1
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Standard MAG-MATE
Terminals
Product Facts
■Terminates all magnet wire
film insulations
■Eliminates need for pre-
stripping conductors
■Eliminates need to post
insulate termination
■Excess magnet wire is
automatically trimmed
during the termination
process
■Simultaneously terminates
two magnet wires of the
same size in one terminal
(for splicing or bi-filing)
■Various lead wire
attachment options
available
■Available in strip form for
semi-automatic or fully
automatic insertions
■Available in loose piece
form for hand tool insertions
■Varnish resist tab terminals
are available for special
applications
■High speed, fully automated
integrated systems provide
uniform terminations
reliability at the lowest
possible applied cost
■Clean metal-to-metal
interface produces stable,
gas-tight electrical
terminations free of oxides
and other contaminants
■Recognized under the
Component Recognition
Program of Underwriters
Laboratories Inc.,
File No. E13288
Applications
■Motor windings and
connections
■Coil connections
■Transformer windings and
connections
■Bobbin connections
■Lighting ballasts
■Power supplies
R
Tyco Electronics offers a full
selection of AMP Standard
MAG-MATE Insulation
Displacement Crimp (IDC)
terminals for magnet wire
terminations.
MAG-MATE terminals are
available in poke-in, poke-in
tab, splice, crimp wire
barrel, solder post, quick
connect tab, pin and
receptacle styles.
Standard MAG-MATE
terminates magnet wire
ranging from 34-12 AWG
[0.16 -2.05 mm].
Each IDC slot terminates up
to four consecutive magnet
wire ranges.
Two magnet wires with the
same diameter can be
terminated in one terminal
down to 23 AWG [0.57 mm].
According to Tyco Electronics
specifications MAG-MATE
cavities are either
integrated into coil bodies
or especially designed
cavity housings. The
magnet wires are precisely
positioned in the “U”shaped
designed termination slots.
The MAG-MATE Inserter
cuts the terminals from the
strip and places the
terminals over the magnet
wire into the plastic cavities.
During this operation the
small stripping devices
penetrate the film insulation
from the magnet wire.
Residual spring energy in
the terminal causes the side
walls of each IDC slot to
function as opposing
cantilever beams.
This constant pressure
results in an intimate metal-
to-metal interface, providing
a reliable, long-term
connection.
The wiping action between
the wire and terminals
removes oxides or other
contaminants present on
both the conductor and the
terminal slot side walls,
producing a clean, stable,
gas-tight electrical
termination.
The AMP MAG-MATE
Inserter may be used as a
semi-automatic bench
machine or integrated in
production lines for fully-
automatic applications.
2Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Typical Plastic Cavities
Manufacture only according
to Tyco Electronics
Specification.
Cavity Size 1,
.187 [4.75] Box Height MAG-MATE
(Reference Application
Spec. 114-2069)
Cavity Size 2,
.300 [7.62] Box Height MAG-MATE
(Reference Application
Spec. 114-2046)
Cavity Size 3,
.300 [7.62] Box Height
Latch-In MAG-MATE, Wide Body
(Reference Application
Spec. 114-2094)
Cavity Size 4,
.500 [12.70] Box Height
MAG-MATE
(Reference Application
Spec. 114-2066)
Cavity Size 5,
.300 [7.62] Box Height
Latch-In MAG-MATE, Narrow
Body
(Reference Application
Spec. 114-2067)
.215
[5.46]Min. .235
[5.97]Min.
.355
[9.08]Min.
Cavity Size 6,
.300 [7.62] Box Height
MAG-MATE
(Reference Application
Spec. 114-2046)
Note: MAG-MATE typical
plastic cavities are not for
design; Tyco Electronics
will supply required
dimensions of cavity for
each customer application.
Plastic cavities, designed
to Tyco Electronics
specifications, may be
molded as part of the coil
bobbin or attached to a
lamination stack in the area
of the magnet wire coil.
Each cavity is a rectangular
box with two narrow slots
on opposing walls and a
plastic post or anvil
extending upward from the
bottom surface.
During or after the winding
process, the magnet wire is
placed across the plastic
cavities and into the slots,
either manually or by coil
winding equipment.
Unraveling is prevented by
a slight friction fit, suitable
bend or by wrapping the
magnet wire around a tie-off
post.
During insertion, two
insulation displacing
terminal slots strip the film
insulation from the magnet
wire producing a stable
electrical termination.
The plastic anvil supports
the magnet wire, helping to
prevent it from being
dragged down when the
terminal is inserted.
Terminal retention is
secured in the plastic
cavities by either locking
barbs or locking latches in
addition to locking barbs for
quick disconnect FASTON
tab terminals.
Excess magnet wire is
trimmed flush with the
outside of the plastic cavity
by a shear blade traveling
with the terminal insertion
ram.
The sheared wire end can
be tucked inside the plastic
cavity, if necessary, by
cutting the wire off before
the terminal is fully seated
allowing the terminal to drag
the severed end of the wire
into the pocket inside the
cavity.
Tyco Electronics will
provide design and mold
engineering resources to
manufacture any
specifically designed
MAG-MATE cavity
housing.
Technical Documents
Application Specifications
describe requirements for using
the product in its intended
application and or crimping
information. They are intended
for the Packaging and Design
Engineer and the Machine
Setup Person.
114-2050—Poke-In Tab
MAG-MATE
Terminals
114-2069—Standard
MAG-MATE .187
[4.75] Box Height
Terminals
114-2046—Standard
MAG-MATE .300
[7.62] Box Height
Terminals
114-2066—Standard
MAG-MATE .500
[12.7] Box Height
Terminals
114-2067—Standard
MAG-MATE .300
[7.62] Box Height
Latch-In Terminals
Narrow Body
114-2094—Standard
MAG-MATE .300
[7.62] Box Height
Latch-In Terminals
Wide Body
3
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Standard MAG-MATE
Terminals
➀Wire Cutter
This part cuts off the
excess magnet wire and
the wire support at the
front of the cavity.
➁Insertion Finger
The insertion finger is part
of the MAG-MATE
Inserter. It pushes the
terminal that was sheared
from the carrier strip
through the inserter “tube”
into the positioned cavity.
➂Contact
Various wire attachments
in three different sizes,
.187, .300, .500 cavity
height (see tables).
➃IDC Slot
In different sizes for
magnet wire diameters
from 34-12 AWG
[0.16-2.05 mm]. Strain
relief slots available
for high vibration
applications.
➄Stripping Shoulders
During the insertion
process, these shoulders
strip the film insulation
from the magnet wire in
four areas.
Standard MAG-MATE
Interconnection System
How the System Operates ➅Locking Barbs
Terminal retention is
secured in the cavity by
four locking barbs.
➆Plastic Cavity
Production must be in
accordance with
Tyco Electronics
Application Specifications.
Consulting
Tyco Electronics is
required for design in.
➇Cavity Slot for Wire
The width has to be in
accordance with the wire
size (see Application
Specification).
➈Magnet Wire
The magnet wire is
positioned in the “U” slot.
➉Wire Support Block
The block supports the
magnet wire during the
cutting process. The
magnet wire is cut flush
to the cavity front side.
Anvil
The anvil supports the
wire during the insertion
process.
Termination Sequence
A = Prepare
B = Insert
C= Finish
➀ Post Trim Blade
➁ Insertion Finger
➂ Poke-In Contact
➃ MAG-MATE Cavity
➄ Magnet Wire
➅ Support Anvil
➂
➀
A B C
➁
➃
➄
➅
11
➃
➂
➅
➈
➄
➆
➇
➉
➀
➁
11
4Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Resistance vs Current Cycles (Copper Wire)Resistance vs Thermal Shock (Copper Wire)
Test Current produces 100°C Magnet Wire Operating Temperature
Current Rating Curves
The diagram shows the
temperature rise of the
contact, depending on the
magnet wire size being
applied.
I (A)
∆T (C)
Test Results
Standard and Slim Line
MAG-MATE products have
been submitted to the following
tests without significant millivolt
increase:
Current Cycling —
480 cycles with each cycle
consisting of 15 minutes “ON”
followed by 15 minutes “OFF”
Thermal Shock —
25 cycles with each cycle
consisting of 30 minutes at
125°C followed by 30 minutes
at -65°C
Humidity —
Temperature Cycling
10 cycles between 25°C and
65°C at 95% RH
Heat Age —
33 days at 118°C
Mini MAG-MATE products
have been submitted to the
following tests in addition to
those listed without significant
millivolt increase:
Vibration —
10-55-01- Hz traversed in 1
minute at .06 inches total
excursion; 2 hours in each of 3
mutually perpendicular
directions.
Industrial Gas with Chlorine —
1000 exposure to 200 ppb each
of sulphur dioxide, nitrogen
dioxide, hydrogen sulphide and
50 ppb chlorine.
Product Specifications
describe technical performance
characteristics and verification
tests. They are intended for the
Design, Test and Quality
Engineer.
108-2012 Standard .187and
.300 MAG-MATE
Terminals
108-2053 Standard .500 Box
MAG-MATE
Terminals
108-1484 Slim Line MAG-MATE
Terminals
108-2016 Mini MAG-MATE
Terminals
33 AWG
30 AWG
27 AWG
26 AWG
24 AWG
22 AWG
19 AWG
16 AWG
15 AWG
Note: For all applications,
Tyco Electronics recommends that
samples of the magnet wire to be
used be submitted for engineering
evaluation.
5
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Standard MAG-MATE
Terminals
300 Box Poke-In Terminals
Material
Tin plated brass
Typical Cavity Size 2
(See page 2)
.300
[7.62]
.300
[7.62]
.118
[3.00]
.135
[3.43]
.300
[7.62]
.118
[3.00]
.135
[3.43]
.118
[3.00]
.135
[3.43]
ABC
Type Copper Magnet Wire Range1Lead Wire Range3Stock Part Number*
AWG mm AWG mm2Thickness Strip L. P. Dual L. P.
34-33 0.16-0.18 20-18 0.5-0.9 .010 63662-1 ——
0.25
33-31 0.18-0.23 20-18 0.5-0.9 .010 62431-1 62527-1 —
0.25
31-28 0.23-0.32 20-18 0.5-0.9 .012 1217234-1 ——
0.30
30-27 0.25-0.36 20-18 0.5-0.9 .012 62429-1 62526-1 63855-1
A0.30 63636-18——
300 Box 27-23 0.36-0.57 20-18 0.5-0.9 .016 62935-1 63044-1 62842-1
Standard IDC ——
0.41 63754-15——
Locking 25-2220.45-0.64 20-18 0.5-0.9 .016 63658-1 1217757-1 —
Poke-In 0.41 1217084-15
.016 62420-1 62524-1 62841-1
22-2020.64-0.81 20-18 0.5-0.9 0.41 62420-46——
1217824-11——
—— 63725-15——
2020.81 20-18 0.5-0.9 .016 63591-1 ——
0.41
19-1720.91-1.15 20-18 0.5-0.9 .016 62833-1 62912-1 1217736-1†
0.41
30 0.25 20-18 0.5-0.9 .012 63786-1†——
B40.30
300 Box 29-2820.29-0.32 20-18 0.5-0.9 .012 1217011-1 ——
Standard IDC w/ 0.30
Strain Relief Slot 28-2620.32-0.40 20-18 0.5-0.9 .012 1217368-1 ——
Locking 0.30
Poke-In 27-2320.36-0.57 20-18 0.5-0.9 .016 63789-1 ——
0.41
31-28 0.23-0.32 ——
.012 1217026-1 ——
0.30
.012 63590-17——
30-27 0.25-0.36 —— 63590-2 ——
0.30 63590-36——
C.016 63551-17——
300 Box 27-23 0.36-0.57 —— 63551-2†——
Standard IDC 0.41 63551-36——
Non-Locking 27-26 0.36-0.40 ——
.016 1217192-1 ——
Poke-In 0.41
25.5-24 0.43-0.51 ——
.016 1217191-1 ——
0.41
23.5-2220.54-0.64 ——
.016 1217190-1 ——
0.41
21.5-2020.68-0.81 ——
.016 1217189-1 ——
0.41
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only; 22 AWG [0.64 mm] or larger unless otherwise noted.
3Solid or overcoated stranded lead wire only. Product will also accept Poke-In Tab Terminal shown on page 7.
4Strain relief slot for high vibration applications.
5Enhanced anti-overstress behind Poke-In feature for severe applications. Part does not accept lead wires.
6Finish is tin plated phosphor bronze.
7Finish is tin over nickel plated brass.
8Deep Poke-In design for enhanced lead wire retention. Special cavity design required. Contact Tyco Electronics Engineering for details.
* Recognized under the Component Program of Underwriters Laboratories, Inc.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
Preferred part numbers are printed in bold.
Chart continued on next page
6Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
300 Box Poke-In Terminals
(Continued)
Material
Tin plated brass
Typical Cavity Size 2
(See page 2)
Note: Special cavity required for
Tri-slot splice terminal.
Contact Tyco Electronics
Engineering for details.
.300
[7.62]
.118
[3.00]
.455
[11.56]
.300
[7.62]
.118
[3.00]
.135
[3.43]
DE
Type Copper Magnet Wire Range1Stock Strip
AWG mm Thickness Part Number
23-19.5 0.57-0.86 .016 1217069-1
A0.41
500 Box 19-17 0.91-1.15 .016 1217068-1
Standard IDC 0.41
Non-Locking 16-15 1.29-1.45 .016 1217067-1
Poke-In 0.41
23-21.5 0.57-0.68 .016 1217358-1
0.41
B321-19.5 0.72-0.86 .016 1217357-1
500 Box 0.41
Standard IDC w/ 19-17 0.91-1.15 .016 1217356-1
Strain Relief Slot 0.41
Non-Locking 16-15 1.29-1.45 .016 1217355-1
Poke-In 0.41
14-1321.61-1.83 .016 1217579-1†
0.41
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only.
3Strain relief slot for high vibration applications.
†These part numbers are available upon special request; contact
Tyco Electronics Engineering for details.
500 Box Poke-In Terminals
Material
Tin plated brass
Typical Cavity Size 4
(See page 2)
.281
[7.14]
.118
[3.00]
.505
[12.83]
.505
[12.83]
.281
[7.14] .118
[3.00]
AB
Type Copper Magnet Wire Range1Stock Strip
AWG mm Thickness Part Number
27-26 0.36-0.40 .016 1217429-1 .
D40.41 1217691-13.
300 Box 25.5-24 0.43-0.51 .016 1217428-1 .
Standard IDC w/ 0.41 1217690-13
Strain Relief Slot 23.5-2220.54-0.64 .016 1217427-1 .
Non-Locking 0.41 1217689-13
Poke-In 21.5-2020.68-0.81 .016 1217426-1 .
0.41 1217688-13
.016
30-2720.25-0.36 0.41 1217221-1†
E.016
300 Box 27-2320.36 -0.57 0.41 63632-1
Standard IDC .016
Tri-Slot 23-2020.57-0.81 0.41 1217533-1†
Non-Locking 27-2320.36-0.57 .016Poke-In 19-1720.91-1.15 63975-1
1820.8-0.9 0.41
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only; 22 AWG [0.64 mm] or larger.
3Enhanced anti-overstress behind Poke-In feature for severe applications. Part
does not accept lead wires.
4Strain relief slot for high vibration applications.
†These part numbers are available upon special request; contact Tyco Electronics
Engineering for details.
* Recognized under the Component Program of Underwriters Laboratories, Inc.
7
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Standard MAG-MATE
Terminals
Poke-In Tab Terminals
Materials
Tin plated brass
AB CD
.312
[7.92]
.208
[5.28]
.135
[3.43]
.312
[7.92]
.340
[8.64]
.135
[3.43]
EFG
1Stranded, fused stranded or solid lead wire.
2Shallow tab serrations.
3Tab serration on top of tab only.
4No serrations on tab.
5Includes diode slot for 20 AWG [0.8 mm] diameter solid
copper diode wire.
6 Special serration location for deeper poke-in.
7 Deeper poke-in. Special cavity detail required.
† These part numbers are available upon special request;
contact Tyco Electronics Engineering for details.
* Recognized under the Component Program of
Underwriters Laboratories, Inc.
Note: All tab terminals accept stranded, fused stranded
or solid lead wire.
H
Type Lead Wire Size1Ins. O.D. Stock Strip
AWG mm2Thickness Part Number
.018 62895-1*
A22-18 0.3-0.9 —0.46
90°Up .020 63410-1
0.51
22-18 0.3-0.9 .060-.100 .018 62896-1*
B1.52-2.54 0.46 1217132-12
90°Up 18-14 0.8-2.0 .090-.140 .020 63218-1
w/Ins. Sup. 2.29-3.56 0.51
22-18 0.3-0.9 —.020 62897-1*
C0.51
Straight 18-14 0.8-2.0 —.020 63775-1
0.51 62898-1*
22-18 0.3-0.9 .060-.100 .018 63574-13
D1.52-2.54 0.46 63631-14,†
Straight 1217470-15
w/Ins. Sup. 18-14 0.8-2.0 .090-.140 .020 63397-1†
2.29-3.56 0.51
E.018
90°Down 22-18 0.3-0.9 —0.46 63364-1
F.090-.140 .020 63458-1
90°Down 18-14 0.8-2.0 2.29-3.56 0.51 1217214-16
w/Ins. Sup.
G20-16 0.5-1.4 —.020 1217406-17
Flag - 300 Box only 0.51 1217875-1†
H18-14 0.8-2.0 .080-.120 .032 1217324-1
Flag - 500 Box only 2.03-3.05 0.81
Poke-In System
.370
[9.40]
.110
[2.79]
.245
[6.22]
.285
[7.24]
.347
[8.81]
.540
[13.72]
Optional Slot for
#20 AWG [0.8 mm] Dia.
Solid Copper Diode Slot
8Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
300 Box Splice Terminals
Material
Tin plated brass
.300 [7.62] Series Box
Typical Cavity Size 2, when
“C” dimension is .120 [3.05]
(See page 2)
Typical Cavity Size 6, when
“C” dimension is .070 [1.78]
(See page 2)
Note: Special cavity required for
Tri-slot splice terminal.
Contact Tyco Electronics
Engineering for details.
Type Copper Magnet Wire Range1Dim. Stock Part Number
AWG mm C Thickness Strip L. P.
33-31 0.18-0.23 .070 .012 —63531-1
1.78 0.30
A31-28 0.23-0.32 .070 .012 —63532-1
300 Box 1.78 0.30
Standard IDC 27-24 0.36-0.50 .070 .012 —63533-1†
Splice 1.78 0.30
20-1830.81-1.02 .120 .020 62903-1 —
3.05 0.51
28-24 0.32-0.51 —.016 1217858-1†—
0.41
23-2020.57-0.81 .016 1217853-1†—
B—0.41
300 Box 27-23 0.36-0.57
Standard IDC 1840.8-0.9 —.016 1217613-1†—
Tri-Slot 19-1720.91-1.15 0.41
Splice 25-2230.45-0.64
1840.8-0.9 —.016 1217209-1 —
23.5-2020.54-0.81 0.41
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only; 22 AWG [0.64 mm] or larger.
3Bare wire only.
4Single solid or fused stranded lead wire only.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
.300
[7.62]
.120
[3.05]
.455
[11.56]
BA
Type Copper Magnet Wire Range1Solid Lead Wire Range Stock Strip
AWG mm AWG mm Thickness Part Number
32-31 0.20-0.23 26-24 0.40-0.51 .012 63005-1†
A0.30
165 Box 30-28 0.25-0.32 26-24 0.40-0.51 .012 63087-1†
Standard IDC 0.30
Splice 30-27 0.25-0.36 26-24 0.40-0.51 .012 62766-1†
0.30
1Two magnet wires may be terminated in the same terminal lower slot if diameters are equal.
† These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
Dual Connection Terminals
Material
Tin plated brass
Note: Special cavity required.
Contact Tyco Electronics
Engineering for details.
A
9
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Standard MAG-MATE
Terminals
.345
[8.76]
.185
[4.70]
.110
[2.79]
.070
[1.78]
B
Dual Connection Terminals
(Continued)
Material
Tin plated phos. bronze
Note: Special cavity required.
Contact Tyco Electronics
Engineering for details.
Type Copper Magnet Wire Range1Mating Tab Stock Strip
AWG mm Thickness Part Number
32-31 0.20-0.23 .070 x .020 .010 1217538-1
B1.78 x 0.51 0.25
185 Box 30-28 0.25-0.32 .070 x .020 .010 1217457-1
Standard IDC 1.78 x 0.51 0.25
Tab Receptacle 29-28 0.29-0.32 .070 x .020 .010 1217458-1
1.78 x 0.51 0.25
1Two magnet wires may be terminated in the same slot if diameters are equal.
