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ASSEMBLY AND WIRING INSTRUCTION

CA-BAYONET IP69K

Circular Connector with Protection Class IP69K

CAS25092E

Bearbeitet:

Geprüft:

Norm:

Änd.-Stand:

Änd.-Datum:

AKU/FA

G5820W

JPE 18.12.2018

ITT Cannon GmbH, D-71384 Weinstadt

1 General Information ....................................................................................... 2

1.1 Scope .......................................................................................................................... 2

1.2 Recommended Method of Mounting........................................................................... 2

1.3 Cross Reference ......................................................................................................... 2

2 Connector Components ................................................................................. 3

2.1 Explosion View Shell Assembly (Box Mounting Receptacle) ..................................... 3

2.2 Explosion View Barrel Assembly (Straight Plug) ........................................................ 3

2.3 Explosion View of Universal Endbell / Concept of Shielding ...................................... 4

3 Contacts and Assembly Tools ....................................................................... 5

3.1 Standard Crimp Contacts ........................................................................................... 5

3.2 Crimping Tools ............................................................................................................ 6

3.3 Insertion Tools ............................................................................................................ 7

3.4 Extraction Tools .......................................................................................................... 8

3.5 Pipe Wrench ............................................................................................................... 8

3.6 Operating Instructions for Machined Contacts ........................................................... 8

4 Preparation .................................................................................................... 9

4.1 Dimensions for Single Conductor, Wire Stripping ...................................................... 9

4.2 Wire Stripping Length for System Cable .................................................................... 9

4.3 Preparation of Shielded System Cable ................Fehler! Textmarke nicht definiert.

5 Assembly Instructions .................................................................................. 10

5.1 Overview and Configuration ..................................................................................... 10

5.2 Insertion of Contacts ................................................................................................. 11

5.3 Removal of Contacts ................................................................................................ 13

5.4 Assembly Instruction for the Universal Endbell ........................................................ 13

6 Annex .......................................................................................................... 16

6.1 Useful Hints ............................................................................................................... 16

6.2 Product Safety Information ....................................................................................... 17

7 Brochure ...................................................................................................... 18

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The provided document is an assembly and wiring instruction for the ITT Cannon CA-BAYONET IP69K Circular Connector. This connector is designed for robust applications requiring a high degree of protection, specifically IP69K, which indicates resistance to high-pressure, high-temperature washdowns, in addition to being dust-tight and submersible (IP68 for 16 hours at 1 bar). It is similar to the CA-B connector series but with enhanced sealing.

Function Description:

The CA-BAYONET IP69K circular connector facilitates secure and reliable electrical connections in harsh environments. It is designed for easy assembly and disassembly, allowing for field termination of wires and cables. The bayonet coupling mechanism ensures quick and positive mating, while the IP69K rating guarantees protection against ingress of dust, water, and other contaminants, even under extreme conditions like high-pressure cleaning. The connector is interchangeable with corresponding types of VG95234 connectors, sharing the same mounting dimensions and contact arrangements, which allows for seamless integration into existing systems. A key feature is the absence of a spring washer and friction ring in the bayonet coupling nut, and it also omits a grommet and ferrule in its standard configuration, relying on a universal endbell and O-ring for sealing.

Important Technical Specifications:

Protection Class: IP69K (dust-tight, protected against high-pressure/steam jet cleaning) and IP68 (16h, 1 bar) when combined with the Universal Endbell and an O-ring between the flange receptacle and wall.
Interchangeability: Compatible with VG95234 types regarding mounting dimensions and contact arrangements.
Contact Sizes and Wire AWG/mm²: A wide range of contact sizes are supported, from 10/20 (0.14-1.0 mm² / 26-18 AWG) up to 500/0 (50.0 mm² / 0 AWG), accommodating various power and signal requirements.
Insulation Diameter: Varies by contact size, e.g., max 3.0 mm for 10/20, max 14.0 mm for 500/0.
Wire Stripping Length: Specified for each contact size, e.g., 6.0 +0.5 mm for 10/20, 13.0 +0.8 -0.4 mm for 500/0.
Endbell Housing Clamping Torque: Ranges from 2.5 - 3 Nm for shell size 10SL to 13 - 16 Nm for shell size 28.
Coupling Nut Clamping Torque: Ranges from 1.0 Nm ±0.2 for cable sealing area D07 (16 mm wrench size) to 3.5 Nm ±0.2 for D19/D20 (34/36 mm wrench size).
Materials: Connectors typically contain conducting (copper, copper alloys, nickel, alumel, chromel, steel) and non-conducting (plastic, natural rubber, synthetic rubber, glass) materials.

Usage Features:

Assembly Flexibility: Parts can be mounted from behind for short and open cables. For longer or pre-connected cables, all parts slide onto the cable before contact assembly.
Contact Insertion:
- Requires specific insertion tools (CIT-20, CIT-16, CIT-12, CIT-8, CIT-4, CIT-0) and guide pins for socket contacts (sizes 15S/16S, 15/16, 12, 25) to prevent insulator/contact damage.
- Contacts are pre-inserted and then fully inserted into the insulator, starting from the center, using slow, continuous pressure until they snap into position.
- Isopropyl alcohol can be used to moisten contacts for easier insertion.
- Damaged or bent contacts must not be installed; they must be removed and replaced.
Cable Preparation: Includes specific dimensions for single conductor wire stripping and system cable stripping (length C, B, A) depending on shell size. Shielded cables require cutting the jacket, removing protective foil, turning over the braid, and fixing it with tape.
Endbell Assembly: Involves mounting the sealing ring (greased), coupling nut, O-ring (ensuring it's not twisted for watertightness), shielding ring (paying attention to tooth pitch), and cable grip. The endbell housing is then screwed over the O-ring and tightened to a specified torque.
Coupling Nut Tightening: The coupling nut is tightened using an open-end wrench to a specified torque. Screw locking varnish can be applied for high vibration applications to prevent loosening.
Safety: Emphasizes proper wiring, use of correct tools, and adherence to specified parameters to prevent electric shock, burns, or fire hazards. Live circuits should not be broken by separating mated connectors.

Maintenance Features:

Contact Removal: Requires specific extraction tools (CET-F80-16, CET-F80-12, CET-8, CET-4, CET-0). The tool is placed over the contact from the mating side, and smooth, continuous pressure is applied to push the contact out.
Visual Inspection: Regular visual checks are recommended for damaged or bent contacts, loose strands, proper crimp quality, and overall integrity of the connector.
Cleaning: Keeping hands, working place, and connectors clean and free of grease is crucial for optimal performance.
Tool Usage: Emphasizes the use of correct crimping, insertion, and extraction tools to ensure proper assembly and prevent damage.
Troubleshooting: Guidelines for identifying issues like loose strands, deformed contacts, or improper crimps.
Product Safety Information: Provides guidance on material content, fire characteristics, electric shock hazards, safe handling, and disposal. It also highlights the importance of adhering to operating voltages, temperature limits, and using the product in accordance with specifications to ensure safety and performance.

ITT CA-BAYONET Specifications

General

Brand	ITT
Model	CA-BAYONET
Category	Cables and connectors
Language	English