 / R J12 -2.5V3 165 15 180
J11 4 M22759/44-16-1 brown J23 / J J10 +2.5V3 165 8 173J12 4 M22759/44-16-9 white J23 / K J11 GNDF1 165 15 180J13 4 M22759/44-16-7 violet J23 / S J12 -2.5V3 165 15 180
+/-2.5V-U0-2 J2 1 M22759/44-16-2 red J25 / B J13 +2.5V4 155 8 163J3 1 M22759/44-16-0 black J25 / A J14 GNDF2 155 8 163J4 1 M22759/44-16-6 blue J25 / N J15 -2.5V4 155 15 170
J5 2 M22759/44-16-2 red J25 / D J13 +2.5V4 155 8 163J6 2 M22759/44-16-0 black J25 / E J14 GNDF2 155 8 163J7 2 M22759/44-16-6 blue J25 / C J15 -2.5V4 155 15 170
J8 3 M22759/44-16-1 brown J25 / H J16 +2.5V5 155 8 163J9 3 M22759/44-16-9 white J25 / G J17 GNDF2 155 15 170
J10 3 M22759/44-16-7 violet J25 / R J18 -2.5V5 155 15 170
J11 4 M22759/44-16-1 brown J25 / J J16 +2.5V5 155 8 163J12 4 M22759/44-16-9 white J25 / K J17 GNDF2 155 15 170J13 4 M22759/44-16-7 violet J25 / S J18 -2.5V5 155 15 170
Cable Wire in Wire UPD side to UBP twisted (L1) free (L-L1) total wire (L)Identifier pin id Twist PartNo Color Conn/Pin Pad Net length[cm] length[cm] length[cm]
3.3V-U0-0 J2 1 M22759/44-12-0 black J21 / A J38 DGND 135 15 150J3 1 M22759/44-12-2 red J21 / B J37 +3.3V 135 15 150
J4 2 M22759/44-12-2 red J21 / D J37 +3.3V 135 15 150J5 2 M22759/44-12-0 black J21 / E J38 DGND 135 15 150
AMS-02 TRD Page 26 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
2 List of Tools
2.1 Wire Cutters
Wire cutting tools that shear the conductor shall be selected in preference to diagonal cutters that cut the conductor by bringing two blade edges together. The cutting edges of wire trimming tools shall be maintained sharp and free from nicks and indentations. Recommended Wire Cutter 512N by EREM or similar.
2.2 Wire Stripper
Either precision mechanical tools or thermal strippers shall be selected for insulation stripping. Thermal strippers shall have variable temperature control. The tools shall not nick, ring, gouge, or stretch conductors or remove plating so that the base metal shows. Superficial scraping of conductors is acceptable providing conductor base material is not exposed. The conductor shall be clean and free from damage. Strands shall be twisted together in the original lay, or as nearly as possible to the original lay.
Use of a Thermal Wire Stripper is recommended.
Fig.5 Thermal Wire Stripper, Model G
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UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
Fig.6: General wire stripping criteria
2.3 Crimper (Connector Pins)
List of mandatory crimping tools: Hand Tool (crimper itself) p/n: M22520/2-01 Hand Tool (crimper itself) p/n: M22520/1-01 AWG 22 turret for M22520/2-01 tool p/n: M22520/2-09 AWG 12-20 turret for M22520/1-01 tool p/n: M22520/1-04
AMS-02 TRD Page 28 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
Crimping Instuction:
1. Insert stripped wire into contact crimp pot. The stripping length of the wires is given in Fig 11. Wire must be visible thru inspection hole. 2. Using correct crimp tool and locator, cycle the tool once to be sure the indentors are open. Insert contact and wire into locator. Fig. 10 shows the socket in the correct position. Squeeze tool handles firmly and completely to insure a proper crimp. The tool will not release unless the crimp indentors in the tool head have been fully actuated. 3. Release crimped contact and wire from tool. Be certain the wire is visible thru inspection hole in contact.