A
Type Copper Magnet Wire Range1Dim. Lead Wire Range3Stock Part Number
AWG mm CAWG mm2Thickness Strip L. P.
.070 22-18 0.3-1.0 .012 63235-1 —
33-31 0.18-0.23 1.78 0.30
.120 24-20 0.2-0.6 .012 63420-1†—
3.05 0.30
31-28 0.23-0.32 .070 22-18 0.3-1.0 .012 63236-1 —
1.78 0.30
30-27 0.25-0.36 .120 24-20 0.2-0.6 .012 62992-1 —
A3.05 0.30
300 Box 28-24 0.32-0.51 .120 24-20 0.2-0.6 .012 63641-1 —
Standard IDC 3.05 0.30
F-Crimp 27-24 0.36-0.51 .070 22-18 0.3-1.0 .012 63237-1 —
1.78 0.30
27-23 0.36-0.57 .120 24-20 0.2-0.6 .016 62459-1 62666-1†
3.05 0.41
25-22 0.45-0.64 .070 22-18 0.3-1.0 .012 63690-1†—
1.78 0.30
22-2020.64-0.81 .120 24-20 0.2-0.6 .016 62458-1 62665-1†
3.05 0.41
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only; 22 AWG [0.64 mm] or larger.
3Stranded, fused stranded or solid lead wire.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
300 Box F-Crimp Terminals
Material
Tin plated brass
.300 [7.62] Series Box
Typical Cavity Size 2, when
“C” dimension is .120 [3.05]
(See page 2)
Typical Cavity Size 6, when “C”
dimension is .070 [1.78]
(See page 2)
10 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
.090
[2.29] .070
[1.78]
.187
[4.75]
.360
[9.14]
A
.090
[2.29]
.467
[11.86]
.187
[4.75]
.070
[1.78]
B
187 Box F-Crimp Terminals
Material
Tin plated brass
.187 [4.75] Series Box
Typical Cavity Size 1
(See page 2)
300 Box Posted PCB
Terminals
Solder Terminal
Material
Tin over copper plated brass
Typical Cavity Size
(See page 2)
Type A—Cavity Size 2
Type B—Cavity Size 6
L
.042
[1.07]
.300
[7.62]
.070
[1.78]
.135
[3.43]
BA
L
Copper Magnet Wire Range1Dim. Stock Thickness Strip
Type AWG mm LTab Section Mag Wire Part Number
33-31 0.18-0.23 .540 .010 .010 63253-1
13.72 0.25 0.25
31-28 0.23-0.32 .540 .010 .010 62928-1*
13.72 0.25 0.25
A29-26 0.29-0.40 .540 .012 .012 62958-1*
300 Box 13.72 0.30 0.30
Standard IDC 27-23 0.36-0.57 .460 .016 .016 63659-1
PCB Post 11.68 0.41 0.41
22-2020.64-0.81 .460 .016 .016 63660-1
11.68 0.41 0.41
19-1720.91-1.15 .460 .016 .016 63661-1
11.68 0.41 0.41
B.475 .020 .012
PCB Post 33-31 0.18-0.23 12.07 0.51 0.30 1217302-1
Shallow Box
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only.
* Recognized under the Component Program of Underwriters Laboratories, Inc.
Note: PC Board hole size .050 [1.27].
Type Copper Magnet Wire Range1Lead Wire Range3Ins. O.D. Stock Strip
AWG mm AWG mm2Thickness Part Number
33-31 0.18-0.23 26-22 0.12-0.3 —.010 63039-1
0.25 63039-23,5
.012 63036-1
30-28 0.25-0.32 26-22 0.12-0.3 —0.30 62608-14
A62608-34
187 Box 27-25 0.36-0.46 26-22 0.12-0.3 —.012 62609-14
Standard IDC 0.30 62609-34
F-Crimp 26-24 0.40-0.51 22-18 0.3-1.0 —.012 1217146-1
0.30
24-2220.51-0.64 26-22 0.12-0.3 —.012 62610-14
0.30
B
187 Box 27-25 0.36-0.46 22-18 0.3-1.0 .071-.088 .012 63856-1
F-Crimp 1.80 -2.23 0.30 63856-2
w/ Ins Sup.
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only.
3Stranded, fused stranded or solid lead wire.
4Strip rereeled to feed through mini-applicator to crimp lead wire first, magnet wire termination is secondary operation.
11
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Standard MAG-MATE
Terminals
187 Box Posted PCB
Terminals
Material
Tin plated brass, except where noted
Typical Cavity Size 1
(See page 2)
A
Type Copper Magnet Wire Range1Dim. Stock Thickness Part Number
AWG mm LStrip L.P.
.267 .010 63565-10—
33-31 0.18-0.23 6.78 0.25
.330 .010 62938-1062934-1 .
8.38 0.25 62938-23—
.267 .012 63160-10—
6.78 0.30
A.287 .012 63818-10—
187 Box 30-28 0.25-0.32 7.29 0.30
Standard IDC .330 .012 62430-1062874-1 .
PCB Post 8.38 0.30 62430-23—
27-25 0.36-0.46 .330 .012 62438-10—
8.38 0.30 62438-20
.287 .012 63819-10—
7.29 0.30
24-2220.51-0.64 .330 .012 62439-1063645-1†
8.38 0.30 62439-24—
62439-33—
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only.
3Reverse reeled version of -1.
4Finish is tin over nickel plated brass.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
L
L
.090
[2.29]
.070
[1.78]
.187
[4.75]
A
187 Box Tab Terminals
Material
Tin plated brass, except when noted
Typical Cavity Size 1
(See page 2)
Type Copper Magnet Wire Range1Dim. Stock Thickness Strip
AWG mm LTab Size Tab Section Mag Wire Part Number
30-28 0.25-0.32 .432 .110 x .020 .020 .012 63702-1
10.97 2.79 x 0.51 0.51 0.30
A29-27 0.29-0.36 .432 .110 x .020 .020 .012 1217196-13
187 Box 10.97 2.79 x 0.51 0.51 0.30
Standard IDC 30 0.25 .550 .071 x .025 .025 .012 1217405-1
Straight Tab 14.00 1.80 x 0.63 0.63 0.30
25-2220.46-0.64 .700 .059 x .032 .032 .012 1217013-1
17.78 1.50 x 0.81 0.81 0.30
B.565 .059 x .032 .032 .012 1217641-1
187 Box 27-25 0.36-0.45 14.36 1.50 x 0.81 0.81 0.30
Standard IDC .700 .059 x .032 .032 .012 1217459-1
Offset Tab-R.H. 17.78 1.50 x 0.81 0.81 0.30
C.565 .059 x .032 .032 .012 1217642-1
187 Box 14.36 1.50 x 0.81 0.81 0.30
Standard IDC 27-25 0.36-0.45 .700 .059 x .032 .032 .012 1217460-1
Offset Tab-L.H. 17.78 1.50 x 0.81 0.81 0.30
1Two magnet wires may be terminated in the same terminal if diameters are equal.
2Single magnet wire only.
3Finish is tin over nickel plated brass.
.090
[2.29]
L
.187
[4.75]
.070
[1.78]
Right
.070
[1.78]
L
.187
[4.75]
.090
[2.29]
Left
BC
12 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Type Copper Magnet Wire Range1Dim. Tab Size Stock Thickness Part Number
AWG mm LTab Section Mag Wire Strip L.P.
.750 .063 x .025 .025 .016 63965-12—
A20 0.79 19.05 1.60 x 0.63 0.63 0.41
300 Box .895 .063 x .025 .025 .016 1217595-12—
Standard IDC 22.73 1.60 x 0.63 0.63 0.41
Straight Tab 31 0.23 .870 .062 x .032 .032 .010 63810-1 —
22.10 1.57 x 0.81 0.81 0.25
.660 .071 x .025 .025 .010 63909-1 —
B33-31 0.18-0.23 16.76 1.80 x 0.63 0.63 0.25
300 Box .669 .091 x .025 .025 .010 63927-1 —
Standard IDC 17.75 2.31 x 0.63 0.63 0.25
Offset Tab-R.H. 30 0.25 .669 .091 x .025 .025 .010 1217052-12—
17.75 2.31 x 0.63 0.63 0.25
.660 .071 x .025 .025 .010 63910-1 —
C33-31 0.18-0.23 16.76 1.80 x 0.63 0.63 0.25 63910-23—
300 Box .669 .091 x .025 .025 .010 63926-1 —
Standard IDC 17.75 2.31 x 0.63 0.63 0.25
Offset Tab-L.H. 30 0.25 .669 .091 x .025 .025 .010 1217051-13—
17.75 2.31 x 0.63 0.63 0.25
D31-28 0.23-0.32 1.230 .071 x .025 .025 .012 63773-1 —
300 Box 31.25 1.80 x 0.63 0.63 0.30
Standard IDC
Universal 32 0.20 1.098 .118 x .025 .025 .010 63247-1 1217032-1
Offset Tab 27.90 3.00 x 0.63 0.63 0.25 63247-23—
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Tinsel wire only.
3Reverse reeled version of -1.
300 Box Tab Terminals
Material
Tin plated brass
Typical Cavity Size 2
(See page 2)
DB
.135
[3.43] .120
[3.05]
L
.300
[7.62]
C
.135
[3.43] .120
[3.05]
L
.300
[7.62]
A
.135
[3.43] .120
[3.05]
L
.300
[7.62]
E
Type Copper Magnet Wire Range1Dim. Tab Size Stock Thickness Strip
AWG mm CTab Section Mag Wire Part Number
33-31 0.18-0.23 .070 .125 x .020 .020 .012 63806-1
1.78 3.17 x 0.51 0.51 0.30
31-28 0.23-0.32 .070 .125 x .020 .020 .012 63807-1
E1.78 3.17 x 0.51 0.51 0.30
300 Box 27-24 0.36-0.50 .070 .125 x .020 .020 .012 63808-1
Standard IDC 1.78 3.17 x 0.51 0.51 0.30
Twisted Tab 2120.72 .120 .118 x .030 .030 .016 63463-1
3.05 3.00 x 0.76 0.76 0.41
19.520.86 .120 .118 x .030 .030 .016 63216-1
3.05 3.00 x 0.76 0.76 0.41
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only.
.135
[3.43] .120
[3.05]
L
.300
[7.62]
C
Typical Cavity Size 2, when
“C” dimension is .120 [3.05]
(See page 2)
Typical Cavity Size 6, when
“C” dimension is .070 [1.78]
(See page 2)
13
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Standard MAG-MATE
Terminals
300 Box Tab Terminals
(Continued)
Material
Tin plated brass
Typical Cavity Size 2
(See page 2)
L
.310
[7.87]
.135
[3.43] .120
[3.05]
GF
.300
[7.62]
L
.120
[3.05]
.132
[3.35]
Type Copper Magnet Wire Range Dim. Tab Size Stock Thickness Strip
AWG mm LTab Section Mag Wire Part Number
33-31 0.18-0.23 .585 .118 x .020 .020 .010 1217746-1†
14.86 3.00 x 0.51 0.51 0.25
30 -28 0.25-0.32 .585 .118 x .020 .020 .010 1217745-1†
14.86 3.00 x 0.51 0.51 0.25
.585 .118 x .020 .020 .016 63973-1
27-23 0.36-0.57 14.86 3.00 x 0.51 0.51 0.41
.585 .125 x .020 .020 .016 63489-1
F14.86 3.00 x 0.51 0.51 0.41
300 Box 25-2220.45-0.64 .585 .118 x .020 .020 .016 1217596-1†
Standard IDC 14.86 3.00 x 0.51 0.51 0.41
Timer Tab 23.5-21.520.54-0.68 .585 .118 x .020 .020 .016 1217593-1†
14.86 3.00 x 0.51 0.51 0.41
23-2020.57-0.81 .775 .125 x .020 .020 .016 63899-1
19.68 3.00 x 0.51 0.51 0.41
19-1720.91-1.15 .585 .118 x .020 .020 .016 63972-1
14.86 3.00 x 0.51 0.51 0.41
18 Lead21.02 .585 .118 x .020 .020 .016 63974-1
14.86 3.00 x 0.51 0.51 0.41 63974-23
G425-2220.45-0.64 .665 .118 x .020 .020 .016 1217210-1
300 Box 16.89 3.00 x 0.51 0.51 0.41 1217210-23
Standard IDC
Poke-In 23.5-2020.54 0.81 .665 .118 x .020 .020 .016 1217211-1
Combination Tab 16.89 3.00 x 0.51 0.51 0.41
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only; 22 AWG [0.64 mm] or larger.
3Reverse reeled version of -1.
4Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] Solid or overcoated stranded lead wire or 90°Poke-In tab.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
14 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Type Copper Magnet Wire Range1Pin Stock Thickness Part Number
AWG mm Dia. I/O Mag Wire Strip L.P.
A
300 Box 27-23 .0.36-0.57 .060 .010 .010 63722-1 —
Straight Pin 1.52 0.25 0.25
B
300 Box 33-31 0.18-0.23 .048 .010 .010 63443-1 —
Offset Pin-R.H. 1.22 0.25 0.25
33-31 0.18-0.23 .048 .010 .010 63444-1 —
1.22 0.25 0.25
31-28 0.23-0.32 .048 .010 .010 63569-1 63879-1
C1.22 0.25 0.25
300 Box 27-23 0.36-0.57 .048 .010 .016 63570-1 63880-1
Offset Pin-L.H. 1.22 0.25 0.25
25-2220.45-0.64 .048 .010 .016 63788-1 —
1.22 0.25 0.41
27-23 0.86-1.15 .090 .016 .016 63278-13—
D2.29 0.41 0.41
500 Box 22-20 0.64-0.81 .090 .016 .016 63277-13—
Straight Pin 2.29 0.41 0.41
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only; 22 AWG [0.64 mm] or larger.
3Varnish resist coating.
Pin I/O Terminals
Material
Tin plated brass
.300 [7.62] Series Box
Styles A, B and C
Typical Cavity Size 2
(See page 2)
.500 [12.7] Series Box
Style D
Typical Cavity Size 4
(See page 2)
CB D
.135
[3.43]
.060
[1.52]
.120
[3.05]
.789
[20.29]
.300
[7.62]
A
Pin Receptacle Terminals
with Right or Left Hand
Diode Lead Slot
Material
Tin plated brass
Typical Cavity Size 2
(See page 2)
Copper Magnet Wire Range1Diode Lead Mating Stock Thickness Strip
Type AWG mm AWG mm Pin Dia. I/O Mag Wire Part Number
A.094 .014 .010 63208-1†
300 Box 32-31 0.20-0.23 22 0.64 2.39 0.36 0.25 63326-1
Diode Offset- R.H.
B.094 .014 .010 63209-1†
300 Box 31-27 0.23-0.36 22 0.64 2.39 0.36 0.25 63308-1
Diode Offset- L.H.
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
A
.092
[2.34]Dia.
.135
[3.43] .120
[3.05]
.300
[7.62]
.913
[23.20]
.092
[2.34]Dia.
.135
[3.43] .120
[3.05]
.300
[7.62]
.913
[23.20]
B
.135
[3.43]
.120
[3.05]
.135
[3.43]
.120
[3.05]
.280
[7.11]
.120
[3.05]
15
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Standard MAG-MATE
Terminals
110 Series
FASTON Tab Terminals
Material
Tin plated brass
Typical Cavity Size 2
(See page 2)
A
Note: .110 [ 2.79] Tab Terminals mate with compatible FASTON receptacles.
Request AMP Catalog 82004.
Type Copper Magnet Wire Range1Diode Lead Tab Size Dim. Stock Thickness Part Number
AWG mm AWG mm LTab Mag Wire Strip L.P.
A22 0.64 .110 x .032 .965 .032 .010 63319-1†—
300 Box 31-27 0.23-0.36 2.79 x 0.81 24.51 0.81 0.25
Standard IDC 20 0.81 .110 x .032 .965 .032 .010 63331-1†63434-1
.110 [2.79] 2.79 x 0.81 24.51 0.81 0.25
FASTON w/ 20 0.81 .110 x .032 .965 .032 .014 —63529-1
Diode Slot 30-27 0.25-0.36 2.79 x 0.81 24.51 0.81 0.36
Offset-R.H. 20 0.81 .110 x .032 .895 .032 .014 63177-1†—
2.79 x 0.81 22.73 0.81 0.36
B22 0.64 .110 x .032 .965 .032 .010 63276-1†—
300 Box 31-27 0.23-0.36 2.79 x 0.81 24.51 0.81 0.25
Standard IDC 20 0.81 .110 x .032 .965 .032 .010 63330-1†63433-1
.110 [2.79] 2.79 x 0.81 24.51 0.81 0.25
FASTON w/ 20 0.81 .110 x .032 .965 .032 .014 —63530-1
Diode Slot 30-27 0.25-0.36 2.79 x 0.81 24.51 0.81 0.36
Offset-L.H. 20 0.81 .110 x .032 .895 .032 .014 63178-1†—
2.79 x 0.81 22.73 0.81 0.36
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
L
A
L
Diode Lead
Slot
B
Copper Magnet Wire Range1Diode Lead Tab Stock Thickness Strip
Type AWG mm AWG mm Size Tab Mag Wire Part Number
A——
.110 x .025 .025 .010 63110-1
300 Box 2.79 x 0.64 0.64 0.25
Standard IDC 33-31 0.18-0.23
.110 [2.79] Tab w/ 22 0.64 .110 x .025 .025 .010 63376-1
Optional Diode Slot 2.79 x 0.64 0.64 0.25
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
Optional Slot for
22 AWG [0.64 mm] Dia.
Solid Copper Diode
Wire (2 Wires Max.)
16 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
110 Series
FASTON Tab Terminals
(Continued)
Material
Tin plated brass
Typical Cavity Size 2
(See page 2)
Note: .110 [2.79] Tab Terminals
mate with compatible
FASTON receptacles.
Request AMP Catalog 82004.
A
.625
[15.88]
.120
[3.05]
.135
[3.43]
.300
[7.62]
BC
Type Copper Magnet Wire Range1Tab Stock Thickness Part Number
AWG mm Size Tab Mag Wire Strip L.P.
30-27 0.25-0.36 .110 x .020 .020 .012 63777-1 —
2.79 x 0.51 0.51 0.30
A527-23 0.36-0.57 .110 x .020 .020 .016 63746-1 —
300 Box 2.79 x 0.51 0.51 0.41
Standard IDC 23-2020.45-0.64 .110 x .020 .020 .016 63486-1 —
.110 [2.79] 2.79 x 0.51 0.51 0.41
FASTON Tab 19-17 0.91-1.15 .110 x .020 .020 .020 63145-1†—
2.79 x 0.51 0.51 0.51
B5,6 27-23 0.36-0.57 .110 x .020 .020 .016 63827-1 —
300 Box 2.79 x 0.51 0.51 0.41
Single IDC w/ 23.5-2020.54-0.81 .110 x .020 .020 .016 1217783-1†—
Strain Relief Slot 2.79 x 0.51 0.51 0.41
C4,5 28-24 0.32-0.51 .110 x .020 .020 .012 63062-131217430-13
Poke-In 2.79 x 0.51 0.51 0.30
Combination Tab 25-2220.45-0.64 .110 x .020 .020 .012 63063-13—
2.79 x 0.51 0.51 0.30 63063-2 —
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only; 22 AWG [0.64 mm] or larger.
3Varnish resist coating.
4Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] Solid or overcoated stranded lead wire or 90°Poke-In tab.
5After insertion into plastic cavity, tab portion must be bent over 45°-90°or potted in to prevent pullout when mating
receptacle is disconnected.
6Strain relief slot for high vibration applications.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
17
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Standard MAG-MATE
Terminals
187 Series
FASTON Tab Terminals
Material
Tin plated brass
Typical Cavity Sizes
(See page 2)
Type A—Cavity Size 2
Note: .187 [4.75] Tab Terminals
mate with compatible FASTON
receptacles. Request AMP
Catalog 82004.
Copper Magnet Dim. Tab Stock Thickness Part
Type Wire Range1L Feature Tab Size Tab Mag. Wire Number
AWG mm Section Section Strip L. P.
