Whirlwind W5 48 User Manual

®

W5 48 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

Mechanical Data:

Operating Temperature:

-40 C to +105 C

-40 F to +221 F

(Strain relief Bushing adds approximately 2“ to Inline)

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

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.

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.

1.81“

Parts

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

4.40“ (with cover in place)

3.52“

2.46“

Inline

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

1.80“ (with cover in place)

1.38“

2.16“

Chassis Mount

1
1
1
16
16
27
27
1

1
1
1
1
16
16
1
27
27
1

2.50“

0.25“

Overall Chain Length 8"

2.50“ (SQUARE)

2.00“ (SQUARE)

O 2.25“

O 0.28“

HOLE CUTOUT ACTUAL SIZE

Input

2.75“

1.75“

Strip wire 0.156“

Insulator covers
transition between
foil and wires

The W5RP 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.

W5 48

Pin MASS Connector System

Technical Data - Crimp Type

K13-3

LOCATOR

DATAPLATE

SELECTOR
KNOB

AFM8

Crimp Tool

INPUT

PINS

1 2 3

16 16 16

G

5 6 7 8 94

14 14 12 12

14

G G

6

1010

G GG

GG

G G

13 14 15 16121110

10 8

10 810106

21 22 23 2420191817

4 2 2 24466

12

27

WIRING SIDE OF CONNECTOR

21 22 23 2420191817

G G

G GG

5 6 7 8 94

13 13 11 11 1113

G G

1 2 3

15 15 15

G

3 1 1 13355

13 14 15 16121110

9 7 7 7995

SOCKETS

16 Pair Color Code

XLR

Pair #

16
14
12
10

8
6

8

4
2

Pin 3 Pin 2 Pin 1

G

GREEN
GREEN

RED
RED

RED
BLACK
BLACK
BLACK

YELLOW

WHITE

BROWN

BLUE

WHITE

BROWN

BLUE

WHITE

PIN

SOCKET

1
3
5
7

9
11
13
15

XLR

Pair #

BLACK
BLACK
BLACK
BLACK

RED
RED
RED

GREEN

RED

GREEN

YELLOW

ORANGE

GREEN

YELLOW

ORANGE

BLUE

Pin 3 Pin 2 Pin 1

G