Connector Contact Comment Tool Comment Turret Comment AWG Pin SizeCable Side Connectors (MS27484)MS27474E10F35P 22D-P S9056 M22520/2-01 Crimp Tool 22D M22520/2-09 Turret P 22D 22 22MS27474E16F6P 12-P S9053U M22520/1-01 Crimp Tool 12-20 M22520/1-04 Turret P/S 12-20 12 12MS27474E20F16P 16-P S9048 M22520/1-01 Crimp Tool 12-20 M22520/1-04 Turret P/S 12-20 16 16
Fig.7 Table of mandatory Tools and Turret for Connectors
Fig.8 crimping tool M22520/1-01 and turret M22520/1-04
Pin Size AWG
AMS-02 TRD Page 29 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
fig. 9 crimping tool M22520/2-01 and turret M22520/2-09
Fig. 10 crimping tool backside with socket
Pin Size
AWG
AMS-02 TRD Page 30 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
Fig.11: Wire Stripping length; Dimensions are shown in inches (millimetres)
Fig.12: General crimping criteria
AMS-02 TRD Page 31 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
2.4 Connector Wire Insertion tools
List of mandatory metal insertion/extraction tools: Insert Tool 22D p/n: MS27495 A22M Extract Tool 22D p/n: MS27495 R22M Insert Tool 16 p/n: MS27495 A16 Extract Tool 16 p/n: MS27495 R16 Insert Tool 12 p/n: MS27495 A12 Extract Tool 12 p/n: MS27495 R12
Fig.13: Insertion tool Instruction
AMS-02 TRD Page 32 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
2.5 Crimper Tool for Terminal Ring Lugs
List of mandatory crimping tools: Hand Tool p/n: 69710-1 AWG 22 die for 69710-1 tool p/n: 69732 AWG 16 die for 69710-1 tool p/n: 69733 AWG 12 die for 69710-1 tool p/n: 69735
Manufacturer Crimping Instructions have to be followed:
a. Strip wire insulation using one of the recommended stripping procedures. b. Check tool for correct die for wire thickness. c. Insert terminal lug, tongue first, into wire side of hand tool barrel crimping jaws, until terminal lug barrel butts flush against tool stop on the locator. d. Squeeze tool handles slowly until tool jaws hold terminal lug barrel firmly in place, but without denting it. e. Insert stripped wire into terminal lug barrel until wire insulation butts flush against near end of wire barrel. f. Squeeze tool handles until ratchet releases. g. Remove completed assembly and examine it for proper crimp.
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UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
Fig.14: Genaral crimping criteria for terminal ring lugs
AMS-02 TRD Page 34 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
3. Assembly Steps Instruction
Assembly sequence overview 1) Cut needed wires with total length given in cable sheet +100mm. 2) Crimp one end of wire and insert it into the connector. 3) Do the manual twisting of wires to required length. 4) Apply expando sleeving and heat shrink tube to the cable. 5) Cut Crate-side wires to required length and crimp terminal ring lugs.
Each step of cable assembly is specified in detail in following step-by-step instruction. Last step (5) should be processed during assembly of U-Crates. Assembly work should be based on cable assembly sheets given in chapter 1.4, these instructions gives additional working considerations. 3.1 Preparation of Wires
Cable Length
LL1
UPD side ConnectorTwisted part;Covered by Sleeving Crate side Lugs
Crate Wall
80mm
Fig.15 Cables are devided into twisted part covered by expando sleeving and a not twisted ends of
wires on crate side
Cable length is specified in two parts. First one is a twisted part, where two or three wires merge into a bundle of twisted wires. All bundles of twisted wires form the cable, which is covered by an expandable sleeving. Lengths (L1) in this part are given after twisting. Each single wire of a cable may be of individual additional length in the second part on crate side of the cable. This is because wires will be attached to different pads on the backplane of the crate. In cable
AMS-02 TRD Page 35 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
sheets the given length (L) corresponds to the length of longest wire. In case of shorter wires on crate-side, the difference in length (L2) is given in the assembly drawings. On UPD-side wires are crimped and inserted into connector pins. On Crate-side single wire ends are crimped with gold plated terminal ring lugs. Two set of FM cables are needed to connect two set of UPD Boxes and U-Crates. Each Cable has to be assembled according to its cable assembly sheet from chapter 1. During assembly cut wires with the total wire length (L) given in the corresponding cable sheet +100mm extra length added. This is because cables will shrink a bit when twisted. Prepare one end of each wire for the crimping of connector pins. Remove insulation by wire stripper from one side for all wires in one cable and crimp this side like shown in next paragraph.
Note: Units in cable sheets are given in Millimeters. 3.2 Connector mounting
3.2.1 Connector pins A visual inspection of stripped wire end should be done before pin crimping. The original lay of wire strands must be maintained. Do the crimping on one end of each wire one by one. Before the crimping of pins the correct crimping tool and turret, the AWG adjustment of the tool and the turret pin size need to be chosen according to tools instruction in chapter 2.3. For manual crimping operations prior to wire insertion, the assembler shall examine the crimp contacts. Make sure that wire strands are visible in the inspection hole of the pin to be crimped.