.630 Dimple .187 x .020 .020 .010 62513-1* 62663-1
33-31 0.18-0.23 16.00 4.75 x 0.51 0.51 0.25
.660 Hole .187 x .020 .020 .012 63584-1 —
16.76 4.75 x 0.51 0.51 0.30
Dimple .187 x .020 .020 .012 62512-1* —
30-27 0.25-0.36 .630 4.75 x 0.51 0.51 0.30 63510-15,†—
16.00 Dimple .187 x .032 .032 .012 62678-1†* 1217178-1
4.75 x 0.81 0.81 0.30
Dimple .187 x .020 .020 .016 62514-1* 63852-1
4.75 x 0.51 0.51 0.41 62514-25*—
.630 Hole .187 x .020 .020 .016 63664-15—
27-23 0.36-0.57 16.00 4.75 x 0.51 0.51 0.41 63664-2 —
—.187 x .020 .020 .016 63461-1 —
4.75 x 0.51 0.51 0.41 1217243-16—
.660 Hole .187 x .020 .020 .016 63585-1 —
16.76 4.75 x 0.51 0.51 0.41
23 0.57 .630 —.187 x .020 .020 .016 63776-1 —
16.00 4.75 x 0.51 0.51 0.41
A4Dimple .187 x .020 .020 .016 62511-1* 62661-1
300 Box 4.75 x 0.51 0.51 0.41 62511-25—
Standard IDC Hole .187 x .020 .020 .016 63663-15—
.187 [4.75] 22-2020.64-0.81 .630 4.75 x 0.51 0.51 0.41 63663-2 —
FASTON 16.00 Dimple .187 x .032 .032 .016 1217065-1 —
Tab 4.75 x 0.81 0.81 0.41
Hole .187 x .032 .032 .016 1217128-1 —
4.75 x 0.81 0.81 0.41
Dimple .187 x .020 .020 .016 63293-1†—
21-1930.72-0.91 .630 4.75 x 0.51 0.51 0.41
Aluminum 16.00 Hole .187 x .020 .020 .016 63669-1 —
4.75 x 0.51 0.51 0.41
Dimple .187 x .020 .020 .020 62904-17—
20-1820.81-1.02 .630 4.75 x 0.51 0.51 0.51
16.00 Hole .187 x .020 .020 .020 63670-1 —
4.75 x 0.51 0.51 0.51
Dimple .187 x .020 .020 .020 63273-1 63829-1
19-1720.91-1.15 .630 4.75 x 0.51 0.51 0.51 63511-15—
16.00 Hole .187 x .020 .020 .020 63665-15—
4.75 x 0.51 0.51 0.51
Dimple .187 x .020 .020 .016 63494-1†—
18.5-16.530.97-1.22 .630 4.75 x 0.51 0.51 0.41
Aluminum 16.00 Hole .187 x .020 .020 .016 63668-1 —
4.75 x 0.51 0.51 0.41
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only.
3Single aluminum magnet wire only.
4After insertion into plastic cavity, tab portion must be bent over 45°-90°or potted in to prevent pullout when
mating receptacle is disconnected.
5Varnish resist coating.
6Special wide body cut off for added stability.
7Single bare copper wire only.
* Recognized under the Component Program of Underwriters Laboratories, Inc.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
A
Chart continued on next page
18 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
.187
[4.75]
L
.310
[7.87]
.120
[3.05]
.135
[3.43]
F
187 Series
FASTON Tab Terminals
(Continued)
Material
Tin plated brass
Typical Cavity Sizes
(See page 2)
Type B—Cavity Size 5
Type C—Cavity Size 5
Type D—Cavity Size 3
187 Series
Combination Poke-In
FASTON Terminals
Material
Tin plated brass
Typical Cavity Sizes
(See page 2)
Type E—Cavity Size 2
Type F—Cavity Size 3
Note: .187 [4.75] Tab Terminals
mate with compatible FASTON
receptacles. Request AMP Catalog
82004.
.187
[4.75]
L
.300
[7.62]
Dimple
.120
[3.05]
.135
[3.43]
CD
E
Copper Magnet Dim. Tab Stock Thickness
Type Wire Range1L Feature Tab Size Tab Mag. Wire Strip
AWG mm Section Section Part Number
33-31 0.18-0.23 .630 Hole .187 x .020 .020 .010 63108-1†
16.00 4.75 x 0.51 0.51 0.25
31-28 0.23-0.32 .630 Hole .187 x .020 .020 .010 62743-1†
16.00 4.75 x 0.51 0.51 0.25
30-27 0.25-0.36 .630 Hole .187 x .020 .020 .012 63109-1†
16.00 4.75 x 0.51 0.51 0.30
Hole .187 x .020 .020 .016 63107-1
27-23 0.36-0.57 .630 4.75 x 0.51 0.51 0.41
16.00 —.187 x .020 .020 .016 1217493-1
B4.75 x 0.51 0.51 0.41
300 Box Hole .187 x .020 .020 .016 63340-1
Standard IDC 23-2020.57-0.81 .630 4.75 x 0.51 0.51 0.41
Narrow Body 16.00 —.187 x .020 .020 .016 1217493-1
Latch Type 4.75 x 0.51 0.51 0.41
22-2020.64-0.81 .630 Hole .187 x .020 .020 .016 63429-1
16.00 4.75 x 0.51 0.51 0.41 63429-26
Dimple .187 x .020 .020 .016 62888-1
19-1720.91-1.15 .630 4.75 x 0.51 0.51 0.41 62888-26
16.00 Hole .187 x .020 .020 .016 63782-1
4.75 x 0.51 0.51 0.41
18 lead20.80-0.92 mm2.630 —.187 x .020 .020 .016 1217592-1†
16.00 4.75 x 0.51 0.51 0.41
C3
Narrow Body 23.5-2020.54-0.81 .630 Dimple .187 x .020 .020 .016 1217004-1
Latch Type w/ 16.00 4.75 x 0.51 0.51 0.41
Strain Relief Slot .630 Dimple .187 x .020 .020 .010 63255-1
33-31 0.18-0.23 16.00 Hole 4.75 x 0.51 0.51 0.25 63544-1†
.730 Hole .187 x .020 .020 .010 63505-1
D18.54 4.75 x 0.51 0.51 0.25
300 Box 31-28 0.23-0.32 .630 Hole .187 x .020 .020 .012 63760-1
Standard IDC 16.00 4.75 x 0.51 0.51 0.30
Wide Body .630 Dimple .187 x .020 .020 .012 63254-1†
Latch Type 30-27 0.25-0.36 16.00 Hole 4.75 x 0.51 0.51 0.30 63478-1†
.730 Hole .187 x .020 .020 .012 63447-1
18.54 4.75 x 0.51 0.51 0.30
27-23 0.36-0.57 .630 Dimple .187 x .020 .020 .016 63256-2
16.00 4.75 x 0.51 0.51 0.41
E4,5
Poke-In 33-31 0.81-0.23 .630 Hole .187 x .020 .020 .010 63018-1
Combination Tab 16.00 4.75 x 0.51 0.51 0.25
F4
Poke-In
Combination Tab 28-24 0.32-0.51 .630 Hole .187 x .032 .032 .016 1217857-1†
Wide Body 16.00 4.75 x 0.81 0.51 0.41
Latch Type
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only; 22 AWG [0.64 mm] or larger.
3Strain relief slot for high vibration applications.
4Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] solid, fused stranded lead wire or 90°poke-in tab terminal.
5After insertion into plastic cavity, tab portion must be bent over 45°-90°or potted in to prevent pullout when mating
receptacle is disconnected.
6Splice free reeling.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
B
.120
[3.05]
Chart continued on next page
Hole or
Dimple
19
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Standard MAG-MATE
Terminals
Copper Magnet Dim. Tab Stock Thickness Part
Type Wire Range1L Feature Tab Size Tab Mag. Wire Number
AWG mm Section Section Strip L. P.
22-20 0.64-0.81 .830 Dimple .187 x .020 .020 .020 —.. 63708-14
21.08 4.75 x 0.51 0.51 0.51
19-17 0.91-1.15 .830 Hole .187 x .020 .020 .020 63643-1 —
21.08 4.75 x 0.51 0.51 0.51
Hole .187 x .020 .020 .020 63667-1463599-14
4.75 x 0.51 0.51 0.51
17.5-16 1.09-1.29 .830 Hole .187 x .020 .020 .020 63427-1†—
G321.08 4.75 x 0.51 0.51 0.51
500 Box Hole .187 x .032 .032 .020 1217075-1 —
Standard IDC 4.75 x 0.81 0.81 0.51
Hole .187 x .020 .020 .020 63666-14—
4.75 x 0.51 0.51 0.51
16-15 1.29-1.45 .830 Hole .187 x .020 .020 .020 63762-1 —
21.08 4.75 x 0.51 0.51 0.51
Dimple .187 x .020 .020 .020 63353-1 —
4.75 x 0.51 0.51 0.51
14.5-1321.54-1.83 .830 Dimple .187 x .020 .020 .016 63428-1 —
21.08 4.75 x 0.51 0.51 0.41
27-23 0.36-0.57 .830 Hole .187 x .020 .020 .020 1217042-1 —
21.08 4.75 x 0.51 0.51 0.51
Hole .187 x .020 .020 .020 63983-1 —
22-20 0.64-0.81 .830 4.75 x 0.51 0.51 0.51
H3,5 21.08 Hole .187 x .032 .032 .020 1217339-1 —
500 Box 4.75 x 0.81 0.81 0.51
Single IDC w/ Hole .187 x .020 .020 .020 63995-1 —
Strain Relief Slot 19-17 0.91-1.15 .830 4.75 x 0.51 0.51 0.51
21.08 Hole .187 x .032 .032 .020 1217090-1 —
4.75 x 0.81 0.81 0.51
16-15 1.29-1.45 .830 Hole .187 x .020 .020 .020 63996-1 —
21.08 4.75 x 0.51 0.51 0.51
J22-20 0.64-0.81 .830 —.187 x .020 .020 .020 1217491-1 —
500 Box 21.08 4.75 x 0.51 0.51 0.51
Standard IDC 19-17 0.91-1.15 .830 —.187 x .020 .020 .020 1217492-1 —
Latch Type 21.08 4.75 x 0.51 0.51 0.51
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only.
3After insertion into plastic cavity, tab portion must be bent over 45°-90°or potted in to prevent pullout when
mating receptacle is disconnected.
4Varnish resist coating.
5Strain relief slot for high vibration applications.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
.187
[4.75]
Hole
L
.505
[12.83]
.120
[3.05]
.281
[7.14]
GH
.187
[4.75]
L
.505
[12.83]
.120
[3.05]
.281
[7.14]
J
187 Series
FASTON Tab Terminals
(Continued)
Material
Tin plated brass
Typical Cavity Sizes
(See page 2)
Type G—Cavity Size 4
Type H—Cavity Size 4
Type J—Cavity Size 4
20 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
.250
[6.35]
.310
[7.87]
.135
[3.43]
L
.120
[3.05]
Hole
D
250 Series
FASTON Tab Terminals
Material
Tin plated brass
Typical Cavity Sizes
(See page 2)
Type A—Use Cavity Size 2
Type B—Use Cavity Size 5
Type C—Use Cavity Size 3
Note: .250 [6.35] tab terminals
mate with compatible FASTON
receptacles. Request AMP Catalog
82004.
Copper Magnet Dim. Tab Stock Thickness Part
Type Wire Range1L Feature Tab Size Tab Mag. Wire Number
AWG mm Section Section Strip L. P.
33-31 0.18-0.231.750 Dimple .250 x .032 .032 .010 62600-1* 62655-1
19.05 6.35 x 0.81 0.81 0.25 62600-27— .
.750 Dimple .250 x .032 .032 .012 62651-1* 62656-1†
30-27 0.25-0.36119.05 Hole 63055-1†— .
Dimple & Hole 6.35 x 0.81 0.81 0.30 63328-1 — .
28-24 0.32-0.511.750 Hole .250 x .032 .032 .016 63607-1 —.
A319.05 6.35 x 0.81 0.81 0.41
300 Box Dimple 62652-17* 62657-1
Standard IDC .750 Dimple .250 x .032 .032 .016 62652-26,7 — .
.250 [6.35] 27-23 0.36-0.57119.05 Dimple 62939-13,4,†— .
FASTON Dimple 6.35 x 0.81 0.81 0.41 63920-17,9 — .
Tab Hole 63159-17,†— .
1.750 .250 x .032 .032 .016 62653-1* 62658-1
22-2020.64-0.81 19.05 Dimple 6.35 x 0.81 0.81 0.41 62653-271217031-17
62653-36— .
20-1820.81-1.021.750 Dimple .250 x .032 .032 .020 63200-1 —.
Bare Wire 19.05 6.35 x 0.81 0.81 0.51
33-31 0.18-0.231.750 Dimple .250 x .032 .032 .010 63026-1†—.
19.05 6.35 x 0.81 0.81 0.25
B30-27 0.25-0.361.750 Dimple .250 x .032 .032 .012 63027-1†—.
Narrow 19.05 6.35 x 0.81 0.81 0.30
Body 27-23 0.36-0.57 .750 Dimple .250 x .032 .032 .016 1217860-1†—.
Latch Type 19.05 6.35 x 0.81 0.81 0.41
23-2020.57-0.81 .750 Dimple .250 x .032 .032 .016 1217870-1†—.
19.05 6.35 x 0.81 0.81 0.41
Dimple 63133-1 — .
33-31 0.18-0.231.750 Hole .250 x .032 .032 .010 63309-1 — .
19.05 Hole 6.35 x 0.81 0.81 0.25 63309-27— .
Hole 63618-18— .
31-28 0.23-0.321.750 Dimple .250 x .032 .032 .012 63403-2†—.
19.05 6.35 x 0.81 0.81 0.30
30-28 0.25-0.321.750 Hole .250 x .032 .032 .012 1217152-1 .—.
19.05 6.35 x 0.81 0.81 0.30
Dimple 63132-1 63203-1†
C Dimple 63132-210 — .
Wide Body 30-27 0.25-0.361.750 Dimple .250 x .032 .032 .012 63132-34— .
Latch Type 19.05 Hole 6.35 x 0.81 0.81 0.30 63499-1 63898-1
Hole 63499-27— .
Hole 63571-1 — .
27-23 0.36-0.571.750 Hole .250 x .032 .032 .016 63571-27— .
19.05 Dimple 6.35 x 0.81 0.81 0.41 63128-1 63207-1†
Dimple 63128-37— .
22-2020.64-0.811.750 Dimple .250 x .032 .032 .016 63601-1 — .
19.05 6.35 x 0.81 0.81 0.41 63601-27— .
19-1720.91-1.151.750 Hole .250 x .032 .032 .016 63614-1 —.
19.05 6.35 x 0.81 0.81 0.41
D5
Poke-In
Combination Tab 28-24 0.32-0.51 .750 Hole .250 x .032 .032 .016 1217856-2†— .
Wide Body 19.05 6.35 x 0.81 0.81 0.41
Latch Type
L
.300
[7.62]
Hole or
Dimple
.120
[3.05]
.135
[3.43]
L
.300
[7.62]
Hole or
Dimple
.120
[3.05]
.135
[3.43]
Locking
Latch
(2)
A
L
.300
[7.62]
Dimple
.120
[3.05]
.135
[3.43]
BC
250 Series
Combination Poke-In
FASTON Tab Terminal
Material
Tin plated brass
Typical Cavity Sizes 3 (Type D)
(See page 2)
Chart continued on next page
1Two magnet wires may be terminated in the same
terminal slot if diameters are equal.
2Single magnet wire only; 22 AWG [0.64 mm] or larger.
3After insertion into plastic holder, tab portion must be
bent over 45°-90°or potted in to prevent pullout when
mating receptacle is disconnected.
4Varnish resist coating.
5Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2]
solid, fused stranded lead wire or 90°Poke-In tab
terminal.
6Reverse reeled version of -1.
7Half hard temper brass.
8Special key hole wire slot block.
9Special wide neck design.
10 Material is unplated brass.
†These part numbers are available upon special request;
contact Tyco Electronics Engineering for details.
* Recognized under the Component Program of
21
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Standard MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Standard MAG-MATE
Terminals
250 Series
FASTON Tab Terminals
(Continued)
Material
Tin plated brass
Typical Cavity Sizes
(See page 2)
Type E—Use Cavity Size 4
Type F—Use Cavity Size 4
EF
Copper Magnet Dim. Tab Stock Thickness Part
Type Wire Range1L Feature Tab Size Tab Mag. Wire Number
AWG mm Section Section Strip L. P.
22-20 0.64-0.81 .952 Hole .250 x .032 .032 .020 63495-1463882-1
24.18 6.35 x 0.81 0.81 0.51
19-17 0.91-1.15 .952 Hole .250 x .032 .032 .020 63464-2†—
E324.18 6.35 x 0.81 0.81 0.51 63464-3463598-1
500 Box 16-15 1.29-1.45 .952 Hole .250 x .032 .032 .020 63459-2 63881-1
Standard IDC 24.18 6.35 x 0.81 0.81 0.51 63459-34—
Wide Neck Dimple .250 x .032 .032 .020 63460-14,†63883-1
14-1321.61-1.83 .952 6.35 x 0.81 0.81 0.51 —1217588-1†
24.18 Hole .250 x .032 .032 .020 63816-1 —
6.35 x 0.81 0.81 0.51 63816-24—
22-20 0.64-0.81 .952 Dimple .250 x .032 .032 .020 63155-1463336-1†
24.18 6.35 x 0.81 0.81 0.51
.952 .250 x .032 .032 .020 62923-14—
F319-17 0.91-1.15 24.18 Dimple 6.35 x 0.81 0.81 0.51 62923-24,5 —
500 Box 62923-34.6 —
Standard IDC 16-15 1.29-1.45 .952 Dimple .250 x .032 .032 .020 63064-1463263-1†
Narrow Neck 24.18 6.35 x 0.81 0.81 0.51
14-1321.61-1.83 .952 Dimple .250 x .032 .032 .020 63465-1 —
24.18 6.35 x 0.81 0.81 0.51 63371-14—
1222.05 .952 Dimple .250 x .032 .032 .020 63425-14—
24.18 6.35 x 0.81 0.81 0.51
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only.
3After insertion into plastic holder, tab portion must be bent over 45°-90°or potted in to prevent pullout when mating
receptacle is disconnected.
4Varnish resist coating.
5Box-up reversed reel version of -1.
6Box-up reeled version of -1.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
LL
22 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Slim Line MAG-MATE Terminals
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02Magnet Wire Terminals and Termination Systems
Product Facts
■Terminates all magnet wire
film insulations
■Eliminates need for pre-
stripping conductors
■Eliminates need to post
insulate termination
■Excess magnet wire is
automatically trimmed
during the termination
process
■Series 187 and 250 Tab
terminals available
■Terminates 33-17 AWG
[0.18-1.15 mm] magnet wire
■Simultaneously terminates
two magnet wires of the
same size in one terminal
from 33-23 AWG [0.18-
0.57 mm]
■Available in strip form for
semi-automatic or fully
automatic insertions
■Available in loose piece
form for hand tool insertions
■Varnish resist tab terminals
are available for special
applications
■High speed, fully automated
integrated systems provide
uniform terminations
reliability at the lowest
possible applied cost
■Clean metal-to-metal
interface produces stable,
gas-tight electrical
terminations free of oxides
and other contaminants
■Recognized under the
Component Recognition
Program of Underwriters
Laboratories Inc.,
File No. E13288
Applications
■Motor windings and
connections
■Coil Connections
■Transformer windings and
connections
■Bobbin connections
■Lighting Ballasts
■Power Supplies
Tyco Electronics offers a full
selection of Series 187 and
250 Slim Line MAG-MATE
Tab insulation displacement
(IDC) terminals for magnet
wire terminations.
Slim Line MAG-MATE
Series 187 and 250 tab
terminals with a single IDC
slot terminate 33-17 AWG
[0.18 to 1.15 mm].
Each IDC slot terminates up
to four consecutive magnet
wire ranges.
Two magnet wires with the
same diameter can be
terminated in one terminal
down to 23 AWG [0.57 mm].
According to Tyco Electronics
specifications MAG-MATE
cavities are either
integrated into coil bodies
or especially designed
cavity housings.The magnet
wires are precisely
positioned in the “U” shaped
designed termination slots.
The MAG-MATE Inserter
cuts the terminals from the
strip and places the
terminals over the magnet
wire into the plastic cavities.
During this operation the
small stripping devices
penetrate the film insulation
from the magnet wire.
Residual spring energy in
the terminal causes the side
walls of each IDC slot to
function as opposing
cantilever beams.
This constant pressure
results in an intimate metal-
to-metal interface, providing
a reliable, long-term
connection.
The wiping action between
the wire and terminals
removes oxides or other
contaminants present on
both the conductor and the
terminal slot side walls,
producing a clean, stable,
gas-tight electrical
termination.
The AMP MAG-MATE
Inserter may be used as a
semi-automatic bench
machine or integrated in
production lines for fully-
automatic applications.
R
Typical Plastic Cavity
Not for design, Tyco Electronics will
supply required dimensions of cavity
for each customer application.
.375
[9.53]
Min.
.270
[6.86] .115
[2.92]
Min. Min.
Reference Application
Spec. 114-2147
Technical Documents
Application Specifications
describe requirements for using
the product in its intended
application and or crimping
information. They are intended
for the Packaging and Design
Engineer and the Machine
Setup Person.
