Whirlwind TV Cables W5 48 User Manual

®
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  
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.  
W5 48 Pin MASS Connector Sys tem  
Technical Data - Crimp Type  
Specifications  
Contacts : # 20 AWG Crimp type  
(7.5 Amp rating)  
Contact Retention: 20 lbs.  
minimum  
Connector Engagement and  
Separation Forces :  
Materials and Finis hes :  
Contacts : Copper alloy, hard  
gold plate over nickel under  
plate per MIL-G-45204  
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.  
15 lbs. maximum  
Ins ulators : Low temperature  
elastomer  
Polarization: Hermaphroditic  
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.  
"O" Rings and Seals : Low  
temperature elastomer  
Shells and Covers : All  
aluminum alloy, black finish,  
chain-stainless steel  
Electrical Data:  
Operating Voltage: 500 VDC or  
400 VAC rms max  
Ins ulation Res is tance: 2500  
megohm minimum  
Contact Res is tance: 6  
milliohms maximum  
Mechanical Data:  
Operating Temperature:  
-40 C to + 105 C  
-40 F to + 221 F  
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.  
(Strain relief Bushing adds approximately 2“ to Inline)  
4.40“ (with cover in place)  
3.52“  
1.80“ (with cover in place)  
1.38“  
2.50“  
1.81“  
2.46“  
2.16“  
0.25“  
Chas s is Mount  
Inline  
Overall Chain Length 8"  
2.50“ (SQUARE)  
2.00“ (SQUARE)  
Parts  
W5CRP  
Mas s 48 Pin Chas s is 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  
1
1
1
16  
16  
27  
27  
1
M48/84CH  
M48/84CHCAP  
M48R-INS  
PT1-16CL-PVC  
PT1-8BK  
M1RPIN  
Mass Gold Sockets Female  
Wiring Diagram for Mass 48/84  
M1RSKT  
W5 PIN OUT  
1
1
1
1
Mas s 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  
W5IRP  
M48-IL  
M48/84ILCAP  
M48R-INS  
M48G  
PT1-16CL-PVC  
PT1-8BK  
SPLIT RING  
M1RPIN  
M1RSKT  
16  
16  
1
27  
27  
1
O 2.25“  
Mass Gold Sockets Female  
Wire Diagram for Mass 48/84  
W5 PIN OUT  
O 0.28“  
HOLE CUTOUT ACTUAL SIZE  
 
Output  
W5 48 Pin MASS Connector Sys tem  
Technical Data - Crimp Type  
AMP 91067-2  
Crimp  
Red INSERTION  
PIN  
White EXTRACTION  
Ins pection Hole  
Tip  
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.  
Make s ure Contact  
and Wire are fully ins erted  
before crimping  
Pus h from oppos ite s ide to remove  
OUTPUT  
PINS  
16 Pair Color Code  
Pin 3  
Pin 2  
Pin 1  
G
XLR  
Pair #  
15  
13  
11  
9
GREEN  
RED  
RED  
BLUE  
ORANGE  
YELLOW  
GREEN  
ORANGE  
YELLOW  
GREEN  
RED  
1
2
3
15  
15  
15  
G
RED  
4
5
6
7
8
9
7
5
3
1
BLACK  
BLACK  
BLACK  
BLACK  
13  
13  
13  
11  
11  
11  
G
G
10  
11  
12  
13  
14  
15  
16  
5
9
9
9
7
7
7
G
G
G
17  
18  
19  
20  
21  
22  
23  
24  
5
5
3
3
3
1
1
1
PIN  
G
G
WIRING SIDE OF CONNECTOR  
17  
18  
19  
20  
21  
22  
23  
24  
6
6
4
4
4
2
2
2
G
G
SOCKET  
10  
11  
12  
13  
14  
15  
16  
6
10  
10  
10  
8
8
8
2
4
6
8
10  
12  
BLACK  
BLACK  
BLACK  
RED  
RED  
RED  
WHITE  
BLUE  
BROWN  
WHITE  
BLUE  
BROWN  
WHITE  
YELLOW  
G
G
G
4
5
6
7
8
9
14  
14  
14  
12  
12  
12  
G
G
1
2
3
16  
16  
16  
G
14  
16  
GREEN  
GREEN  
SOCKETS  
Pin 3  
Pin 2  
Pin 1  
G
XLR  
Pair #  
99 Ling Road . Roches ter, NY 14612 . Phone 585 663-8820 . Fax 585 865-8930 . Email: s ales @whirlwindus a.com . http://www.whirlwindus a.com  
 

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