1.81“

®

W6 84 Pin MASS Connector System

Technical Data - Crimp Type

Specifications

Materials and Finishes:

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

Blue Locking Ring: Locking ID

Ring for W6 inline

Contacts: #20 AWG Crimp type

(7.5 Amp rating)

Contact Retention: 20 lbs. minimum

Connector Engagement and

Separation Forces:

20 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

Mechanical Data:

Operating Temperature:

-40 C to +105 C

-40 F to +221 F

(Strain relief Bushing adds approximately 2“ to Inline)

4.40“ (with cover in place)

3.52“

The W6RP is an 84 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 W6RP has equal numbers of both pins and sockets within the resilient rubber 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 ring is merely unscrewed to expose threads, which are gripped by the other locking ring.

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 pins and even numbered cable pairs attached to sockets in the Output connector. Input wiring has odd pairs attached to sockets and even pairs attached to pins. For example, channel one is on pins in the

Output connector and mates with channel one on sockets in the Input connector, which maintains color coding throughout the system. For planning system layout, whirlwind standard starts at the stage box and designates the first connector as an Output.

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.

1.80“ (with cover in place)

1.38“ 2.50“

2.46“ 2.16“

Inline

Parts

W6CRP

M48/84CH

M48/84CHCAP

M84R-INS

PT1-16CL-PVC

PT1-8BK

M1RPIN

M1RSKT

W6 PIN OUT

W6IRP

M84-IL

M48/84ILCAP

M84R-INS

M122-SG

PT1-16CL-PVC

PT1-8BK

SPLIT RING

M1RPIN

M1RSKT

W6 PIN OUT

Mass 84 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 84 Pin Inline Connector

Mass 84 Inline Shell with Blue Coupling Nut

Mass Inline Dust Cap

Mass 84 Removable Crimp Insert

Small OD Mass 122 Strain Relief

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

28

28

1

45

1

1

1

1

45

1

1

1

1

28

28

45

45

1

Chassis Mount

0.25“

Overall Chain Length 8“

2.50“ (SQUARE)

2.00“ (SQUARE)

O 2.25“

O 0.28“

HOLE CUTOUT ACTUAL SIZE

Input

W6 84

Pin MASS Connector System

Technical Data - Crimp Type

1.75“

2.75“

Strip wire 0.156“

Insulator covers transition between foil and wires

K13-3

LOCATOR

DATAPLATE

SELECTOR

KNOB

The W6RP is a rear insert, rear release crimp type connector. Contacts are 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

PVC tubing and use the heat shrink tubing over the foil of each pair.

The whirlwind M1R-Tool Kit contains the required tools to attach the contacts to the wires and to load or remove them from the insert housing. The crimp tool body is a mil spec Daniels AFM8 with a K13-3 contact locator. The contact insertion/extraction tool is an AMP 91067-2.

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 whirlwind multipair cable and setting 6 is for 22 AWG such as Belden 8451 and

1266A.