114-2140—Slim Line
MAG-MATE
Terminals
23
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Slim Line MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Slim Line MAG-MATE
Terminals
Magnet Wire Terminals and Termination Systems
187 Series
FASTON Tab Terminals
Material
Tin Plated Brass
250 Series
FASTON Tab Terminals
Material
Tin Plated Brass
L
.250
[6.35] .032
[0.81]
.135
[3.43].016
[0.41]
Hole or
Dimple
B
Copper Magnet Dim. Tab Stock Thickness Part
Type Wire Range1L Feature Tab Size Tab Mag. Wire Number
AWG mm Section Section Strip L. P.
Hole .187 x .020 .020 .012 63710-2 —
33-31 0.18-0.23 .630 Dimple 4.75 x 0.51 0.51 0.30 63738-2 —
16.00 Hole .187 x .032 .032 .012 1217666-1 —
4.75 x 0.81 0.81 0.30
30-28 0.25-0.32 .630 Hole .187 x .020 .020 .012 63711-2 —
16.00 Dimple 4.75 x 0.51 0.51 0.30 63737-2 —
A.630 Hole .187 x .020 .020 .016 63712-2 —
.187 [4.75] 27-24 0.36-0.51 16.00 Dimple 4.75 x 0.51 0.51 0.41 63736-2 —
FASTON Tab .760 Plain .187 x .020 .020 .016 1217497-1 —
19.31 4.75 x 0.51 0.51 0.41 1217497-23—
Hole .187 x .020 .020 .016 63713-2 1217714-1
23-2020.57-0.81 .630 Dimple 4.75 x 0.51 0.51 0.41 63735-2 —
16.00 Hole .187 x .032 .032 .016 1217516-1 —
4.75 x 0.81 0.81 0.41
19-1720.91-1.15 .630 Hole .187 x .020 .020 .016 63714-2 —
16.00 Dimple 4.75 x 0.51 0.51 0.41 63734-2 —
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only; 22 AWG [0.64] or larger.
3Reverse reeled version of -1.
Copper Magnet Dim. Tab Stock Thickness
Type Wire Range1L Feature Tab Size Tab Mag. Wire Strip
AWG mm Section Section Part Number
33-31 0.18-0.23 .752 Hole .250 x .032 .032 .012 63716-2
19.10 Dimple 6.35 x 0.81 0.81 0.30 63744-2
30-28 0.25-0.32 .752 Hole .250 x .032 .032 .012 63717-2
B19.10 Dimple 6.35 x 0.81 0.81 0.30 63743-2
.250 [6.35] 27-24 0.36-0.51 .752 Hole .250 x .032 .032 .016 63718-2
FASTON Tab 19.10 Dimple 6.35 x 0.81 0.81 0.41 63742-2
23-2020.57-0.81 .752 Hole .250 x .032 .032 .016 63719-2
19.10 Dimple 6.35 x 0.81 0.81 0.41 63741-2
19-1720.91-1.15 .752 Hole .250 x .032 .032 .016 63720-2
19.10 Dimple 6.35 x 0.81 0.81 0.41 63740-2
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2Single magnet wire only; 22 AWG [0.64] or larger.
L
.135
[3.43].016
[0.41]
Hole or
Dimple
.187
[4.75] .020
[0.51]
A
24 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Slim Line MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
C
L
.013
[0.33]
.139
[3.53] .032
[0.81]
.059
[1.50]
.220
[5.59]
.135
[3.43]
Copper Magnet Dim. Diode Stock Thickness
Type Wire Range1L Size Tab Size Tab Mag. Wire Strip
AWG mm Section Section Part Number
33-31 0.18-0.23 .725 #20 .059 x .032 0.032 0.012 63888-1
C18.42 0.8 1.50 x 0.81 0.81 0.30
Combination 33-31 0.18-0.23 .725 #22.5 .059 x .032 0.032 0.012 63903-1
Diode Slot/Tab 18.42 0.6 1.50 x 0.81 0.81 0.30
33-31 0.18-0.23 .760 #22.5 .059 x .032 0.032 0.012 1217709-1
19.29 0.6 1.50 x 0.81 0.81 0.30
1Two magnet wires may be terminated in the same terminal slot if diameters are equal.
Tab Terminals
Material
Tin Plated Brass
25
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Mini MAG-MATE Terminals
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Mini MAG-MATE
Terminals
Magnet Wire Terminals and Termination Systems
Product Facts
■Terminates all fine gauge
magnet wire film
insulations
■Eliminates need to pre-
stripping conductors
■Eliminates need to post
insulate termination
■Terminates 52-30 AWG
[0.254-0.0198 mm]
diameter copper magnet
wire
■Poke-In leaf style accepts
22 -18 AWG [0.3-0.9 mm]
overcoated stranded or
solid lead wire
■Available in strip form for
semi-automatic or fully
automatic insertions
■Available in both open and
closed cavity systems
■High speed, fully automated
integrated systems provide
uniform terminations
reliability at the lowest
possible applied cost
■Recognized under the
Component Recognition
Program of Underwriters
Laboratories Inc,
File No. E13288
Applications
■Ignition coils
■Small motors
■Synchronist timers
■Electric meter coils
■Solenoids
■Relays
Tyco Electronics offer AMP
Mini MAG-MATE poke-in,
crimp wire barrel, post and
quick disconnect tab
insulation displacement
(IDC) terminals for fine
gauge magnet wire
terminations.
Mini MAG-MATE terminals
are designed to terminate
52-30 AWG [0.254-
0.198 mm] diameter copper
magnet wire; poke-in leaf
terminals accept 22-18
AWG [0.3-0.9 mm2]
overcoated stranded or
solid lead wire.
The terminal design uses
the AMPLIVAR serrated burr
technology to penetrate the
film insulation of copper
magnet wire.
Mini MAG-MATE cavity
pockets, designed to
Tyco Electronics
specifications, include a
wire receiving slot and wire
tie-off post that is either
integrated into coil bodies
or specially designed cavity
housings.
The magnet wire is
wrapped around the tie-off
post and placed across the
cavity slot. After the coil is
wound, the finish end of the
magnet wire is dressed
through the second cavity
slot and tied to its tie-off
post.
The Mini MAG-MATE
Inserter shears the terminal
from the carrier strip and
insert the terminal into the
cavity by a dual ram
insertion mechanism.
As the unexpanded terminal
approaches the bottom of
the cavity the upper ram
stops. The lower ram
continues to push to a
prescribed depth to expand
the terminal and complete
the termination process.
The fully seated terminal fits
squarely into the cavity,
while the serrated leg of the
terminal cams against the
pre-positioned magnet wire
to penetrate the film
insulation and provide a
stable electrical termination.
Typical Plastic Cavity
Not for design, Tyco Electronics will
supply required dimensions of cavity
for each customer application.
Reference Application
Spec. 114-2047
R
Technical Documents
Application Specifications
describe requirements for using
the product in its intended
application and or crimping
information. They are intended
for the Packaging and Design
Engineer and the Machine
Setup Person.
114-2047—Mini MAG-MATE
Terminals
26 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Mini MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02Magnet Wire Terminals and Termination Systems
Termination Sequence
Terminal Removed from Carrier
Terminal Inserted
Poke-In Tab Terminal
Material
.010 [0.25] tin plated brass
Termination Complete
AB
Type Copper Magnet Wire Range Lead Wire Range1Mating Stock Thickness Strip
AWG mm AWG mm2Tab Poke-In Beam Mag Wire Part Number
52-42 0.02-0.06 22-18 0.3-0.9 —0.010 0.010 62781-1
A0.25 0.25
Lead 44-36 0.05-0.13 22-18 0.3-0.9 —0.010 0.010 62780-1
Wire 0.25 0.25
Poke-In 38-30 0.10-0.25 22-18 0.3-0.9 —0.010 0.010 62606-1
0.25 0.25
52-42 0.02-0.06 ——
.050 x .020 0.010 0.010 63613-13
1.27 x 0.51 0.25 0.25
B44-36 0.05-0.13 ——
.060 x .020 0.010 0.010 63795-12
Tab 1.52 x 0.51 0.25 0.25 63845-12,3
Poke-In 38-30 0.10-0.25 ——
.060 x .020 0.010 0.010 63844-12,3
1.52 x 0.51 0.25 0.25
1Solid or overcoated stranded lead wire only.
2Radius on beam leaf tip.
3Finish is select gold plated on lead tip.
27
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Mini MAG-MATE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Mini MAG-MATE
Terminals
Magnet Wire Terminals and Termination Systems
Posted Terminal
Material
Tin over premilled brass
FASTON Tab Terminals
Material
Tin over premilled brass
Type Copper Magnet Wire Range Post Size Stock Thickness Strip
AWG mm Post Mag Wire Part Number
44-36 0.05-0.13 .024 x .020 .020 .010 1217804-1†
A0.62 x 0.51 0.51 0.25
PCB Post 38-30 0.10-0.25 .024 x .020 0.020 0.010 63675-4
0.62 x 0.51 0.51 0.25
44-36 0.05-0.13 .150 x .020 0.020 0.010 63955-1
B3.81 x 0.51 0.51 0.25
Solder Post 38-30 0.10-0.25 .150 x .020 0.020 0.010 63956-1
3.81 x 0.51 0.51 0.25
C38-30 0.10-0.25 .070 x .020 0.020 0.010 63041-1
Wire Wrap Post 1.78 x 0.51 0.51 0.25
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
Type Copper Magnet Wire Range Tab Size Stock Thickness Strip
AWG mm Post Mag Wire Part Number
A.110 x .020 .020 .010
.110 [2.79] 38-30 0.10-0.25 2.79 x 0.51 0.51 0.25 63161-1
FASTON Tab
44-36 0.05-0.13 .187 x .020 .020 .010 63778-1
B4.75 x 0.51 0.51 0.25
.187 [4.75] 38-30 0.10-0.25 .187 x .020 .020 .010 62816-1
FASTON Tab 4.75 x 0.51 0.51 0.25 1217529-1
44-36 0.05-0.13 .250 x .032 .032 .010 1217000-1
C6.35 x 0.81 0.81 0.25
.250 [6.35] 38-30 0.10-0.25 .250 x .032 .032 .010 63999-1
FASTON Tab 6.35 x 0.81 0.81 0.25
Type Copper Magnet Wire Range Lead Wire Range Stock Thickness Strip
AWG mm AWG mm2Crimp Barrel Mag Wire Part Number
52-42 0.02-0.06 26-22 0.12-0.30 0.010 0.010 63828-1
A0.25 0.25
Crimp 44-36 0.05-0.13 26-22 0.12-0.30 0.010 0.010 1217830-11,†
Wire 0.25 0.25
Barrel 38-30 0.10-0.25 22-18 0.3-0.9 0.010 0.010 63199-11
0.25 0.25 1217231-1†
1Wire and insulation barrel reversed so lead wire exits over magnet wire termination area.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
C
AB C
.060
[1.52]
.880
[22.35]
.138
[3.51]
A
Crimp Wire Barrel Terminal
Material
Tin plated brass
.060
[1.52]
.770
[19.56]
.138
[3.51]
B
.060
[1.52]
.169
[4.29]
.138
[3.51]
.540
[13.72]
A
28 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
SIAMEZE Terminals
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Product Facts
■Terminates all copper
magnet wire film
insulations
■Eliminates need for pre-
stripping conductors
■Moving Beam contact
design connects a wide
range of magnet wire sizes
with a single terminal
■Standard range terminals
connect 34-18 AWG [0.16-
1.0 mm] magnet wire
■Fine range terminals
connect 36-27 AWG [0.13-
0.38 mm] magnet wire
■Medium range terminals
connect 23-12 AWG [0.56-
2.03 mm] magnet wire
■Excess magnet wire is
automatically trimmed
during the termination
process
■Available in strip form for
semi-automatic or fully
automatic insertions
■Loose piece terminals
available for hand tool
insertions
■High-speed automatic coil
winding machine
terminations provide
uniform reliability at the
lowest possible applied cost
■Clean metal-to-metal
interface produces stable,
gas-tight electrical
terminations free of oxides
and other contaminants
■Recognized under the
Component Program of
Underwriters
Laboratories Inc.,
File No. E13288
Applications
■Motor windings and
connections
■Coil connections
■Transformer windings and
connections
■Ballasts
■Power supplies
■Solenoids
■Actuators
R
Tyco Electronics offers a full
selection of AMP SIAMEZE
insulation displacement
(IDC) terminals for
interconnecting copper
magnet wires, lead wires,
and other components.
The AMP SIAMEZE
insulation displacement
(IDC) technology eliminates
the need to strip the film
insulation from copper
magnet wires and lead wires.
Terminals are available in
wire-to-wire, Lead Lok,
quick disconnect tabs,
posts, pin and receptacle
terminals.
Standard Range SIAMEZE
terminals terminate 34-18
AWG [0.16-1.0 mm] copper
magnet wires.
Fine Range SIAMEZE
terminals terminate 36-27
AWG [0.13-0.38 mm]
copper magnet wires.
Medium Range and Heavy
Range SIAMEZE terminals
terminate 23-12 AWG [0.56-
2.03 mm] copper magnet
wires.
Available with either Moving
Beam contacts whereby a
single terminal connects to
a very wide range of
magnet wire sizes, or a
Compliant Beam for
contacting two magnet
wires of the same diameter
in one terminal for splicing
or bi-filar applications.
According to Tyco Electronics
specifications SIAMEZE
cavities are either integrated
into coil bodies or specially
designed cavity housings.
The magnet wires are
positioned in the “U”
shaped slots.
The SIAMEZE Inserter cuts
the terminals from the strip
and places the terminals
over the magnet wire into
the plastic cavities.
During this operation the
small stripping devices
penetrate the film insulation
from the magnet wire.
Residual spring energy in
the terminal causes the side
walls of the IDC slot to
function as opposing
cantilever beams.
This constant pressure
results in an intimate metal-
to-metal interface, providing
a reliable, long-term
connection.
The wiping action between
the wire and terminals
remove all oxides or other
contaminants present on
both the conductor and the
terminal slot side walls,
producing a clean, stable,
gas-tight electrical
termination.
The AMP SIAMEZE Inserter
may be used as a semi-
automatic bench machine
or integrated in production
lines for fully-automatic
applications.
Plastic cavities, designed
to Tyco Electronics
specifications, may be
molded as part of the coil
bobbin or attached to a
lamination stack in the area
of the magnet wire coil.
Each cavity is a rectangular
box with two narrow slots on
opposing walls and a
plastic cutoff or tie-off post.
During or after the winding
process, the magnet wire is
placed across the plastic
cavities and into the slots,
either manually or by coil
winding equipment.
Unraveling is prevented by
a slight friction fit, suitable
bend or by wrapping the
magnet wire around the tie-
off post.
During insertion, the
insulation displacing
terminal slot strip the film
insulation from the magnet
wire producing a stable
electrical termination.
Terminal retention is
retained in the plastic
cavities by single or multiple
locking barbs or locking
latches for large quick
disconnect FASTON tab
terminals.
Excess magnet wire is
trimmed flush with the
outside of the plastic cavity
by a shear blade traveling
with the terminal insertion
ram.
Tyco Electronics can
provide design and mold
engineering resources to
manufacture most
specifically designed
SIAMEZE cavity housings.
.380
[9.65]
Min.
.204
[5.18]
.276
[7.01]
Min. Min.*
Cavity Part Number 1601421
.570
[14.48]
Min.
.140
[3.56]
.350
[8.89]
Min. Min.
Cavity Part Number 1601423
.270
[6.86]
Min.
.104
[2.63]
.276
[7.01]
Min. Min.
Cavity Part Number 1601424
.380
[9.65]
Min.
.104
[2.63]
.276
[7.01]
Min. Min.
Cavity Part Number 1601425
.305
[7.75]
Min.
.104
[2.63]
.276
[7.01]
Min. Min.
Cavity Part Number 1601427
.330
[8.38]
Min.
.116
[2.95]
.276
[7.01]
Min. Min.
Cavity Part Number 1601431
Typical Plastic Cavity —
Pockets
Note: SIAMEZE typical plastic
cavities are not for design;
Tyco Electronics will supply required
dimensions of cavity for each
customer application.
* Minimum dimension with Lead Lok slot.
29
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
SIAMEZE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
SIAMEZE Terminals
30 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
SIAMEZE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
.050
[1.27] Min.
.050
[1.27]
Wrap Post Part Number 1601447
.380
[9.65]
Min.
.167
[4.24]
.276
[7.01]
Min. Min.
Cavity Part Number 1601462
.380
[9.65]
Min.
.167
[4.24]
.276
[7.01]
Min. Min.
Cavity Part Number 1601463 Cavity Part Number 1601470
.380
[9.65]
Min.
.204
[5.18]
Min.*
.490
[12.60]
Min.
Cavity Part Number 1601433
.293
[7.44]
.104
[2.63]
.276
[7.01]
Min.
Min.
Min.
Cavity Part Number 1601434
.535
[13.59]
.135
[3.44]
.446
[11.33]
Min.
Min.
Min.
Cavity Part Number 1601435
.630
[16.00]
.135
[3.44]
.410
[10.41]
Min.
Min.
Min.
Cavity Part Number 1601436
.350
[8.89]
.135
[3.44]
.580
[14.72]
Min.
Min.
Cavity Part Number 1601437
.520
[13.21]
.135
[3.44]
.410
[10.41]
Min.
Min.
Min.
Cavity Part Number 1601438
Typical Plastic Cavity —
Pockets (Continued)
.640
[16.26]
.152
[3.85]
.404
[10.26]
Min.
Min.
Min.
* Minimum dimension with Lead Lok slot.
.380
[9.65]
Min.
.204
[5.18]
Min.*
.716
[18.19]
Min.
Cavity Part Number 1601440
.380
[9.65]
.116
[2.95]
.473
[12.01]
Min.
Min.
Min.
Cavity Part Number 1601432
➀Trim Blade
The trim blade cuts the
excess magnet wire and
the wire cutoff block at
the front of the cavity.
➁Terminal Insertion
Finger
The terminal insertion
finger is part of the
SIAMEZE Inserter. It
pushes the terminal that
was sheared from the
carrier strip through the
“tube” into the cavity.
➂Contact
Various wire attachments
in standard, fine, medium
and heavy duty terminals
are available (See tables).
➃IDC Slot
The IDC slot in the
terminal will terminate a
wide range of magnet
wire sizes.
➄Stripping Burrs
During the insertion
process, these burrs
strip the film insulation
from the magnet wire.
➅Locking Barbs
Terminal retention is
provided in the cavity by
single or multiple locking
barbs.
SIAMEZE
Interconnection System
How the System Operates ➆Plastic Cavity
Production has to be
in accordance with
Tyco Electronics
specifications (for cavity
drawing numbers see
tables). Consulting
Tyco Electronics is
required for design in.
➇Cavity Slot for Wire
The width has to be in
accordance with the wire
size (see cavity
drawings).
➈Magnet Wire
The magnet wire is
positioned in “U” slot
manually or automatically
by coil winding
equipment.
➉Wire Cutoff Block
The wire cutoff block
supports the magnet
wire during the trimming
process. The magnet
wire is cut plain to the
cavity front side.
Terminal Insertion
Complete
The magnet wire
termination is complete
when the terminal is fully
seated in the cavity.
11
➃
➂
➆
➅
➇
➈
➄
➉
➀
➁
11
Test Results
Standard Range SIAMEZE
products have been
submitted to the following
tests without significant
millivolt increase:
Current Cycling —
50 cycles with each cycle
consisting of 15 minutes
“ON” followed by 15
minutes “OFF”
Thermal Shock —
10 cycles with each cycle
consisting of 30 minutes at
150°C followed by 30
minutes at 21°C
Humidity —
Temperature Cycling
10 cycles between 25°C
and 65°C at 80 to 100% RH
31
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
SIAMEZE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
SIAMEZE Terminals
32 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
SIAMEZE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
ABC
DE
.300
[7.62]
.146
[3.71]
.300
[7.62]
.146
[3.71]
.020
[0.51]
.300
[7.62]
.146
[3.71]
.550
[13.97]
.280
[7.11] .032
[0.81]
.020
[0.51]
.020
[0.51]
.300
[7.62]
.146
[3.71]
.020
[0.51]
Recommended Copper Magnet Lead Wire Part Number
Type Pocket7Wire Range Range
AWG mm2AWG mm2Reeled Loose
A 1601421 27–26 0.36–0.13 18-2260.8-0.3 1601117-1 4-1601117-12,5
Moving 1601462 2-1601117-11
Beam 1601463 18-34 1.02-0.16 18-2260.8-0.3 1601000-1 4-1601000-12,5
1601000-254-1601000-22,5
18–34 1.02–0.16 20 0.5 1601056-1 4-1601056-12,5
B2-1601056-11
Wire 1601421 18-34 1.02-0.16 18 0.8 1601074-1 4-1601074-12,5
Specific 2-1601074-11
1601046-1 4-1601046-12,5
C 1601433 18-34 1.02-0.16 18-2260.8-0.3 2-1601046-116-1601046-13,5
High Carry 1601440 8-1601046-14,5
D1601125-1 4-1601125-12,5
High Carry 1601433 27-36 0.36-0.13 20 0.5 2-1601125-116-1601125-13,5
Specific ,5
E1601136-1 4-1601136-12,5
Medium 1601436 12-23 2.06-0.56 16-20 1.3-0.5 2-1601136-116-1601136-13,5
Range
1Reversed Reeled—Consult Tyco Electronics drawing for orientation.