AMS-02 TRD Page 36 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
3.2.2 Connector wiring First step is to assemble the connector and connector backshell. Before the wire insertion the connector should be inspected for damage, scratch, or discoloration. In case of any failure the connector must not be used. Wires with crimped pins are inserted into connectors housing with proper insertion tool. Detailed instructions of tool application are given in chapter 2.4. Wires assignment is given in corresponding cable assembly sheet. Mappings of the equipped connectors are shown in Fig.16 for general overview and should be checked again when the complete connector is assembled. Wires twist assignment is marked.
Cable +/-2.5V-Ux-x
Cable 120/5V-Ux-x Cable 3.3V-Ux-x
Fig.16 Twisted Wires Bundles Overview (connectors in upright position)
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UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
3.3 Twisting of wires The wire twisting should be done by hand only. Do not use a drilling machine, since twisting quality is hard to control. Twisting of three wires should be done with braid technique shown in Fig.17. An example for two wires is shown in fig. 18. Take care of uniformity. Final twisting step should be 3 twists per foot for AWG16/12 wires (1 twist per 10cm) and 6 twists per foot for AWG22 wires (1 twist per 5cm). After twisting one pair, fix it on the end with 3M Capton Tape. Then twist all other pairs one-by-one. A careful visual inspection of wire insulation should be done after twisting. For temporary fixation of twisted wires use 3M capton tape.
Fig.17 Braid twisting instruction 3-wire
fig.18 Twisting Example 2-wire
AWG16: 1 twist per 100mm AWG22: 1 twist per 50mm
100mm (AWG12)
AMS-02 TRD Page 38 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
Do wire twisting until twisted length complies with twisted part (L1) length from corresponding cable sheet. Check wires twist assignment on Fig.16.
3.4 Expandable Sleeving
Materials to prepare (see assembly drawings for quantity):
Expando sleeve DM686 ¼” 5211000603S Kynar heat shrink tube RW-175 Lacing tape A-A-52084-PTH-5
3M Kapton Polyimide Tape 3M 5413 or 3M 5563 if avail. After wire twisting cables ties must not be used. Fix the whole bundle of twisted wires inserted to the same connector with 3M Kapton tape each 20-30cm of length. An expandable sleeving is applied according to a common procedure for all xPD<>Crate Cabling. The bundle of all twisted wires is covered by an expandable sleeving with the length of the twisted part (L1). When the length of the expandable sleeving is fitted, take care that the ends of the sleeve is not frayed. In order to fix the ends lacing tape is wrapped around the wire like show in Fig.19 for xPD and Crate ends. Shrink tube (Kynar RW-175) is applied to cover both ends. The minimum shrink temperature is 155°C (311°F). Make sure that the part of the cable that is covered by expandable sleeving (including connector) and heat shrink tube is of the length (L1) like shown below. “Connector wrench tool” may be the corresponding counterpart connector fixed on metal plate and should be self-assembled.
L1
AMS-02 TRD Page 39 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
twisted wire bundleconnector without shell
wire length = L + 100mm (+/-5cm)
temporary shrink tubefixation
M3 capton tape
20-30cm
shrink tubefixation
50mm40mm
expando sleeve
cut length = L1
lacing tape
shrink tube
50mm
lacing tape
sleeve length = L1 (+/-2cm)
rubber insertconnector shell
2. fix screw 1. use wrenchto fix shell
M3 capton tape
shrink tube
50mm
1
2
3
4
5
6
7
8
Protecting Procedure U<>UPD CablesSTEP
WORKING STEP COMMENTS
1) clean cables and check twisting2) check wirelength: L+10cm (see cablesheet)3) use amount of M3 capton tape as needed to keep wirebundles together
1) preferred shrink tube length: 5cm (max. length: 8cm) 2) Kynar heat shrink tube p/n RW-175
1) see cable sheet for length L12) Expando sleeve DM686 ¼” p/n 5211000603S
1) use amount of lacing tape to increase thickness of cable to fit shell-rubber2) make a knot on beginning and end of wrapping3) use appropriate force to hold sleeve in place4) Lacing tape p/n A-A-52084-PTH-5
1) preferred shrink tube length: 5cm2) Attention : Do not overheat expando sleeve! needed temperatur for heat shrink tube: 155°C
1) use „connector wrench“ to tighten connector shell2) insert rubber and fix shell screws
1) squeeze expando sleeve by pulling away from connector2) check length L1 from connector front to end of sleeve (see cable sheet)
1) see work step 4 comments1) preferred shrink tube length: 5cm2) Attention : Do not overheat expando sleeve! needed temperatur for heat shrink tube: 155°C2) store cable in plastic bag until final installation
NOTES:
NOTES:
NOTES:
NOTES:
NOTES:
NOTES:
NOTES:
NOTES:
Fig.19 Expando Sleeve Fixation
AMS-02 TRD Page 40 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
3.5 Final Cut and Crimping
This step should be done with the U-Backplane on side during U-Crate assembly.
