Whirlwind W5 48 Instruction manual

W5 48 Pin MASS Connector System
Technical Data - Crimp Type
W5CRP
M48/84CH
M48/84CHCAP
M48R-INS
PT1-16CL-PVC
PT1-8BK
M1RPIN
M1RSKT
W5 PIN OUT
W5IRP
M48-IL
M48/84ILCAP
M48R-INS
M48G
PT1-16CL-PVC
PT1-8BK
SPLIT RING
M1RPIN
M1RSKT
W5 PIN OUT
Mass 48 Pin Chassis Connector
Mass Chassis Flange Black
Mass Chassis Dust Cap
Mass Removable Crimp Insert
1/16“ Clear PVC Tube Cut to 1.5“ Length
1/8“ Black Shrink Tube Cut to 0.5“ Length
Mass Gold Pins Male
Mass Gold Sockets Female
Wiring Diagram for Mass 48/84
Mass 48 Pin Inline Connector
Mass 48 Inline Shell with Black Coupling Nut
Mass Inline Dust Cap
Mass 48 Removable Crimp Insert
Strain Relief for W5 inline
1/16“ Clear PVC Tube Cut to 1.5” Length
1/8“ Black Shrink Tube Cut to 0.5” Length
Split ring 3/4” for cap and chain assembly
Mass Gold Pins Male
Mass Gold Sockets Female
Wire Diagram for Mass 48/84
1
1
1
16
16
27
27
1
1
1
1
1
16
16
1
27
27
1
The W5RP is a 48 contact addition to the virtually indestructible
whirlwind Mass Connector family. This new design uses crimp type,
replaceable pins and sockets. Like all Mass connectors, the W5RP
hasequalnumbersofbothpinsandsocketswithintheresilientrubber
insert. This arrangement allows two identical contact inserts to mate,
requiring only a panel mount or inline housing to complete the
assembly. Housings are made from machined aluminum and the
threaded locking ring ensures positive connection even under
adverse conditions. When mating two inline connectors, one locking
ringis merelyunscrewed toexpose threads,which aregripped bythe
otherlockingring.
To properly mate Mass connectors, unscrew the locking rings to
expose the inserts, align the inserts and push together using only
hand pressure and then screw the locking ring on to secure the
connection.
Due to the unique hermaphroditic design the usual connector
designations of male and female do not apply, therefore Mass
connectors are specified as Outputs and Inputs. An Output wired
connector must mate with an Input connector configuration. The
whirlwind wiring standard is odd numbered cable pairs attached to
pinsandevennumberedcablepairsattachedtosocketsintheOutput
connector. Input wiring has odd pairs attached to sockets and even
pairs attached to pins. For example, channel one is on pins in the
Outputconnector andmates withchannel oneon sockets in the Input
connector, which maintains color coding throughout the system. For
planningsystemlayout,whirlwindstandardstartsatthestageboxand
designatesthefirstconnectorasanOutput.
Cables with Mass connectors at both ends require one end to be
wired as an Output and the other wired as Input. Each wire must
connect to a pin at one end and the same numbered socket at the
other.
Parts 2.50“ (SQUARE)
HOLE CUTOUT ACTUAL SIZE
2.00“ (SQUARE)
O 2.25“
O 0.28“
(Strain relief Bushing adds approximately 2“ to Inline)
Materials and Finishes:
Mechanical Data:
Contacts: Copper alloy, hard
gold plate over nickel under
plate per MIL-G-45204
Insulators: Low temperature
elastomer
"O" Rings and Seals: Low
temperature elastomer
Shells and Covers: All
aluminum alloy, black finish,
chain-stainless steel
Operating Temperature:
-40 C to +105 C
-40 F to +221 F
Contacts: #20 AWG Crimp type
(7.5 Amp rating)
Contact Retention: 20 lbs.
minimum
Connector Engagement and
Separation Forces:
15 lbs. maximum
Polarization: Hermaphroditic
Electrical Data:
Operating Voltage: 500 VDC or
400 VAC rms max
Insulation Resistance: 2500
megohm minimum
Contact Resistance: 6
milliohms maximum
Specifications
2.50“
Overall Chain Length 8"
Inline
4.40“ (with cover in place)
3.52“
1.81“
1.38“
2.16“
1.80“ (with cover in place)
0.25“
2.46“
Chassis Mount
®