2Loose Single.
3Loose Bussed Pair.
4Loose Bussed Triple.
5Finish is Post Plated Tin over Copper (Consult Tyco Electronics drawing for specifics).
6Lead wire may be stranded, solid or bonded with 105°C PVC insulation. Contact Tyco Electronics Engineering when
using other types of insulation.
7Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447.
Wire-to-Wire Terminals
Material
Brass
Lead Lok Terminals
Product Facts
■Provides perpendicular and
parallel lead wire strain
relief retention forces in
excess of 20 lbs.
■AMP Inserter automatically
positions and secures lead
wire during insertion
■Manual, semi-automated,
fully automated systems
allow for lead wire
termination
■Accepts #18 -#22
[0.3 mm2-0.8 mm2] AWG
solid or stranded lead wire
with .115 [2.92] max.
insulation diameter
■No lead wire stripping
required
Tyco Electronics features
the AMP Lead Lok strain
relief terminal system that
provides optimum lead wire
retention when used in
conjunction with SIAMEZE
insulation displacement
terminals.
After the one-step insertion
of AMP SIAMEZE wire-to-
wire terminals into
Tyco Electronics specified
plastic cavities, the
application is ready for the
secondary lead wire
attachment.
The lead wire is manually
positioned over the magnet
wire terminated SIAMEZE
wire-to-wire terminal.
The AMP Lead Lok Inserter
cuts the Lead Lok terminals
from the strip and places
the terminal over the lead
wire in the plastic cavities.
During this operation, the
lead wire is automatically
seated, the insulation
pierced and the exposed
solid or stranded conductor
is terminated in the IDC slot
of the SIAMEZE wire-to-wire
terminal.
Residual spring energy in
the terminal causes the side
walls of the IDC slot to
function as opposing
cantilever beams.
This constant pressure
results in an intimate metal-
to-metal interface, providing
a reliable, long-term
connection.
Perpendicular and parallel
lead wire strain relief
retention forces in excess of
20 lbs are achieved.
The AMP Lead Lok Inserter
may be a secondary station
in the AMP SIAMEZE Wire-
to-Wire semi-automatic
bench machine or a
separate semi-automatic
bench machine inserter
depending on the
application and required
production rates.
33
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
SIAMEZE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
SIAMEZE Terminals
34 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
SIAMEZE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
➀Lead Lok Insertion
Finger
The Lead Lok insertion
finger pushes the
Lead Lok that was
sheared from the carrier
strip and positions the
Lead Lok and lead wire
into the IDC slot.
➁Lead Lok Terminal
The Lead Lok terminal
provides maximum lead
wire retention in the
cavity.
➂Locking Barbs
The Lead Lok multiple
locking barbs provide
retention in the cavity.
➃Lead Wire
Stranded, solid and
bonded lead wire with
105°C PVC insulation
can be used. Contact
Tyco Electronics
Engineering for other
lead wires and insulation
under consideration.
➄IDC Slot
The IDC slot will pierce
the lead wire during
insertion.
➅Lead Wire Insertion
Complete
The lead wire termination
is complete when the
Lead Lok is fully seated
in the cavity.
Lead Lok
Interconnection System
How the System Operates
➂
➃
➅
➄
➀
➁
Type Recommended Lead Wire Range Part Number
Pocket AWG mm2Reeled Loose
A1601421 1601140-1
Lead Lok 1601433 18-2220.8-0.3 2-1601140-114-1601140-1
1601440
1Reverse Reeled—Consult Tyco Electronics drawing for orientation.
2Lead wire may be stranded, solid or bonded with 105°C PVC insulation.
Contact Tyco Electronics Engineering when using other types of insulation.
.250
[6.35]
.150
[3.81] .025
[0.64]
Posted Terminals
Material
Brass
L
.146
[3.71] .020
[0.51]
L
.146
[3.71] .020
[0.51]
L
.146
[3.71] .020
[0.51]
L
.146
[3.71] .020
[0.51]
L
.280
[7.11] .032
[0.81]
.020
[0.51]
L
.146
[3.71]
A B C
Type Recommended Copper Magnet Wire Range LTab SIze Part Number
Pocket7AWG mm2Dim. Reeled Loose
27-36 0.36-0.13 .345 .040 x .020 2-1601120-231,
8.76 1.02 x 0.51 2-1601120-21,3 4-1601120-23
18-34 1.02-0.16 .345 .040 x .020 2-1601009-221,
A1601424 8.76 1.02 x 0.51 2-1601009-21,2 4-1601009-22
PC Tab 16-1761.27-1.15 .345 .040 x .020 2-1601147-231,
8.76 1.02 x 0.51 2-1601147-21,3 4-1601147-23
2960.29 .345 .040 x .020 2-1601155-221,
8.76 1.02 x 0.51 2-1601155-21,2 4-1601155-22
27-36 0.36-0.13 .485 .040 x .020 2-1601128-231,
B12.32 1.02 x 0.51 2-1601128-21,3 4-1601128-23
Extended .485 .040 x .020 2-1601041-221,
PC Tab 1601425 18-34 1.02-0.16 12.32 1.02 x 0.51 2-1601041-21,2 4-1601041-22
.456 .040 x .020 2-1601095-241,
11.57 1.02 x 0.51 2-1601095-21,4 4-1601095-24
.754 .047 x .032 2-1601110-241,
19.16 1.20 x. 0.81 2-1601110-21,4 4-1601110-24
.669 .059 x .032 2-1601099-11,6
17.00 1.50 x 0.81 2-1601099-11,6 4-1601099-1 .
C.756 .059 x .032 2-1601063-251,
Long Narrow 1601431 18-34 1.02-0.16 19.21 1.50 x 0.81 2-1601063-21,5 4-1601063-25
Width Blade .904 .059 x .032 2-1601037-251,
22.96 1.50 x 0.81 2-1601037-21,5 4-1601037-25
1.005 .059 x .032 2-1601066-241,
25.53 1.50 x 0.81 2-1601066-21,4 4-1601066-24
.974 .071 x .025 2-1601104-251,
24.74 1.80 x 0.64 2-1601104-21,5 4-1601104-25
D27-36 0.36-0.13 .710 .059 x .032 2-1601121-241, —
Tab Pair 1601425 18.03 1.50 x 0.81 2-1601121-21,4
with 18-34 1.02-0.16 .710 .059 x .032 2-1601065-241, —
Diode Slot 18.03 1.50 x 0.81 2-1601065-21,4
E.837 .118 x .025 2-1601008-241,
Long Medium 1601425 18-34 1.02-0.16 21.26 3.00 x 0.51 2-1601008-241, 4-1601008-24
Width Blade .837 .118 x .032 2-1601051-241,
21.26 3.00 x 0.81 2-1601051-21,4 4-1601051-24
F
Long Medium 1601438 12-23 0.56-2.06 .872 .130 x .032 1601138-1 4-1601138-1 .
Blade 22.15 3.30 x 0.81 2-1601138-11,0
Medium Range
1Reverse Reeled—Consult Tyco Electronics drawing for orientation. 2Finish is Post Plated Tin over Copper (Consult Tyco Electronics drawing for specifics).
3Finish is Post Plated Tin over Nickel (Consult Tyco Electronics drawing for specifics). 4Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics).
5Finish is Pre-Plated Tin (Consult Tyco Electronics drawing for specifics). 6Two magnet wires may be terminated in the same slot if diameters are equal.
7Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447.
D E F
35
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
SIAMEZE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
SIAMEZE Terminals
36 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
SIAMEZE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
110 Series
FASTON Tab Terminals
Material
Brass
B
L
.146
[3.71]
.020
[0.51] C
L
.146
[3.71]
.020
[0.51] D
L
.146
[3.71]
.020
[0.51]
A
L
.146
[3.71]
.020
[0.51]
Type Recommended Copper Magnet Wire Range L Tab Tab Size Part Number
Pocket7AWG mm Dim. Feature Reeled Loose
27-36 0.36-0.13 .640 Hole .110 x .020 2-1601116-1,00 4-1601116-1 ,0
16.26 2.79 x 0.51 2-1601116-11,0
2-1601005-1,00
Hole .110 x .020 2-1601005-11,0 4-1601005-1 ,0
.640 2.79 x 0.51 2-1601005-23,0
18-34 1.02-0.16 16.26 2-1601005-21,3,0 4-1601005-23 ,
A.110 x .020 2-1601085-13,0
Single 1601425 —2.79 x 0.51 2-1601085-11,3,0 4-1601085-13 ,
Barb .110 x .020 2-1601045-1,00
Hole 2.79 x 0.51 2-1601045-11,0 4-1601045-1 ,0
18-34 1.02-0.16 .846 2-1601059-1,00
21.49 —.110 x .020 2-1601059-11,0 4-1601059-1 ,0
2.79 x 0.51 2-1601059-24,0
2-1601059-21,400 4-1601059-24,0
18-34 1.02-0.16 .925 .110 x .020 2-1601073-1,00
23.50 Hole 2.79 x 0.51 2-1601073-11,0 4-1601073-1 ,0
B.945 .110 x .032 2-1601097-23,0
Single Barb 1601431 18-34 1.02-0.16 24.00 —2.79 x 0.81 2-1601097-21,3 4-1601097-23 ,
Low Transition 1.240 .110 x .032 2-1601133-22,5
27-36 0.36-0.13 31.50 —2.79 x 0.81 2-1601133-21,2,5 4-1601133-22 ,
2-1601039-1,00
.655 .110 x .020 2-1601039-11,0 4-1601039-1 ,0
C18-34 1.02-0.16 16.63 Hole 2.79 x 0.51 2-1601039-23,0
Multi-Barb 1601425 2-1601039-21,3,0 4-1601039-23 ,
.630 .110 x .032 2-1601064-1,00
18-34 1.02-0.16 15.99 —2.79 x 0.81 2-1601064-11,0 4-1601064-1 ,0
1.240 .110 x .032 2-1601112-22,5
18-34 1.02-0.16 31.50 —2.79 x 0.81 2-1601112-21,2,5 4-1601112-22 ,
D.915 —.110 x .020 2-1601151-23,0
Multi-Barb 1601425 21-246.51-.72 23.24 2.79 x 0.51 2-1601151-21,3 4-1601151-23,
w/ 90°Twist
1Reversed Reeled—Consult Tyco Electronics drawing for orientation.
2Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics).
3 Finish is Pre-Plated Tin (Consult Tyco Electronics drawing for specifics).
4Finish is Pre-Plated Silver over Nickel (Consult Tyco Electronics drawing for specifics).
5Dual Carrier Strip.
6Two magnet wires may be terminated in the same slot if diameters are equal.
7Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447.
L
.146
[3.71] .020
[0.51]
L
.146
[3.71] .020
[0.51]
L
.146
[3.71] .020
[0.51]
L
.146
[3.71] .020
[0.51]
L
.146
[3.71] .020
[0.51]
187 Series
FASTON Tab Terminals
Material
Brass
Type Recommended Copper Magnet Wire Range L Tab Tab Size Part Number
Pocket6AWG mm Dim. Feature Reeled Loose
A.605 .187 x .020 1601006-23,
Single 1601425 18-34 1.02-0.16 Hole 4-1601006-23,0,0
Barb 15.37 4.75 x 0.51 2-1601006-21,3,0
.505 Hole .187 x .020 1601011-1,0
B12.83 4.75 x 0.51 2-1601011-11,0,0 4-1601011-1 ,0,0
Single Barb .590 .187 x .020 1601018-22,5
Short 1601427 18-34 1.02-0.16 14.99 —4.75 x 0.51 2-1601018-21,2,5,0 4-1601018-22 ,0
Pocket .985 .187 x .020 1601033-22,5
25.02 —4.75 x 0.51 2-1601033-21,2,5,0 4-1601033-22 ,0
.618 .187 x .020 1601021-22,
15.70 —4.75 x 0.51 2-1601021-21,2,0,0 4-1601021-22 ,0
.655 .187 x .020 1601013-1,0
16.64 Hole 4.75 x 0.51 2-1601013-11,0,0 4-1601013-1 ,0,0
.791 .187 x .020 1601072-22,
20.09 —4.75 x 0.51 2-1601072-21,2,0 4-1601072-22 ,0
C1601425 18-34 1.02-0.16 .832 .187 x .020 1601068-22,
Multi-Barb 21.14 —4.75 x 0.51 2-1601068-21,2,0 4-1601068-22, 0
1601035-1,0
.655 Hole .187 x .032 2-1601035-11,0,0 4-1601035-1,0,0
16.64 4.75 x 0.81 1601035-23,4-1601035-23, 0
2-1601035-21,3,0
.745 Hole .187 x .032 1601040-1,0 4-1601040-1 ,0,0
18.92 4.75 x 0.81 2-1601040-11,0,0
.655 .187 x .020 1601142-1,,0
20-23** 0.58-0.81 16.64 Hole 4.75 x 0.51 2-1601142-11,0,0 4-1601142-1,0,0
D.492 .187 x .032 1601058-22,4
Multi-Barb 1601434 Hole 4-1601058-22,4
Short Profile 12.50 4.75 x 0.81 2-1601058-21,2,4
1601020-1,0 4-1601020-1,0,0
E.655 .187 x .020 2-1601020-11,0,0
Multi-Barb 1601425 18-34 1.02-0.16 16.64 Hole 4.75 x 0.51 1601020-23,
.187/.250 Profile 2-1601020-21,3,0 4-1601020-23 ,0
.805 Hole .187 x .020 1601049-23,4-1601049-23 ,0
20.45 4.75 x 0.51 2-1601049-21,3,0
F1601423 18-34 1.02-0.16 .775 Hole .187 x .020 1601004-1,0 4-1601004-1 ,0,0
Latch 19.68 4.75 x 0.51 2-1601004-11,0,0
1Reverse Reeled—Consult Tyco Electronics drawing for orientation.
2Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics).
3Finish is Pre-Plated Tin (Consult Tyco Electronics drawing for specifics).
4Extra Short Tab-Does not meet UL & NEMA length requirements.
5Carrier strip not in retention barb area as shown.
6Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447.
L
.146
[3.71] .020
[0.51]
A B C D E F
37
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
SIAMEZE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
SIAMEZE Terminals
38 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
SIAMEZE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
250 Series
FASTON Tab Terminals
Material
Brass
.280
[7.12]
L
.032
[0.81]
L
.315
[8.00] .032
[0.81]
L
.146
[3.71] .020
[0.51]
L
.146
[3.71] .020
[0.51]
Type Recommended Copper Magnet Wire Range L Tab Tab Size Part Number
Pocket6AWG mm Dim. Feature Reeled Loose
A.778 .250 x .032 1601139-23........
Single Barb 1601438 12-23 2.03-0.56 —4-1601139-23
Medium Range 19.76 6.35 x 0.81 2-1601139-21,3......
.885 .250 x .032 1601115-1........
B12-20 2.03-0.8 22.48 Hole 6.35 x 0.81 2-1601115-11...... 4-1601115-1
16-1751.27-1.15 .885 Hole .250 x .032 1601159-1........
Single Barb 1601435 22.48 6.35 x 0.81 2-1601159-11...... 4-1601159-1
Heavy Range 14-1551.60-1.40 .885 Hole 250 x .032 1601161-1........ 4-1601161-1
22.48 6.35 x 0.81 2-1601161-11......
.745 .250 x .032 1601118-23......
27-36 0.36-0.13 18.92 Hole 6.35 x 0.81 2-1601118-21,3... 4-1601118-2,3
.745 .250 x .032 1601002-23......
18.92 Hole 6.35 x 0.81 2-1601002-21,3... 4-1601002-23
1601028-23......
Hole .250 x .032 2-1601028-21,3... 4-1601028-23
C1601425 .805 6.35 x 0.81 1601028-1...
Multi-Barb 18-34 1.02-0.16 20.45 2-1601028-113...... 4-1601028-1 .
Dimple .250 x .032 1601061-23......
6.35 x 0.81 2-1601061-21,3... 4-1601061-23
1.000 Hole .250 x .032 1601044-1........ 4-1601044-1
25.4 6.35 x 0.81 2-1601044-11....
1.281 .250 x .032 1601052-22,4...
32.53 Hole 6.35 x 0.81 2-1601052-21,2,4 4-1601052-22
D1601423 18-34 1.02-0.16 .850 Hole .250 x .032 1601003-1... 4-1601003-12
Latch 21.59 6.35 x 0.81 2-1601003-11......
1Reverse Reeled—Consult Tyco Electronics drawing for orientation.
2Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics).
3Finish is Pre-Plated Tin (Consult Tyco Electronics drawing for specifics).
4Double Carrier Strip.
5Two magnet wires may be terminated in the same slot if diameters are equal.
6Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447.
A B C D
Receptacle Terminals
.300
[7.62]
.146
[3.71]
.020
[0.51]
Pin Terminals
Type Recommended Copper Magnet Wire Range LPin Dia. Part Number
Pocket5AWG mm2Dim. Reeled Loose
A1601424 18-34 1.02-0.16 .718 .084 1601077-1 4-1601077-1
Round Pin 18.24 2.13 2-1601077-11
B
Pseudo Round Pin 1601432 27-36 0.36-0.13 .855 .039 1601130-22,3 —
with Diode Slot 21.71 1.00 2-1601131-22,3,4
1Reverse Reeled—Consult Tyco Electronics drawing for orientation.
2Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics).
3Diameter is approximate as Pin is not perfectly round.
4Reverse Reeled Mirror Image—Consult Tyco Electronics drawing for orientation.
5Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447.
LL
.084
[2.13]
.020
[0.51]
Dia.
.146
[3.71] .020
[0.51]
.146
[3.71]
.039
[1.00] Dia.
Type Recommended Copper Magnet Wire Range L Mating Part Number
Pocket3AWG mm2Dim. Tab Size Reeled Loose
A1601425 18-34 1.02-0.16 .300 .020 2-1601075-221,
Edge Contact In Line 7.62 0.51 2-1601075-21,2 4-1601075-22
B1601421 15-23 1.47-0.56 .310 .032 2-1601137-221,
Edge Contact Off Line 7.87 0.81 2-1601137-21,2 4-1601137-22
C1601470 21.5 0.71 .715 .250 x .020 2-1601149-221,
Blind Mate Full Surround 18.15 6.35 x 0.51 2-1601149-21,2 4-1601149-22
1Reverse Reeled—Consult Tyco Electronics drawing for orientation.
2Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics).
3Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447.
A B
A
.032
[0.81]
.480
[12.19]
.310
[7.87]
B
.715
[18.15]
.199
[5.04]
.315
[8.00]
.146
[3.71] .031
[0.79]
C
39
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
SIAMEZE Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
SIAMEZE Terminals
40 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
MAG-MATE and SIAMEZE Application Tooling
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
MAG-MATE Product
Terminator (MPT)
Product Facts
■Single, dual and triple
insertion
■Two-reel, two-product
capability, with alternating
feed capability
■Available as horizontal
bench, vertical bench or
independent module
■Module easily integrates
into production lines using
simple handshake signals
■Fine adjustment
mechanism for insertion
depth (.001 increments)
■Tube-type insertion tooling
for standard MAG-MATE
terminals
■Microprocessor controlled
operation
■Holding fixture for bobbin
can be designed and built
by Tyco Electronics or the
customer
For quick, easy and reliable
termination of magnet wire
without pre-stripping the
insulation or soldering,
Tyco Electronics offers the
MAG-MATE product family
and the MPT-5 (MAG-MATE
Product Terminator ) air-
operated insertion machine
with micro-processor
control. The MPT-5 machine
inserts a MAG-MATE
terminal into a customer-
designed cavity in the coil
bobbin or similar magnet-
wire housing, terminating
the wire and providing an
I/O terminal or other
connection. The MAG-MATE
system can create a
termination that is very
close to the coil.
Dual reel capability of the
MPT-5 allows insertion of
two different MAG-MATE
terminals, with the capability
to alternate between insert-
ing one and two terminals
at a time. Two terminations
per second are possible
with dual insertion. Loaded
with two different terminals,
a single MPT-5 can cover a
range of 8 AWGs.