Ends of free wires on crate-side of the cable are cut to length given in tables 1.5.x or corresponding cable sheet. Free cable length must be measured from the end of shrink-tube on crate side of the cable. Note that each single wire of a cable in this part may be of individual additional length. In cable sheets the given length (L) corresponds to the length of longest wire. In case of shorter wires on crate-side, the difference in length (L2) is given in the assembly drawings. Length of the resulting trimmed wire should be checked on U-Crate Backplane immediately. Wires will be attached to different pads on the backplane of the crate. (This step should be done with assistance from TRD group; see Fig.21)
After length of cut wires is checked, remove insulation by electrical wire stripper. Gold plated ring lugs are crimped to the ends of wires according to terminal ring lug mounting instruction in chapter 2.5. Note the different types of ring lugs and tools for AWG12, AWG16 and AWG22 wires.
Fig.20: Sample Cable with applied sleeving
UPD-side Pin connector
Twisted wires covered by expando sleevings
Fixation by lacing tape and shrink tube
Crate-side terminal ring lugs
Free wire ends (length must be exact, see 1.5)
AMS-02 TRD Page 41 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
3.6 Cable Installation
Fig.21: U-Crate Backplane (UBP) with installed cables (prelim.)
For power taps with 2 lugs use screw and washer M3x6, for 3 lugs M3x8 for temporary fixation.
Cables running through the same crate-slot are fixed together by cable tie. Length of protected cable should be of 80mm measured from crate wall.
AMS-02 TRD Page 42 of 42
UPD <> U-Crate Cabling
Assembly Procedure Date 23/Feb/2007
4. Bill of Materials (BOM total)
No Part Number Description Type Unit Qty
1 M22759/44-22-0 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 22, Black wire m 21
2 M22759/44-22-1 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 22, Brown wire m 21
3 M22759/44-22-2 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 22, Red wire m 21
4 M22759/44-22-3 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 22, Orange wire m 21
5 M22759/44-22-4 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 22, Yellow wire m 21
6 M22759/44-22-9 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 22, White wire m 21
7 M22759/44-16-0 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 16, Black wire m 21
8 M22759/44-16-1 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 16, Brown wire m 21
9 M22759/44-16-2 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 16, Red wire m 21
10 M22759/44-16-6 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 16, Blue wire m 21
11 M22759/44-16-7 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 16, Violet wire m 21
12 M22759/44-16-9 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 16, White wire m 21
13 M22759/44-12-0 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 12, Black wire m 8
14 M22759/44-12-2 M22759 Wire, Silver plated, XL-ETFE light weight insulation, AWG 12, Red wire m 8
15 MS27484E10F35P MIL-DTL-38999, Series II, Connector, Straight Grounded Plug, shell 10, 13 pins connector pc 6
16 MS27484E16F6P MIL-DTL-38999, Series II, Connector, Straight Grounded Plug, shell 16, 6 pins connector pc 2
17 MS27484E20F16P MIL-DTL-38999, Series II, Connector, Straight Grounded Plug, shell 20, 16 pins connector pc 6
18 MS27506F10-2 MIL-DTL-38999, Series II, Backshell, Straight Clamping, Shell 10 backshell pc 6
19 MS27506F16-2 MIL-DTL-38999, Series II, Backshell, Straight Clamping, Shell 16 backshell pc 2
20 MS27506F20-2 MIL-DTL-38999, Series II, Backshell, Straight Clamping, Shell 20 backshell pc 6
21 5211000603S Expando sleeve DM686 ¼” sleeving m 2622 RW-175 Kynar heat shrink tube shrink tube m 223 A-A-52084-PTH-5 Lacing tape tape m 5024 AMP 1-332433-0 Ring Lugs for AWG12 (insul.) ring lug pc 825 AMP 332453 Ring Lugs for AWG16 (insul.) ring lug pc 7226 AMP 1-332446-1 Ring Lugs for AWG22 (insul.) ring lug pc 7227 3M 5563/5413 3M Kapton Polyimide Film Tape (acrylic/silicone) tape m 7
Separate BOM for each cable is given in its cable assembly sheet.
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