®
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
Output
PIN
Crimp
Inspection Hole
W5 48
Pin MASS Connector System
Technical Data - Crimp Type
AMP 91067-2
Red INSERTION
White EXTRACTION
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.
OUTPUT
PINS
1 2 3
15 15 15
G
5 6 7 8 94
13 13 11 11 1113
G G
G GG
G G
13 14 15 16121110
9 7 7 7995
21 22 23 2420191817
3 1 1 13355
Make sure Contact
and Wire are fully inserted
before crimping
Push from opposite side to remove
16 Pair Color Code
XLR
Pair #
15
13
11
9
7
5
3
1
PIN
Tip
Pin 3 Pin 2 Pin 1
GREEN
RED
RED
RED
BLACK
BLACK
BLACK
BLACK
BLUE
ORANGE
YELLOW
GREEN
ORANGE
YELLOW
GREEN
RED
G
WIRING SIDE OF CONNECTOR
21 22 23 2420191817
G G
G GG
GG
5 6 7 8 94
14 14 12 12 1214
G G
1 2 3
16 16 16
G
SOCKETS
99 Ling Road . Rochester, NY 14612 . Phone 585 663-8820 . Fax 585 865-8930 . Email: sales@whirlwindusa.com . http://www.whirlwindusa.com
4 2 2 24466
13 14 15 16121110
10 8 810106
10 810106
SOCKET
2
4
6
8
10
12
14
16
XLR
BLACK
BLACK
BLACK
RED
RED
RED
GREEN
GREEN
WHITE
BLUE
BROWN
WHITE
BLUE
BROWN
WHITE
YELLOW
Pin 3 Pin 2 Pin 1
Pair #
G
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