A fifth generation machine,
the MPT-5 is lighter and
quieter than previous
versions. The MPT-5 is
available as a horizontal or
vertical bench machine or
as a discrete module for
integration into automated
lines. The discrete module
also can be used to make a
custom horizontal or vertical
bench machine. A fixture to
hold the coil assembly,
which is required for bench
operation, can be designed
and built by Tyco Electronics
or the customer.
The MPT-5 uses three or
four air cylinders to feed
terminals from one or both
reels, cut terminals from the
carrier strip, and insert
terminals into the cavities.
The display shows the
operating conditions of the
machine such as the batch
count, total count, error
messages, and ready state.
The display also lets the
operator step through the
machine sequence or
manually cycles the
machine for set up or easy
diagnosis of problems.
Solderless MAG-MATE
Terminations:
■No need to pre-strip the
magnet wire
■No wire embrittlements
due to solder
■No soldering fumes
■Compact, clean
termination
■Ideal for automation
■Fast magnet wire
connections: Up to two
per second with dual
insertion
41
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
MAG-MATE and SIAMEZE Application Tooling (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
MPT-5S/L Machine for Mag
Wire Coil Termination
utilizing SIAMEZE and
Lead Lok terminals
Product Facts
■Single, dual and triple
insertion
■Two-reel, two-product
capability, with alternating
feed capability
■Available as horizontal
bench, vertical bench or
independent module
■Module easily integrates
into production lines using
simple handshake signals
■Fine adjustment mechanism
for insertion depth
(.001 increments)
■Tube-type insertion tooling
for standard SIAMEZE &
Lead Lok terminals
■Microprocessor controlled
operation
■Holding fixture for bobbin
can be designed and built
by Tyco Electronics or the
customer
For quick, easy and reliable
termination of magnet wire
without pre-stripping the
insulation or soldering,
Tyco Electronics offers the
SIAMEZE terminals and
Lead Lok product family
and the MPT-5S/L
(MAG-MATE Product
Terminator) air-operated
insertion machine with
micro-processor control.
The MPT-5S/L machine
inserts a SIAMEZE terminal
into a customer-designed
cavity in the coil bobbin or
similar magnet-wire
housing, terminating the
wire and providing an I/O
terminal or other connection.
The MPT-5S/L can insert
both the SIAMEZE terminal
for magnet wire termination
and the Lead Lok terminal
to assure your lead wire
connection.
Dual reel capability of the
MPT-5S/L allows insertion
of two different SIAMEZE
terminals, with the capability
to alternate between
inserting one and two
terminals at a time. Two
terminations per second are
possible with dual insertion.
A fifth generation machine,
the MPT-5s/L is lighter and
quieter than previous
versions. The MPT-5S/L is
available as a horizontal or
vertical bench machine or
as a discrete module for
integration into automated
lines. The discrete module
also can be used to make
a custom horizontal or
vertical bench machine.
A fixture to hold the coil
assembly, which is required
for bench operation, can
be designed and built by
Tyco Electronics or the
customer.
The MPT-5S/L uses three
or four air cylinders to feed
terminals from one or both
reels, cut terminals from the
carrier strip, and insert
terminals into the cavities.
The display shows the
operating conditions of the
machine such as the batch
count, total count, error
messages, and ready state.
The display also lets the
operator step through the
machine sequence or
manually cycles the
machine for set up or easy
diagnosis of problems.
Solderless SIAMEZE
terminations:
■No need to pre-strip the
magnet wire
■No wire embrittlements
due to solder
■No soldering fumes
■Compact, clean
termination
■Ideal for automation
■Fast magnet and lead
wire connections: Up to
two per second with dual
insertion
MAG-MATE and SIAMEZE
Application Tooling
42 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
MAG-MATE and SIAMEZE Application Tooling (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
The Module The MPT-5 insertion module
is the cornerstone of
Tyco Electronics magnet
wire application tooling. A
fifth generation machine,
the MPT-5 module is used
in conjunction with our
bench machine, LPT-522,
Rotary Index Table, and
can also be order
separately when using your
equipment manufacture of
choice. Electric, pneumatic
and de-reeling controls
are available allowing for
easy integration in your
production line. Experienced
Tyco Electronics personnel
will work with the customer
and the equipment
manufacturer to adapt the
module to their automated
assembly system.
Specifications
Electrical—120 VAC, 60 Hz, 5 A, 1 Ø,
or 240 VAC, 50 Hz, 2 A, 1 Ø
Air—80 psi [5.52 bar], 3 scfm
[0.00142 m3/s]
Weight—Approx. 60 lb [27.2 kg]
Width—8 [204]
Depth—7 [178]
Height—30 [762]
This insertion tool is
capable of applying
terminals furnished as
loose piece parts. Use for
prototype, production start-
up and moderate volume
production runs. Terminals
can be inserted at rates up
to 300 per hour.
Hand Tools
Part Number 274250-2
Poke-In Terminals
Part Number 274260-1
.187 [4.75] Tab Terminals
Part Number 274282-1
.250 [6.35] Tab Terminals
Application Tooling for
MAG-MATE Terminals
43
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
MAG-MATE and SIAMEZE Application Tooling (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Application Tooling for
MAG-MATE Terminals
Rotary Index Table
The Rotary Index Table is a
semiautomatic machine that
automatically positions fixtured coils,
bobbins, and field assemblies for
insertion of MAG-MATE terminals. The
table is used with MPT-5 insertion
modules, which mount vertically above
the table and insert terminals fed from a
reel. Modules which are not included as
part of the base machine, are available
for the entire MAG-MATE line, including
Standard and Mini MAG-MATE,
SIAMEZE and Lead Lok products.
In operation, the operator places the
coil/bobbin/field assembly on the
worktable and cycles the machine. The
table rotates 90˚ or 180˚ to position the
assembly under the insertion module for
processing. As each terminal is
inserted, the machine automatically
indexes to the next insertion position.
While this assembly is being processed,
the operator can remove the assembly
processed during the previous cycle
and load a new coil/bobbin/field
assembly. This load-while-run feature
helps maximize productivity. Assembly
rates of up to 600 coils per hour (at six
terminations per coil) are possible with dual
insertion.
A hand-held operator’s terminal contains a
keypad and easy-to-read LCD display to
allow quick, easy programming of machine
functions, including insertion sequences.
Up to 30 programs (insertion sequences)
can be stored in the EEPROM internal
memory.
The machine is available with any
combination of one or two MPT-5 insertion
modules that are fixed or indexing, with or
without a rotating fixture for axial insertion.
One version allows indexing only in the Y
axis for processing in-line cavities. The
other includes a rotary fixture that allows
the coil/bobbin/field assembly to be rotated
to process cavities radially or
linear/angularly opposed.
Besides its fast production rates, the rotary
table is also designed to enhance
productivity through reliability and easy
setup. The number of adjustments required
for normal operation has been minimized,
while the procedure for product
changeovers takes only a few minutes. The
result is a machine with little downtime.
Options include a continuity test station, a
bend station that bends terminals up to 90˚
after insertion, dual modules that insert two
identical or different terminals
simultaneously, and
X-axis travel.
Cost savings and productivity are
enhanced with Tyco Electronics Field
Engineering Service, which provides
complete setup and installation assistance,
operating and maintenance training, and
continuing rapid response through the Toll-
Free Technical Support Center at 1-800-
522-6752.
Product Facts
■High-volume rates, up to
600 assemblies per hour
■Handles Standard and Mini
MAG-MATE terminals
through interchangeable
insertion modules
■Load-while-run feature
increases productivity
■Fast, simple machine setup
and changeover
■Versions to handle in-line,
radial, and linear/angularly
opposed cavities
■Easy programming through
hand-held keypad/display
■Up to 30 insertion
sequences stored in
EEPROM memory
■Options include
■Continuity test station
■Bend station
■Dual MAG-MATE
modules
■X- or Y-axis travel
■Auto-change single/dual
insertion modules
MAG-MATE and SIAMEZE
Application Tooling
44 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
MAG-MATE and SIAMEZE Application Tooling (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
The Linear Product Terminator-522
was designed for intermediate to
high volume applications. It is also a
very flexible platform since it can
accommodate two secondary
application modules. These can
include, but are not limited to,
special wrap-off post trim, continuity
testing with defective coil
identification, and tab bending.
The LPT-522 features our MPT-5
insertion module as well as a
programmable linear slide and
rotary table system. The flexible
system can process coils that have
cavity configurations in a linear
pattern, axial pattern, or
combination of both.
The LPT-522 machine is of a serial
process design, which allows for a
unique coil holding fixture. This
fixture can be palletized to increase
your efficiency and production
rates. The palletized system allows
the operator to load/unload a pallet
of coils while a second pallet is
processing on this machine,
increasing the machine up time and
decreasing non-productive labor.
LPT-522 Linear Product
Terminator
Product Facts
■Intermediate to high
volume rates, up to 600
assemblies per hour
■Flexible platform
accommodates secondary
application modules
■Version to handle in-line,
radial, and linear/angularly
opposed cavities
■Programmable linear slide
and rotary table
■Easy programming through
keypad display
■Palletized fixture system for
greater efficiency and
production rates
■Microprocessor controlled
■Fine insertion depth
adjustment
(.001 increments)
■Two-reel, two-product
capability with or without
alternating feed
■Single, dual separate, and
on-the-fly dual common
insertion capability
Specifications
Air — 10 scfm@80 psi minimum
Electrical — 110 VAC, 5 AMP
Footprint — 60"x 52"
45
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
MAG-MATE and SIAMEZE Application Tooling (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Magnet Wire Termination Machines—Cost Comparison
Rotary Index Insertion Process Optional Continuity Test Station
Machine Horizontal Bench Vertical Bench LPT-522 Insertion RIT Insertion
Attribute Machine (HBM) Machine (VBM) Machine Machine
● Single row bobbin ● Single/Dual/Axial bobbin ● Same as VBM plus: ● Same as LPT, plus:
Applications ● Single terminal feed ● Single or dual feed -Multiple bobbin capacity -Up to 3 different terminals
● Bottom trim ● Bottom or top trim ✍Auxiliary stations ● Parallel processing
● Serial Processing
Machine Cost ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Fixture Cost ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Complexity ■ ■■ ■■■■ ■ ■ ■ ■
Production Rate ■ ■ ■ ■ ■ ■ ■ ■ ■
Cost / Insertion ■■■ ■■■■ ■■ ■
[■= lowest level] [■■= mid level] [■■■= high level] [■■■■= highest level]
Note: All machine options work in conjunction with our MPT-5 module. The MPT-5 module can incorporate an on-the-fly feature, which allows for selection of dual common insertions. The
MPT-5 module can also be incorporated in your automated line using your integrator of choice. Please call for details.
LPT-522 Linear Product
Terminator (Continued)
MAG-MATE and SIAMEZE
Application Tooling
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
46
AMPLIVAR Splices
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Product Facts
■Compression crimp
eliminates cold solder
points, weld burns and wire
embrittlement usually
connected with thermal-type
terminations
■Excellent tensile strength—
vibration resistant
■Provides a superior
electrical connection that is
free of many contaminants
such as stripper residue and
solder flux
■Precision formed, strip-fed
splices terminated in AMP
automatic machines for high
production rates per hour
■High termination rates, low
wire consumption and the
elimination of rejects
caused by solder flux or
heat damage results in the
lowest applied costs
■Precisely controlled crimp
termination helps eliminate
human error for maximum
reliability
■Splice up to 3 magnet wires
together with stranded lead
in one barrel
Applications
■Motor windings and
connections
■Coil connections
■Transformer windings and
connections
■Solid wire connections
■Lighting ballasts
■Power supplies
■Starters and alternators
Tyco Electronics offers a
full selection of AMP
AMPLIVAR splices that are
specifically designed to
terminate magnet wire to
itself or in combination with
standard solid or stranded
lead wire.
AMPLIVAR splices have
machined, sharp edged
serrations inside the crimp
barrels. These serrations,
made by a special
production process, pierce
the insulating layer of
magnet wires in a manner
that provides a large
contact area.
In a one-step operation the
magnet wire is automatically
multiple ring-stripped of its
insulation as it is forced into
the serrations during the
precisely controlled crimp.
The resulting termination
produces a high tensile
strength, air-sealed
connection that is as
resistant to corrosion as the
insulated conductor.
As many as three magnet
wires can be terminated
simultaneously in one
splice. In addition, copper
or aluminum magnet wire,
or a combination of both,
can be terminated.
When required, copper or
aluminum magnet wire can
Section AA
be combined with standard,
pre-stripped solid or
stranded lead wires.
Depending on your specific
application, AMPLIVAR
splices are available in 5,
7 and 9 serration versions
for terminations in the 100
to 22,000 CMA range as
well as miniature and
subminiature designs for
terminations in the 100 to
1850 CMA range.
The crimping of AMPLIVAR
splices is done by semi-
automatic crimping
machines for high output
per hour production rates.
Stranded Wire
on top
Magnet Wire
on bottom
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
47
AMPLIVAR Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
AMPLIVAR Splices
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Technical Features
Applicable Types of Wire —
Cu, Al (Solid) together or in
combination with stranded
lead wire
Wire Size Range —
from 300 to 13,000 CMA
(0.1 mm2to 6.6 mm2)
Terminal Base Material —
Brass, phosphor bronze
Surface Finish — plain and
tin plated except where noted
Temperature Range —
–65°C to +150°C
Rated Current — according
connected wire size
Rated Voltage — according
terminated winding
Test Results
The AMPLIVAR products have
been subjected to the following
tests without significant millivolt
losses.
Temperature Cycling —
25 cycles with each cycle
consisting of 30 minutes at
+125°C followed by 30 minutes
at –65°C
Heat Age — 96 hours at +150°C
Thermal Shock — 25 cycles
with each cycle consisting of 30
minutes at +150°C followed by
30 minutes at –65°C
Salt Spray — 96 hours at
+35°C with a 5% salt solution
spray
Humidity — 96 hours at
90–95% relative humidity and
+40°C
Current Cycling — 10,000
cycles with each consisting of
3 minutes on and 3 minutes
off at a current (25 A) which
establishes a wire temperature
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
48
AMPLIVAR Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
1. All magnet wires must be
placed in the bottom of
the wire barrel before
crimping. If lead wire is to
be crimped in the same
termination, it should be
placed on top of the
magnet wires.
2. Wire barrels are
designed to accept a
maximum of three
insulated magnet wires
plus stranded lead wires.
3. The ratio of magnet wire
diameters crimped in any
wire barrel should not
exceed 2:1. This ratio is
approximately a range
from the largest to the
smallest magnet wire of
six sizes.
4. The sum of the circular
mil area (CMA) of the
magnet wires and any
lead wires should not
exceed the capacity of
the splice.
5. The sum of the diameters
of the individual magnet
wires plus twice the
terminal stock thickness
must be equal to or less
than the crimp width.
1. Use 9-serration splices,
tin plated when
terminating aluminum
magnet wire or
combinations with
aluminum magnet wire.
2. Use 9-serration splices
for hermetic and severe
environment applications.
3. Use splices identified
with an asterisk [*] when
terminating 7-serration
26 AWG [0.40 mm]
or smaller wires and
9-serration 28 AWG [0.32
mm] or smaller wires.
4. Calculate the total CMA
of the magnet wires plus
any lead wires to be
terminated. Always use
the coated magnet wire
for CMA (see pages
94–96).
5. Calculate the total
magnet wire diameters
(see pages 94 and 95).
6. Select a splice for trial
calculations. It should
have the proper CMA
range. Plating finish
should be considered at
this time.
7. Calculate the sum of the
magnet wire diameters
plus two splice stock
thicknesses. If this total is
less than the crimp width
of the splice selected, it
may be used. If the total
is greater than the crimp
width, a splice with a
greater crimp width must
be selected. Consult
Tyco Electronics for
special wide tooling
recommendations.
Example:
■Selection of a Pigtail Splice to terminate the following wires:
One 28 AWG [0.32 mm] copper magnet wire.
One 22 AWG [0.64 mm] aluminum magnet wire.
One 18 AWG [0.8–0.9 mm2] 19-strand copper lead wire.
■Calculate the total CMA (Procedure 4):
28 AWG [0.32 mm] coated magnet wire = 185 CMA
22 AWG [0.64 mm] coated magnet wire = 708 CMA
18 AWG [0.8–0.9 mm2] stranded lead wire = 1608 CMA
Total = 2501 CMA
■Calculate the sum of the magnet wire diameters (Procedure 5):
28 AWG [0.32 mm] coated magnet wire = .0136 [0.35]
22 AWG [0.64 mm] coated magnet wire = .0266 [0.68]
Total = .0402 [1.03]
■Select a terminal for trial calculations. Splice No. 62305-2,
page 49 (Procedure 6):
CMA range = 600–3000
Stock thickness = .016 [0.41]
Crimp width = .110 [2.79]
9-serration, tin plated for aluminum magnet wire (Procedure 1).
Splice identified with asterisk [*] for 28 AWG [0.32 mm]
(Procedure 3).
■Calculate the sum of the magnet wire diameters plus two splice
stock thicknesses (Procedure 7):
.0402 + (.016 x 2) = .0722
[1.02 + (0.41 x 2) = 1.84
.0722 [1.84] is less than the splice crimp width of .110 [2.79];
therefore, Part No. 62305-2 may be used.
114-2002 AMPLIVAR 7-
Serration Pigtail
Splices
114-2003 AMPLIVAR 9-
Serration Pigtail
Splices
114-2005 AMPLIVAR
Subminiature Thru
Splices
114-2006 AMPLIVAR
Subminiature Pigtail
Splices
114-2009 AMPLIVAR 5-
Serration Thru
Splices
114-2016 AMPLIVAR
Miniature Pigtail
Splices
6. Magnet wire of 26 AWG
[0.40 mm] or smaller
should be used with
7-serration splices having
“shallow serrations,” and
magnet wire of 28 AWG
[0.32 mm] or smaller
should be used with
9-serration splices having
“shallow serrations” (part
numbers identified with
asterisk [*] are in the
tabular data on the
following technical
pages).
7. Magnet wire of 20 AWG
[0.81 mm] or larger
having an insulation
thickness heavier than
“single film coated,”
should not be used with
splices having “shallow
serrations” (those part
numbers marked with an
asterisk [*] in the tabular
data on the following
technical pages).
8. When aluminum magnet
wire is used, splices and
terminals must be tin
plated.
9. Consult Tyco Electronics
for splice and terminal
selection and
recommendations for
all non-standard
applications.
General Application Guidelines
To assist you in obtaining the optimum AMPLIVAR
termination, the following guidelines are recommended:
Suggested Splice Selection Procedure
Use the following guide to help you to determine the proper
splice for your application:
Technical Documents
Application Specifications describe requirements for using the
product in its intended application and or crimping information.
They are intended for the Packaging and Design Engineer and the
Machine Setup Person.
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
49
AMPLIVAR Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
AMPLIVAR Splices
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
9 Serrations —
Pigtail Type
Product Facts
(Plus All 7 Serration Facts)
■Splice length is increased
on larger CMA splices for
improved performance
■Serration depths are
varied within the splice
to give optimum electrical/
mechanical performance on
all wire sizes
■Serration sidewall angles
are varied to allow better
wire stripping and
serration fill
■Flat bottom of splice helps
keep magnet wires on
bottom as required during
crimping
■Magnet wires 28 AWG
[0.32 mm] and larger may
be terminated without
requiring shallow serrations
■Additional serrations
enhance stability of crimp
7 Serrations —
Pigtail Type
Product Facts
■Taper on both crimper and
anvil improves flex life of
termination
■Longer “flat” on tooling
improves electrical
performance (.125 vs. .080
[3.18 vs. 2.03])
■Radius on wire entry end
of splice helps prevent
nicking wires and improves
mechanical performance
■Serrations are offset to
sheared end to place
additional serrations in
“electrical” portion of
crimped splice
■Splice CMA ranges are
overlapped so that two
splices are available for any
given CMA
AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part
mm2Solid Dia. CMA Thickness Width L Number
22-15.5 .028-.055 600-3000 .020 .110 .225 Brass 62000-1*
0.38-1.54 0.70-1.40 0.51 2.79 5.72
22-15.5 .028-.055 600-3000 .020 .110 .225 Brass 62157-1*
0.38-1.54 0.70-1.40 0.51 2.79 5.72
22-15.5 .028-.055 600-3000 .020 .110 .225 Tin Plated Brass 62000-2*
0.38-1.54 0.70-1.40 0.51 2.79 5.72
22-15.5 .028-.055 600-3000 .020 .110 .225 Tin Plated Brass 62157-2*
0.38-1.54 0.70-1.40 0.51 2.79 5.72
22-15.5 .028-.055 600-3000 .020 .110 .225 Tin Plated Brass 62200-21
0.38-1.54 0.70-1.40 0.51 2.79 5.72
18.5-13.5 .039-.071 1500-5000 .020 .110 .225 Brass 62040-2*
0.80-2.54 1.00-1.80 0.51 2.79 5.72
18.5-13.5 .039-.071 1500-5000 .020 .110 .225 Tin Plated Brass 62040-1*
0.80-2.54 1.00-1.80 0.51 2.79 5.72
18.5-13.5 .039-.071 1500-5000 .020 .110 .225 Phosphor Bronze 964156-1
0.80-2.54 1.00-1.80 0.51 2.79 5.72
15.5-12 .055-.083 3000-7000 .020 .140 .225 Brass 62001-1*
1.54-3.46 1.40-2.10 0.51 3.56 5.72
15.5-12 .055-.083 3000-7000 .020 .140 .225 Tin Plated Brass 62001-2*
1.54-3.46 1.40-2.10 0.51 3.56 5.72
15.5-12 .055-.083 3000-7000 .020 .140 .225 Tin Plated Brass 62201-21
1.54-3.46 1.40-2.10 0.51 3.56 5.72
12-10 .085-.110 7000-12,000 .025 .250 .225 Tin Plated Brass 62295-1*
2.10-6.0 2.10-2.85 0.64 6.35 5.72
12-10 .085-.110 7000-12,000 .025 .250 .225 Brass 62295-2*
2.10-6.0 2.10-2.85 0.64 6.35 5.72
12-9 .085-.115 7000-13,000 .025 .180 .225 Tin Plated Brass 62002-2*
2.10-6.38 2.10-3.47 0.64 4.57 5.72
*These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller.