W5 48 Pin MASS Connector System
Technical Data - Crimp Type
Input
2.75“
1.75“
Insulator covers
transition between
foil and wires
TheW5RPisa rearinsert,rearrelease crimp typeconnector.Contactsare
loaded into the insert body and removed from the rear (wiring side) of the
housing. To prepare the wires for use follow the diagram for removing the
jacket and the foil shield from the cable pair. Be careful not to nick and do not
tin the ends of the wire being stripped. Insulate the drain wires with the clear
PVCtubingandusetheheatshrinktubingoverthefoilofeachpair.
The whirlwind M1R-Tool Kit contains the required tools to attach the
contactsto thewires andto loador removethem fromthe inserthousing. The
crimp tool body is a mil spec Daniels AFM8 with a K13-3 contact locator. The
contactinsertion/extractiontoolisanAMP91067-2.
Before attaching contacts to the wires, the selector knob on the top of the
crimp tool must be set for the proper gauge. Setting 5 is for 24 AWG such as
whirlwindmultipaircableandsetting6isfor22AWGsuchasBelden8451and
1266A.
DATAPLATE
SELECTOR
KNOB
AFM8
Crimp Tool
K13-3
LOCATOR
Strip wire 0.156“
16 Pair Color Code
16 16 16
123
14 14 12 12
10 8
27
8
12
1010
14 5 6 7 8 94
613 14 15 16121110
21 22 23 2420191817
G
G G
G GG
4 2 2 24466 G G
21 22 23 2420191817
13 14 15 16121110
5 6 7 8 94
123
3 1 1 13355 G G
10 810106 GG
9 7 7 7995 G GG
13 13 11 11 1113
G G
15 15 15
G
PINS
SOCKETS
1
3
5
7
9
11
13
15
BLACK
BLACK
BLACK
BLACK
RED
RED
RED
GREEN
RED
GREEN
YELLOW
ORANGE
GREEN
YELLOW
ORANGE
BLUE
16
14
12
10
8
6
4
2
GREEN
GREEN
RED
RED
RED
BLACK
BLACK
BLACK
YELLOW
WHITE
BROWN
BLUE
WHITE
BROWN
BLUE
WHITE
PIN
SOCKET
INPUT
WIRING SIDE OF CONNECTOR
XLR Pin 3 Pin 2 Pin 1
G
Pair #
XLR Pin 3 Pin 2 Pin 1
G
Pair #

99 Ling Road . Rochester, NY 14612 . Phone [phone] . Fax [phone] . Email: [email protected] . http://www.whirlwindusa.com
Output
Check for proper wire strip length by pushing wire into a contact and
looking to see the wire strands through the hole in the side. Load the contact
into the crimp tool locator and push the wire into place. Squeeze the handles
whilemakingsurethatthewirestaysinthewirehole.Thecrimperisafullcycle
racheting type and can only be released by completing the cycle, at which
pointthecrimpcontactwillpullfreelyfromthetool.Inspecttheconnectionand
continue,followingthecolorcodetoapplypinsandsocketstotheproperwire
pairs.
Load the pins and sockets into the insert housing according to the pin out
color code. Contacts are inserted into the hard plastic wafer and pushed into
placewiththeredhandledendoftheinsertiontoolorsmallneedlenosepliers.
Fully inserted contacts are locked in place by spring metal retention clips
embedded in the plastic wafer. In the event a contact must be removed from
the insert use the white handled, extraction end of the contact tool. Carefully
slipthe toolinto theplastic waferuntil thesmall holein theend ofthe extractor
is even with the surface of the wafer. Do not force the tool in as it is easily
deformed.Onlywhenthetoolisproperlyseatedwillthespringfingersrelease,
allowing the contact to be removed. If the wire is still attached, gently pull the
wire to remove it. If the wire is broken, push the contact from the rubber face
sidewithanoppositecontactuntilitisexposedintheback.
PIN
W5 48 Pin MASS Connector System
Technical Data - Crimp Type
White EXTRACTION
Red INSERTION
Tip
Push from opposite side to remove
Make sure Contact
and Wire are fully inserted
before crimping
Crimp
AMP 91067-2
Inspection Hole
1 2 3
5 6 7 8 94
13 14 15 16121110
21 22 23 2420191817
16 16 16
G
14 14 12 12 1214
G G
4 2 2 24466 G G
21 22 23 2420191817
13 14 15 16121110
5 6 7 8 94
1 2 3
10 8 810106 G GG 10 810106 GG
9 7 7 7995 G GG
13 13 11 11 1113
G G
15 15 15
G
3 1 1 13355 G G
PINS
SOCKETS
WIRING SIDE OF CONNECTOR
16 Pair Color Code
2
4
6
8
10
12
14
16
GREEN
RED
RED
RED
BLACK
BLACK
BLACK
BLACK
BLUE
ORANGE
YELLOW
GREEN
ORANGE
YELLOW
GREEN
RED
15
13
11
9
7
5
3
1
BLACK
BLACK
BLACK
RED
RED
RED
GREEN
GREEN
WHITE
BLUE
BROWN
WHITE
BLUE
BROWN
WHITE
YELLOW
PIN
SOCKET
OUTPUT XLR Pin 3 Pin 2 Pin 1
G
Pair #
XLR Pin 3 Pin 2 Pin 1
G
Pair #