AFM8

Crimp Tool

32

8

INPUT

22

8

G

5 6

26 26

G

14

1 2

28 28

G

7

15

26

16

PINS

8 9

3 4

28 22

G

10

24 24 24

G

17 18 19

11

22

12

22

13 20 21

20 20 20

G

23 24

33

8

14 14

G

34

6

G

35

6

25

14

18 18 18

G

26 27

36

6

12

G

37

4

G

12

38

4

28

12

16 16 16

G

29 30

39

4

10 10

G

40

2

G

41

2

31

10

42

2

WIRING SIDE OF CONNECTOR

32

7

22

7

G

33

7

23

13

G

34

5

G

24

13

35

5

25

13

36

5

26

11

G

37

3

G

17

27

38

3

28

11 11

39

3

29

9

G

40

1

G

30

9

41

1

13 14 15 16 18 19 20 21

19 19 19

G

5 6 7

17 17 17

G

8 9 10

15 15 15

G

11 12

25 25 25 23 23 23 21 21

G G

1 2 3 4

27 27

G

27 21

G

31

9

42

1

SOCKETS

SOCKET

PIN

28 Pair Color Code

XLR

Pair #

8

6

4

14

12

10

2

28

26

24

22

20

18

16

Pin 3

ORANGE

BROWN

BLUE

WHITE

WHITE

GREEN

GREEN

GREEN

RED

RED

RED

BLACK

BLACK

BLACK

Pin 2

YELLOW

YELLOW

BROWN

ORANGE

YELLOW

ORANGE

YELLOW

WHITE

BROWN

BLUE

WHITE

BROWN

BLUE

WHITE

9

11

13

15

17

5

7

1

3

19

21

23

25

27

XLR

Pair #

BLACK

BLACK

BLACK

BLACK

RED

RED

RED

GREEN

GREEN

WHITE

WHITE

BLUE

BLUE

BROWN

Pin 3

RED

GREEN

YELLOW

ORANGE

GREEN

YELLOW

ORANGE

BLUE

BROWN

BLUE

BROWN

YELLOW

ORANGE

ORANGE

Pin 2

Pin 1

G

Pin 1

G

Output

PIN

Crimp

W6 84

Pin MASS Connector System

Technical Data - Crimp Type

AMP 91067-2

Red INSERTION

White EXTRACTION

Inspection Hole

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 while making sure that the wire stays in the wire hole . The crimper is a full cycle racheting type and can only be released by completing the cycle, at which point the crimp contact will pull freely from the tool. Inspect the connection and continue, following the color code to apply pins and sockets to the proper wire 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 place with the red handled end of the insertion tool or small needle nose pliers.

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 slip the tool into the plastic wafer until the small hole in the end of the extractor is even with the surface of the wafer. Do not force the tool in as it is easily deformed. Only when the tool is properly seated will the spring fingers release, 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 side with an opposite contact until it is exposed in the back.

Tip

Make sure Contact and Wire are fully inserted before crimping

Push from opposite side to remove

32

7

OUTPUT

22

7

G

1 2

27 27

G

7 8

PINS

9

3 4

27 21

G

10 5 6 11 12

25 25 25 23 23 23 21 21

G G

14 15 16 17 18 19 20 13 21

19 19 19

G

23 24

33

7

13

G

34

5

G

13

35

5

25

13

17 17 17

G

26

11

G

27 28

11 11

36

5

37

3

G

38

3

15 15 15

G

29 30

39

3

9

G

40

1

G

9

41

1

31

9

42

1

PIN

28 Pair Color Code

XLR

Pair #

9

7

5

15

13

11

3

1

27

25

23

21

19

17

Pin 3

BROWN

BLUE

BLUE

WHITE

WHITE

GREEN

GREEN

RED

RED

RED

BLACK

BLACK

BLACK

BLACK

Pin 2

ORANGE

ORANGE

YELLOW

BROWN

BLUE

BROWN

BLUE

ORANGE

YELLOW

GREEN

ORANGE

YELLOW

GREEN

RED

Pin 1

G

WIRING SIDE OF CONNECTOR

32

8

22

8

G

33

8

34

6

G

23 24

14 14

G

14

35

6

25

14

36

6

37

4

G

26 27

12 12

G

17

38

4

28

12

39

4

40

2

G

29 30

10 10

G

20

41

2

13 15 16 18 19 21

20 20 20

G

5 6

26

G

26

7

26

18 18 18

G

8 9

1 2

10

24 24 24

G

3

16 16 16

G

11 12

4

22 22

28 28

G

28 22

G

31

10

42

2

SOCKETS

SOCKET

8

10

12

14

16

2

4

6

18

20

22

24

26

28

XLR

Pair #

BLACK

BLACK

BLACK

RED

RED

RED

GREEN

GREEN

GREEN

WHITE

WHITE

BLUE

BROWN

ORANGE

Pin 3

WHITE

BLUE

BROWN

WHITE

BLUE

BROWN

WHITE

YELLOW

ORANGE

YELLOW

ORANGE

BROWN

YELLOW

YELLOW

Pin 2 Pin 1

G

99 Ling Road . Rochester, NY 14612 . Phone 585 663-8820 . Fax 585 865-8930 . Email: [email protected] . http://www.whirlwindusa.com

6/03