1Flat bottom.
AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part
mm2Solid Dia. CMA Thickness Width L Number
24-18.5 .020-.039 400-1500 .016 .080 .225 Tin Plated Brass 62303-2*
0.26-0.80 0.55-1.00 0.41 2.03 5.72
22-15.5 .028-.055 600-3000 .020 .110 .225 Tin Plated Brass 62304-2*
0.38-1.54 0.70-1.40 0.51 2.79 5.72
22-15.5 .028-.055 600-3000 .016 .110 .225 Tin Plated Brass 62305-2*
0.38-1.54 0.70-1.40 0.41 2.79 5.72
18.5-13.5 .039-.071 1500-5000 .020 .110 .225 Tin Plated Brass 62306-2*
0.80-2.54 1.00-1.80 0.51 2.79 5.72
18.5-13.5 .039-.071 1500-5000 .016 .110 .225 Tin Plated Brass 62307-2*
0.80-2.54 1.00-1.80 0.41 2.79 5.72
15.5-12 .055-.083 3000-7000 .020 .140 .265 Tin Plated Brass 62308-2*
1.54-3.46 1.40-2.10 0.51 3.56 6.73
13.5-10 .071-.098 5000-10,000 .025 .180 .265 Tin Plated Brass 62309-2*
2.54-4.90 1.80-2.50 0.64 4.57 6.73
12-9 .083-.112 7000-13,000 .025 .180 .265 Tin Plated Brass 62310-2*
3.46-6.38 2.10-2.85 0.64 4.57 6.73
10-6.5 .098-.137 10,000-22,000 .030 .220 .340 Tin Plated Brass 62311-21*
4.90-9.45 2.50-3.47 0.76 5.59 8.64
*These splices are recommended for applications using wire size 28 AWG [0.32 mm] or smaller.
1Special high force application equipment required.
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
50
AMPLIVAR Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
5 Serrations —
Thru Type
Product Facts
■Wide range of thru splices
■Serrations centered in splice
to achieve optimum
electrical and mechanical
performance in a thru splice
■CMA range accepts a wide
variety of wire sizes and
combinations
Type AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part
mm2Solid Dia. CMA Thickness Width L Number
17-12.5 .045-.075 2000-5400 .020 .110 .235 Brass 63564-1
1.00-2.80 1.15-1.85 0.51 5.08 5.97
A10-8 .100-.125 10,000-16,000 .032 .180 .267 Tin Plated Brass 63561-1
5.00-8.00 2.55-3.20 0.80 4.57 6.78
10-7.5 .100-.150 10,400-22,900 .030 .300 .310 Tin Plated Brass 63562-1
5.00-11.50 2.60-3.80 0.76 7.62 7.87
22-15.5 .028-.055 600-3000 .020 .110 .225 Brass 42076
0.38-1.54 0.70-1.40 0.51 2.79 5.72
22-15.5 .028-.055 600-3000 .020 .110 .225 Brass 42192-1*
0.38-1.54 0.70-1.40 0.51 2.79 5.72
22-15.5 .028-.055 600-3000 .020 .110 .225 Tin Plated Brass 42192-2*
0.38-1.54 0.70-1.40 0.51 2.79 5.72
22-15.5 .028-.055 600-3000 .020 .110 .225 Brass 42778-1*1
0.38-1.54 0.70-1.40 0.51 2.79 5.72
22-15.5 .028-.055 600-3000 .020 .110 .225 Tin Plated Brass 42778-2*1
0.38-1.54 0.70-1.40 0.51 2.79 5.72
18.5-13.5 .039-.071 1500-5000 .020 .110 .225 Brass 41765
0.80-2.54 1.00-1.80 0.51 2.79 5.72
18.5-13.5 .039-.071 1500-5000 .020 .110 .225 Tin Plated Brass 41899
0.80-2.54 1.00-1.80 0.51 2.79 5.72
18.5-13.5 .039-.071 1500-5000 .020 .110 .225 Brass 42119-1*
0.80-2.54 1.00-1.80 0.51 2.79 5.72
18.5-13.5 .039-.071 1500-5000 .020 .110 .225 Brass 42776-1*1
0.80-2.54 1.00-1.80 0.51 2.79 5.72
B18.5-13.5 .039-.071 1500-5000 .020 .110 .225 Tin Plated Brass 42776-2*1
0.80-2.54 1.00-1.80 0.51 2.79 5.72
15.5-12 .055-.083 3000-7000 .020 .140 .225 Brass 41766
1.54-3.46 1.40-2.10 0.51 3.56 5.72
15.5-12 .055-.083 3000-7000 .020 .140 .225 Tin Plated Brass 41900
1.54-3.46 1.40-2.10 0.51 3.56 5.72
15.5-12 .055-.083 3000-7000 .020 .140 .225 Brass 42779-11
1.54-3.46 1.40-2.10 0.51 3.56 5.72
15.5-12 .055-.083 3000-7000 .020 .140 .225 Tin Plated Brass 42779-21
1.54-3.46 1.40-2.10 0.51 3.56 5.72
12-10 .083-.110 7000-12,000 .025 .250 .225 Tin Plated Brass 61074-11,2
3.46-6.00 2.10-2.80 0.64 6.35 5.72
12-9 .083-.112 7000-13,000 .025 .180 .225 Brass 41770
3.46-6.38 2.10-2.85 0.64 4.57 5.72
12-9 .083-.112 7000-13,000 .025 .180 .225 Tin Plated Brass 41904
3.46-6.38 2.10-2.85 0.64 4.57 5.72
12-9 .083-.112 7000-13,000 .025 .180 .225 Brass 42780-11
3.46-6.38 2.10-2.85 0.64 4.57 5.72
12-9 .083-.112 7000-13,000 .025 .180 .225 Tin Plated Brass 42780-21
3.46-6.38 2.10-2.85 0.64 4.57 5.72
* These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller.
1Increased terminal pitch.
2Increased U-diameter.
B
A
L
7 Serrations —
Thru Type
Product Facts
■Crimp bellmouth provides
retention in circular cavity
slot in bobbin AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part
mm2Solid Dia. CMA Thickness Width L Number
22-15.5 .028-.055 600-3000 .020 .110 .225 Tin Plated Brass 1217384-1**
0.38-1.54 0.70-1.40 0.51 2.79 5.72
*These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller.
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
51
AMPLIVAR Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
AMPLIVAR Splices
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Miniature Splice —
Pigtail Type
Product Facts
■The Miniature AMPLIVAR
splice was developed for
crimping thinner copper
magnet wires having a
diameter between .003 and
.016 [0.08 and 0.40 mm]
and has to be connected
with a stranded conductor
■The diameter of one
conductor strand should not
exceed the magnet wire
diameter to be applied
Subminiature Splice —
Thru or Pigtail Type
Product Facts
■The compactness of these
splices makes them ideal
for use in small subfractional
motors, transformers,
relays, solenoids, indicator
lamps and small appliance
terminations
■These splices provide the
same reliability as the
larger AMPLIVAR splices
AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part
mm2Solid Dia. CMA Thickness Width L Number
27-21 .014-.030 200-850 .012 .055 .195 Tin Plated Brass 63431-1
0.10-0.40 0.35-0.75 0.30 1.40 4.95
25-18 .015-.045 300-1850 .012 .070 .195 Copper-Nickel 61166-1
0.16-0.90 0.45-1.10 0.30 1.78 4.95
24-18.5 .020-.039 480-1500 .014 .080 .195 Tin Plated Brass 62341-1
0.20-0.75 0.55-1.00 0.36 2.03 4.95
24-18.5 .020-.039 480-1500 .014 .080 .195 Brass 62341-2
0.20-0.75 0.55-1.00 0.36 2.03 4.95
24-18 .020-.040 480-1700 .016 .070 .195 Brass 62044-1
0.20-0.80 0.55-1.00 0.41 1.78 4.95
AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part
mm2Solid Dia. CMA Thickness Width L Number
30-26 .010-.015 100-300 .010 .042 .080 Tin Plated Brass 63621-2
0.05-0.15 0.30-0.50 0.25 1.08 2.03
24-19 .020-.035 400-1300 .016 .070 .100 Tin Plated Brass 62194-2
0.26-0.60 0.55-0.90 0.41 1.78 2.54
24-19 .020-.035 400-1300 .016 .070 .100 Gold Plated Brass 62194-4
0.26-0.60 0.55-0.90 0.41 1.78 2.54
L
5 Serrations —
Pigtail Type
Product Facts
■Serration depths are varied
within the splice to give
optimum electrical /
mechanical performance on
all wire sizes
■Flat bottom of splice helps
keep magnet wires on
bottom as required during
crimping
AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part
mm2Solid Dia. CMA Thickness Width L Number
20-17 .030-.045 1000-2000 .016 .100 .225 Tin Plated Brass 62670-2*1
0.50-1.00 0.80-1.15 0.41 2.54 5.72
*These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller.
1Flat bottom.
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
52
AMPLIVAR Terminals
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Products Facts
■Ring tongue terminals
available for 2 to 3/8 stud
diameters
■FASTON Tab terminals
accept .125 [3.18], .187
[4.75] and .250 [6.35]
receptacle terminals
■FASTON Receptacle
terminals accept .187 [4.75]
and .250 [6.35] tab
terminals
■FASTON Stator Receptacle
accept .250 x .032 [6.35 x
0.81] tab terminal
■Pin receptacle terminals
accept .062 [1.57] and .090
[2.29] diameter pins
Applications
■Motor windings
■Transformers
■Power supplies
■Starters and alternators
AMPLIVAR magnet wire
terminals are designed to
terminate copper and/or
aluminum magnet wire.
Terminals are insulation
displacing; therefore,
magnet wires do not require
a separate prestripping
operation.
The unique wire barrel
design, with serrations and
burrs, produces a superior
metal-to-metal compression
crimp with excellent tensile
strength.
Terminals are available in a
variety of ring tongue,
FASTON straight, flag and
stator receptacles and tab
quick-disconnect style
terminals.
Direct connection to
magnet wire eliminates the
need for separate stranded
wire terminal connection to
input/output devices.
Matched with AMP
automated application
tooling allows high
production rates for strip-
form terminals.
Product Specifications describe the
product qualification test results
completed by Tyco Electronics for
consideration of product use in a
specific application. They are intended
for the Design and Product Reliability
Engineer.
108-16000 — AMPLIVAR Ring Tongue
Terminals
108-1718 — AMPLIVAR .125 Blade
Terminals [Type A]
114-2145 AMPLIVAR .125
Blade Terminals
114-2146 AMPLIVAR
FASTIN-FASTON
Series 187 Tab
Terminals
114-2070 AMPLIVAR
FASTON Series
250 Tab Terminals
114-2144 AMPLIVAR
FASTON Series
.250 Straight
Receptacle
Terminals
114-2152 AMPLIVAR Flag
FASTON Series
187 & 250
Receptacle
Terminal
114-2080 AMPLIVAR Pin
Receptacle
Terminals [Type A]
114-2128 AMPLIVAR Stator
Receptacle with
FASTON Mating
End
Technical Documents
Application Specifications describe requirements for using the
product in its intended application and or crimping information.
They are intended for the Packaging and Design Engineer and the
Machine Setup Person.
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
53
AMPLIVAR Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Ring Tongue Terminals Wire Size Range 29–22 AWG [0.287–0.643 mm]
Type Insulation Hole Stud Stock Material Dimensions Part
Dia. Range Dia. Size Thk. WLECNumber
B.040-.060 .197 10 .020 Tin Plated Brass .342 .833 .662 .312 63399-1
1.02-1.52 5 0.51 8.69 21.16 16.81 7.92
Wire Size Range 23–19 AWG [0.574–0.912 mm]
Type Insulation Hole Stud Stock Material Dimensions Part
Dia. Range Dia. Size Thk. WLECNumber
B.100-.140 .171 8.020 Tin Plated Brass .342 .833 .662 .312 60321-2
2.54-3.56 4.34 0.51 8.69 21.16 16.81 7.92
A.125-.165 .171 8.020 Tin Plated Brass .300 .700 .550 .230 60323-2
3.18-4.19 4.34 0.51 7.62 17.78 13.97 5.84
B.100-.140 .197 10 .020 Tin Plated Brass .342 .833 .662 .312 60319-2
2.54-3.56 5 0.51 8.69 21.16 16.81 7.92
A.125-.165 .197 10 .020 Tin Plated Brass .300 .695 .545 .230 60325-2
3.18-4.19 5 0.51 7.62 17.65 13.84 5.84
Wire Size Range 22–18 AWG [0.643–1.024 mm]
Type Insulation Hole Stud Stock Material Dimensions Part
Dia. Range Dia. Size Thk. WLECNumber
B.125-.165 .265 1/4 .025 Tin Plated Brass .420 .872 .662 .312 63612-1
3.18-4.19 6.73 0.64 10.67 22.15 16.81 7.92
E—
.145 6.025 Tin Plated Brass .290 .500 .355 .195 63649-1
3.58 0.64 7.37 12.7 9.02 4.95
C—
.265 1/4 .025 Tin Plated Brass .420 .702 .492 .312 62835-1
6.73 0.64 10.67 17.83 12.5 7.92
E—
.171 8.025 Brass .290 .500 .355 .195 63446-1
4.34 0.64 Tin Plated Brass 7.37 12.7 9.02 4.95 63446-2
Wire Size Range 20–16 AWG [0.813–1.29 mm]
Type Insulation Hole Stud Stock Material Dimensions Part
Dia. Range Dia. Size Thk. WLECNumber
A.125-.165 .171 8.020 Tin Plated Brass .300 .695 .545 .230 060322-2
3.18-4.19 4.34 0.51 7.62 17.65 13.84 5.84
H——8
.020 Brass .340 1.220 .660 .500 505071-1
0.51 8.64 30.98 16.76 12.7
L——3/8
.020 Brass .625 .939 .627 .467 505075-1
0.51 15.88 23.85 15.93 11.86
M——3/8
.020 Brass .645 .950 .627 .467 505072-1
0.51 16.38 24.12 15.93 11.86
Wire Size Range 18–14 AWG [1.024–1.628 mm]
Type Insulation Hole Stud Stock Material Dimensions Part
Dia. Range Dia. Size Thk. WLECNumber
.100-.140 .171 8.020 Brass .342 .833 .662 .312 060320-1
2.54-3.56 4.34 0.51 8.69 21.16 16.81 7.92
B.100-.140 .171 8.020 Tin Plated Brass .342 .833 .662 .312 060320-2
2.54-3.56 4.34 0.51 8.69 21.16 16.81 7.92
.100-.140 .197 10 .020 Brass .342 .833 .662 .312 060318-1
2.54-3.56 5 0.51 8.69 21.16 16.81 7.92
.080-.120 .173 8.028 Lu-Bronze1.370 .915 .730 .380 485079-1
D2.03-3.05 4.39 0.71 9.4 23.24 18.54 9.65
.080-.120 .185 8.028 Lu-Bronze1.365 .882 .700 .380 485044-1
2.03-3.05 4.7 0.71 9.27 22.4 17.78 9.65
1High conductivity copper-tin-zinc alloy.
A
B
C
D
E
G
.243
[6.15]
F
.243
[6.15]
Wire Range 17–13.5 AWG [1.151–1.78 mm]
Type Insulation Hole Stud Stock Material Dimensions Part
Dia. Range Dia. Size Thk. WLECNumber
——8.020 Brass .310 .692 .505 .312 63147-1
F0.51 7.87 17.58 12.83 7.92
——8.020 Tin Plated Brass .310 .692 .505 .312 63147-2*
0.51 7.87 17.58 12.83 7.92
*Available on request
Wire Size Range 14–12 AWG [1.628–2.05 mm] or (2) 15 AWG [1.45 mm]
Type Insulation Hole Stud Stock Material Dimensions Part
Dia. Range Dia. Size Thk. WLECNumber
G——8.025 Brass .342 .945 .750 .570 062755-1
0.64 8.69 24.00 19.05 14.48
AMPLIVAR Terminals
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
54
AMPLIVAR Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Wire Range (2) 17 AWG [1.51 mm] or (2) 15 AWG [1.45 mm]
Type Insulation Hole Stud Stock Material Dimensions Part
Dia. Range Dia. Size Thk. WLECNumber
.150-.190
or (2) .115 .171 8.025 Tin Plated Brass .342 .827 .656 .312 60752-2
3.18-4.83 4.34 0.64 8.69 21.01 16.66 7.92
Bor (2) 2.92
.150-.190
or (2) .115 .197 10 .025 Tin Plated Brass .342 .827 .656 .312 61151-1
3.18-4.83 5.00 0.64 8.69 21.01 16.66 7.92
or (2) 2.92
Wire Range (1) 18 AWG [1.024 mm] and (1) 20.5 AWG [0.768 mm]
Type Insulation Hole Stud Stock Material Dimensions Part
Dia. Range Dia. Size Thk. WLECNumber
J——8.020 Brass .340 .955 .660 .500 505044-1
0.51 8.64 24.26 16.76 12.7
Wire Range 16–13.5 AWG [1.29–1.78 mm]
Type Insulation Hole Stud Stock Material Dimensions Part
Dia. Range Dia. Size Thk. WLECNumber
K——10 .020 Brass .340 1.220 .660 .500 505079-1
0.51 8.64 30.99 16.76 12.7
Wire Range 14.5 AWG [1.539 mm]
Type Insulation Hole Stud Stock Material Dimensions Part
Dia. Range Dia. Size Thk. WLECNumber
——2.025 Tin Plated Brass .240 .620 .500 .165 505036-1
N0.64 6.1 15.75 12.7 4.19
——2.025 Brass .240 .620 .500 .165 505036-3
0.64 6.1 15.75 12.7 4.19
Wire Range (2) 13 AWG [1.83 mm]
Type Insulation Hole Stud Stock Material Dimensions Part
Dia. Range Dia. Size Thk. WLECNumber
B.150-.190 .171 8.025 Tin Plated Brass .342 .827 .656 .312 63864-1
3.81-4.83 4.34 0.64 8.69 21.00 16.66 7.92
H
J
K
M
N
Stud Retaining Terminals
Alternator Eyelet Terminal
Wire Size Range 13–11 AWG [1.83–2.3 mm]
Type Insulation Hole Stud Stock Material Dimensions Part
Dia. Range Dia. Size Thk. WLECNumber
A.085-.150 .180 8.025 Brass .342 .833 .662 .312 061710-1
2.16-3.81 4.57 0.64 8.69 21.16 16.81 7.92
—.180 8.025 Tin Plated Brass .342 .665 .495 .312 350571-1
C4.57 0.64 8.69 16.89 12.57 7.92
—.197 10 .025 Tin Plated Brass .342 .665 .495 .312 640212-1
5.00 0.64 8.69 16.89 12.57 7.92
45°
45°
L
.388
[9.85]
.376
[9.55]
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
55
AMPLIVAR Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
AMPLIVAR Terminals
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Type Wire Range Material Dim. Part
AWG mm2L Number
B 27-23 0.1-0.2 Tin Plated Brass .935 63484-12
23.75
24-21 0.2-0.4 Tin Plated Brass .935 61440-3†
23.75
22-16 0.3-1.4 Tin Plated Brass 1.015 62447-1
A25.78
15-13 1.6-2.6 Tin Plated Brass .935 61442-3†
23.75
15-12 1.6-3.0 Tin Plated Brass 1.015 62445-1
25.78
2Varnish resist coating.
†These part numbers are available upon special request, contact Tyco Electronics Engineering for details.
187 Series FASTON Tabs1
Board Thickness
A = .062–.072 [1.57–1.83]
Stock Thickness
A =.020 [0.51]
B =.032 [0.81]
250 Series FASTON Tabs1
Stock Thickness
.032 [0.81]
Wire Range Material Part Quick-Change
AWG mm2Number Applicator3
14-12 2.0-3.0 Tin Plated Brass 62922-12466510-1
2Varnish resist coating.
3Quick-Change Applicator for AMP-O-LECTRIC Machine 565435-5. For AMPOMATOR Machine and other machines
not listed, contact Tyco Electronics.
AB
1Mates with FASTON receptacles.
See AMP Catalog 82004.
125 Series Blade
Stock Thickness
A =.013 [0.33]
B =.020 [0.51]
Mates with Power Blade Receptacle
terminals 61603-1, 61604-1, 770642-1
and 1217039-1
Housings
Contact Tyco Electronics Engineering for
housing options available
.810
[20.57]
.125
[3.18]
.020
[.508]
.330
[8.38]
.940
[23.88]
.125
[3.18]
.020
[.508]
.370
[9.40]
AB
Type Magnet Wire Range Material Material Part
AWG mm2Solid Dia. CMA Thickness Number
27-20.5 0.10-0.45 .015-.030 200-850 Tin Plated Brass .013 63871-1
0.35-0.75 0.33
A 24-18 0.2-0.8 .020-.040 400-1600 Tin Plated Brass .013 63889-1
0.50-1.00 0.33
18.5-13.5 0.75-2.5 .040-.070 1500-5000 Tin Plated Brass .016 63870
0.50-1.80 0.41
27-20.5 0.10-0.45 .015-.030 200-850 Tin Plated Brass .013 1217072-1
0.35-0.75 0.33
B 24-18 0.2-0.8 .020-.040 400-1600 Tin Plated Brass .020 1217029-1
0.50-1.00 0.51
18.5-13.5 0.75-2.5 .040-.070 1500-5000 Tin Plated Brass .020 1217073-1
0.50-1.80 0.51
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
56
AMPLIVAR Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Wire Range Material Dimensions Part
AWG mm2WLET Number
28-23.5 0.08-0.2 Tin Plated Brass .250 .580 .342 45°63136-1
6.35 14.73 8.69
25-19.5 0.16-0.6 Tin Plated Brass .250 .650 .450 30°63140-1
6.35 16.51 11.43
23-19 0.2-0.6 Tin Plated Brass .250 .225 .583 15°63165-1
6.35 5.72 14.81
250 Series FASTON
Receptacles1
Stock Thickness
.016 [0.41]
1Mates with FASTON tabs.
See AMP Catalog 82004.
Magnet Wire Range Insulation Mating Material Material Part Applicator
CMA mm2Dia. Diameter Tab Thk. Thickness Number No.
24-19 0.51-0.98 .050-.080 .020 Brass .016 63623-11567451-22
1.30-2.00 0.51 Tin Plated Brass 0.41 63623-21
23-19 or 0.60-0.98 or .050-.100 .025 .016
(2) 24 or (2) 0.57 or 1.30-2.55 0.64 Brass 0.41 62069-1 567343-22
(2) 26 (2) 0.45
20-16 or 0.85-1.37 or .100-.140 or .032 Brass .016 60384-1
(2) 23 or (2) 0.63 or (2) .060 Max. [0.81] 0.41 466010-12
(2) 20 (2) 0.88 2.55-3.55 Tin Plated Brass 60384-2
20-16 0.85-1.37 .100-.140 .020 Brass .016 62080-1 466010-12
2.55-3.55 0.51 0.41
18-14 or .120-.170 or .032 .016
(2) 17 1.02-1.71 (2) .060 Max. [0.81] Tin Plated Brass 0.41 60385-2 466816-12
3.05-4.30
18-14 or 1.02-1.71 .120-.170 .020 Brass .016 63622-11466816-12
(2) 19 3.05-4.30 0.51 0.41
18-14 or 1.02-1.71 .120-.170 .020 Brass .016 1217835-11466816-12
(2) 19 3.05-4.30 0.51 0.41
1Low insertion force
2Quick-Change Applicator for AMP-O-LECTRIC Machine 565435-5.
.690
[17.53]
.290
[7.37]
.280
[7.11]
250 Series FASTON Tabs1
(Continued)
Stock Thickness
.032 [0.81]
1Mates with FASTON receptacles.
See AMP Catalog 82004.
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
57
AMPLIVAR Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
AMPLIVAR Terminals
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Pin Receptacles
Stock Thickness
.016 [0.41]
Type Wire Range Insulation Material Dimensions Part
AWG mm2Dia. Range W Max. L C Number
A 29-22 0.07-0.3 .040-.060 Tin Plated Brass .084 .590 .195 63506-1
1.02-1.52 2.13 14.99 4.95
B 21-16 0.4-1.4 —Tin Plated .235 .660 .250 60177-2
Phos. Bronze 5.97 16.76 6.35
AB
187 Series FASTON Flag
Receptacles
Stock Thickness
.016 [0.41]
Magnet Wire Range Insulation Mating Material Material Part Applicator
CMA mm2Dia. Diameter Tab Thk. Thickness Number No.
500-960 0.56-0.79 .020-.040 .020 Tin Plated Brass .016 63942-1 566411-11
0.51-1.02 0.51 0.41
24-20 AWG 0.51-0.81 .020-.040 .032 Tin Plated Brass .016 1217624-1 566411-11
0.51-1.02 0.81 0.41
1500-2350 0.99-1.22 .020-.040 .020 Tin Plated Brass .016 63941-1 566410-11
0.51-1.02 0.51 0.41
2000-4050 1.14-1.63 .020-.040 .020 Tin Plated Brass .016 63940-1 680353-32
0.51-1.02 0.51 0.41
2000-4050 1.14-1.63 .020-.040 .032 Tin Plated Brass .016 1217417-1 680353-32
0.51-1.02 0.81 0.41
1Standard Applicator for “G” Splice Terminator No. 356462-2.
2Quick-Change Applicator for “G” Splice Terminator No. 356462-1.
.045
[1.14] .240
[6.10] .4.35
[11.05]
.232
[5.89]
250 Series FASTON Flag
Receptacles
Stock Thickness
.018 [0.45]
Magnet Wire Range Insulation Mating Material Material Part Applicator
CMA mm2Dia. Diameter Tab Thk. Thickness Number No.
16-12 1.29-2.13 .120-.170 .032 Tin Plated .018 63944-1 680421-31
3.05-4.32 0.81 Phos Bronze 0.45
1Quick-Change Applicator for ”G” Splice Terminator No. 356462-1.
.070
[1.78] .305
[7.75]
.600
[15.24]
.300
[7.62]
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
58
AMPLIVAR Terminals (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Stator Terminal —
Receptacle
.250 x .032 [6.35 x 0.81]
➀Stator Terminal with
Receptacle .250 x .032
[6.35 x 0.81]
➁Plastic Cavity
Production only
according to
Tyco Electronics
Specifications (Contact
Tyco Electronics
Engineering for details).
For design and
material selection
Tyco Electronics
Engineering has to be
contacted before
decision.
The terminal is
separated from the strip
and placed automatic-
ally into the cavity.
➂Wire Clamping Barrel
The magnet wire is
positioned via posts
into the AMPLIVAR
crimp barrel and fixed
inside clamping barrel.
➃AMPLIVAR Crimp
The AMP application
equipment crimps the
AMPLIVAR connection
and cuts the extending
clamping barrel in one
operation.
Additional versions
upon request.
Application Tooling
for Production Line
Integrating available
upon request.
➀
➁
➂
➃
250 Series Stator
Receptacles —
7 Serrations
.070
[1.78]
.860
[21.84]
.300
[7.62]
.305
[7.75]
Magnet Wire Range Mating Tab Stock Crimp Material Part
AWG mm2Solid Dia. CMA Thickness Thickness Width Number
27-22 0.10-0.3 .014-.026 200-700 .032 .018 .070 Tin Plated Brass 63480-1
0.35-0.66 0.81 0.44 1.77
21-15 0.4-1.6 .028-.060 800-3600 .032 .018 .110 Tin Plated Brass 62381-1
0.71-1.52 0.81 0.44 2.79
22-15.5 0.3-1.5 .053-.086 2800-7400 .032 .018 .155 Tin Plated Brass 63964-1
1.35-2.18 0.81 0.44 3.94
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
59
Cluster Blocks
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Cluster Blocks
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Product Facts
■Pin receptacle terminals
available in tin-plated
phosphor bronze
■Versions available to accept
.090 [2.29] and .125 [3.18]
header pins
■Accepts wire range 18–16
AWG [0.8–1.4 mm2] and
14–12 AWG [2.0–3.0 mm2]
■Thermoplastic polyester
housing
■Impervious to many oils and
refrigerants
■Insulation compatibility
■Housings available to
accept standard and
reversed header pin layouts
■High-performance electrical
and mechanical contact
■High-impact resistance
housings
■Assemblies accept pins
from one side only to
prevent reversed polarity
■High-speed application of
pin receptacle terminals
with AMP automatic
terminating machines and
quick-change applicators for
high volume production
rates at the lowest
installed cost
■Pin receptacle terminals are
easily removed from the
housing for maintenance
and repair
■Recognized under the
Component Program of
Underwriters
Laboratories Inc.,
File No. E28476
Tyco Electronics features
AMP Cluster Blocks that
offer manufacturers of
air conditioning and
refrigeration products a
low-cost, fully insulated,
quick-connect means for
electrically connecting
sealed hermetic header
pins on compressors.
Cluster Blocks feature high
impact resistance to shock
and abuse, and long-life
performance in the
presence of oils and
refrigerants. Since the
connectors accept pins
from only one side, the
danger of reversing polarity
at the time of installation is
prevented.
The one-piece housings are
molded from thermoplastic
polyester. The connector
accepts .090 [2.29] and
.125 [3.18] diameter pin
sizes in either standard or
reverse pin layouts.
Housings accept both lead
wire and AMPLIVAR direct
connect pin receptacle
terminals made from
phosphor bronze material.
These are precision formed
and available on reels for
high-speed application.
High retention pin
receptacle terminals are
available to provide
optimum terminal retention
in housings.
Typical Assembly
R
Pin Receptacle Terminal
(Crimped to Wire)
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
60
Cluster Blocks .090 [2.29] Pin Size (Lead Wire)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Housings
.090 ± .001
[2.29 ± 0.03]
Pin Dia.
3 Plcs.
.530
[13.46]
.229
[5.82] .459
[11.66]
Dia.
Pin Location
A and B
W
K
L
H
B
H
K
L
W
A
W
H
KL
C
.108
[2.74]
.108
[2.74]
.090 ± .001
[2.29 ± 0.03]
Pin Dia.
4 Plcs.
.108
[2.74]
.108
[2.74]
.324
[8.23]
.683
[17.35]
.324
[8.23]
.324
[8.23]
Dia.
Pin Location
C
Type Center Pin Header Pin Dim. Dim. Dim. Dim. Material Part
Position Circle Dia. L W H K Number
Forward .530 1.245 .710 .355 .850 PBT Polyester 1217263-1
13.46 31.60 18.05 9.00 21.60 15% Glass Reinforced
A Forward .530 1.240 .710 .320 .840 PBT Polyester 360050-1
13.46 31.50 18.05 8.15 21.35 15% Glass Reinforced
Forward .530 1.220 .695 .260 .820 PBT Polyester 521078-1
13.46 31.00 17.65 6.60 20.85 15% Glass Reinforced
Back .530 1.225 .810 .320 .840 PBT Polyester 360033-1
B13.46 31.10 20.55 8.15 21.35 15% Glass Reinforced
Back .530 1.200 .695 .310 .805 PBT Polyester 281006-0
13.46 30.50 17.65 7.85 20.40 Non-Reinforced
C—.683 1.490 .900 .355 .845 PBT Polyester 1217262-1
17.35 37.85 22.85 9.00 21.45 15% Glass Reinforced
.670
[17.02]
.313
[7.95]
.180
[4.57]
.115
[2.92]
A
.670
[17.02]
.313
[7.95]
.180
[4.57]
.115
[2.92]
B
Pin Receptacles
Type AWG/ Wire Range Crimp Insulation Crimp Stock Material Part
mm2Solid Dia. CMA Width Diameter Width Thickness Number
A22-14 .025-.065 —.100 .080-.150 .130 .016 Tin Plated Phos Bronze 1217264-1
0.3-2.0 0.65-1.65 2.54 2.00-3.80 3.30 0.41
18-16 .040-.050 —.110 .060-.100 .140 .016 Tin Plated Phos Bronze 62131-3
B0.8-1.4 1.00-1.30 2.79 1.50-2.55 3.56 0.41
18-16 .040-.050 —.110 .090-.170 .180 .016 Tin Plated Phos Bronze 63448-1
0.8-1.4 1.00-1.30 2.79 2.30-4.30 4.57 0.41
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
61
Cluster Blocks .125 [3.18] Pin Size (Lead Wire and Direct Connect)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Cluster Blocks
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
W
H
K
L
Housings
.125 ± .001
[3.18 ± 0.03]
Pin Dia.
3 Plcs.
.530
[13.46]
.229
[5.82] .459
[11.66]
Dia.
W
H
L
K
D
W
K
L
H
A
W
L
K
H
B
Type Center Pin Header Pin Dim. Dim. Dim. Dim. Material Part
Position Circle Dia. L W H K Number
Forward .530 1.755 .765 .525 1.230 PBT Polyester 1217181-1
A13.46 44.60 19.45 13.35 31.25 15% Glass Reinforced
Forward .530 1.755 .765 .470 1.230 PBT Polyester 360052-1
13.46 44.60 19.45 11.95 31.25 15% Glass Reinforced
Forward .687 1.730 .895 .615 1.080 PBT Polyester 1217186-1
B17.45 43.95 22.75 15.60 27.45 15% Glass Reinforced
Forward .687 1.595 .895 .380 1.080 PBT Polyester 520995-1
17.45 40.50 22.75 9.65 27.45 15% Glass Reinforced
C Forward .815 1.975 1.015 .590 1.050 PBT Polyester 1217261-1
20.70 50.15 25.80 15.00 26.65 Non-Reinforced
Back .530 1.860 .765 .525 1.225 PBT Polyester 1217200-1
13.46 47.25 19.45 13.35 31.10 15% Glass Reinforced
D Back .530 1.755 .765 .470 1.225 PBT Polyester 360051-1
13.46 44.60 19.45 11.95 31.10 15% Glass Reinforced
Back .687 1.850 .895 .615 1.225 PBT Polyester 1217187-1
17.45 47.00 22.75 15.60 31.10 15% Glass Reinforced
C
Pin Location
A and D
.125 ± .001
[3.18 ± 0.03]
Pin Dia.
3 Plcs.
.687
[17.45]
.297
[7.55] .595
[15.12]
Dia.
Pin Location
B
.125 ± .001
[3.18 ± 0.03]
Pin Dia.
3 Plcs.
.815
[20.70]
.353
[8.96] .706
[17.92]
Dia.
Pin Location
C
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
62
Cluster Blocks .125 [3.18] Pin Size (Lead Wire and Direct Connect) (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
C
AMPLIVAR Direct Connect D
AMPLIVAR Direct Connect
A
Lead Wire
.240
[6.1]
.400
[10.16]
.870
[22.1]
.160
[4.06]
.240
[6.1]
.400
[10.16]
.870
[22.1]
.160
[4.06]
B
Lead Wire
Pin Receptacles
Type AWG/ Wire Range Crimp Insulation Crimp Stock Material Part
mm2Solid Dia. CMA Width Diameter Width Thickness Number
18-16 .040-.050 —.110 .090-.130 .155 .020 Tin Plated Phos Bronze 62244-3
0.8-1.4 1.00-1.30 2.79 2.30-3.30 3.94 0.51
A18-16 .040-.050 —.110 .090-.130 .155 .020 Phos Bronze 62244-5
0.8-1.4 1.00-1.30 2.79 2.30-3.30 3.94 0.51
14-10 .065-.100 —.140 .130-.170 .180 .020 Tin Plated Phos Bronze 62243-3
2.0-6.0 1.60-2.60 3.56 3.30-4.30 4.57 0.51
18-16 .040-.050 —.110 .090-.130 .155 .020 Tin Plated Phos Bronze 1217176-1
B0.8-1.4 1.00-1.30 2.79 2.30-3.30 3.94 0.51
14-10 .065-.100 —.140 .130-.170 .170 .020 Tin Plated Phos Bronze 1217175-1
2.0-6.0 1.60-2.60 3.56 3.30-4.30 4.32 0.51
—.020-.040 400-1600 .090 .060-.100 .140 .020 Tin Plated Phos Bronze 63908-1
0.50-1.00 2.27 1.50-2.55 3.56 0.51
—.020-.040 400-1600 .090 .060-.100 .140 .020 Tin Plated Phos Bronze 63453-1
0.50-1.00 2.27 1.50-2.55 3.56 0.51
—.040-.065 1500-4200 .110 .075-.125 .155 .020 Tin Plated Phos Bronze 63907-1
1.00-1.65 2.79 1.90-3.20 3.94 0.51
C—.040-.065 1500-4200 .110 .075-.125 .155 .020 Tin Plated Phos Bronze 63454-1
1.00-1.65 2.79 1.90-3.20 3.94 0.51
—.065-.090 4000-8500 .140 .090-.170 .170 .020 Tin Plated Phos Bronze 63906-1
1.65-2.30 3.56 2.30-4.30 4.32 0.51
—.065-.090 4000-8500 .140 .090-.170 .170 .020 Tin Plated Phos Bronze 63455-1
1.65-2.30 3.56 2.30-4.30 4.32 0.51
—.065-.090 4000-8500 .160 .090-.170 .170 .020 Tin Plated Phos Bronze 1217122-1
1.65-2.30 4.06 2.30-4.30 4.32 0.51
—.020-.040 400-1600 .090 .060-.100 .140 .020 Tin Plated Phos Bronze 1217670-1
0.50-1.00 2.27 1.50-2.55 3.56 0.51
—.020-.040 400-1600 .090 .060-.100 .140 .020 Tin Plated Phos Bronze 1217172-1
0.50-1.00 2.27 1.50-2.55 3.56 0.51
—.040-.065 1500-4200 .110 .075-.125 .155 .020 Tin Plated Phos Bronze 1217671-1
D1.00-1.65 2.79 1.90-3.20 3.94 0.51
—.040-.065 1500-4200 .110 .075-.125 .155 .020 Tin Plated Phos Bronze 1217174-1
1.00-1.65 2.79 1.90-3.20 3.94 0.51
—.065-.090 4000-8500 .140 .090-.170 .170 .020 Tin Plated Phos Bronze 1217672-1
1.65-2.30 3.56 2.30-4.30 4.32 0.51
—.065-.090 4000-8500 .140 .110-.150 .170 .020 Tin Plated Phos Bronze 1217173-1
1.65-2.30 3.56 2.80-3.80 4.32 0.51
.805
[20.45]
.400
[10.16]
.160
[4.06]
.240
[6.10]
.805
[20.45]
.400
[10.16]
.160
[4.06]
.240
[6.10]
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
63
AMPLIVAR and Cluster Blocks Application Tooling
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
AMPLIVAR and Cluster Blocks
Application Tooling
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
AMPLIVAR Product
Terminator (APT)
Product Facts
■No need to strip magnet
wire
■Connects up to 3 wires in
1 splice
■Crimp Quality Monitor
(CQM) system measures
crimp heights
■Machine shut height easily
adjusts in .0005 [0.013]
increments
■Quick-change tooling with-
out major shut-height
adjustments
Specifications
Weight — Approximately 150 lb
[68 kg] with CQM
Width — 38 [965] with CQM and
product reel
Depth — 35 [889]
Height — 14 [356]
Electrical — 120 VAC, 60 Hz, 1 A, 1f,
or 240 VAC, 50 Hz, .5 A, 1f
Air — 80-100 psi [5.52-7.59 bar],
22 scfm [0.000141 m3/s]
For pigtail splices or direct
connection of contacts to
magnet wire, the AMPLIVAR
Product Terminator (APT)
and strip-form AMPLIVAR
products offer a fast and
efficient system, with no
need to strip mag-wire
insulation. To apply a splice
or contact, simply place the
wires in the target area and
depress the foot switch. The
machine automatically
shears the splice or contact
from the strip, crimps it,
shears off excess wire, and
advances the next splice or
contact into position.
APT semi-automatic bench
machines are available in
two versions: the IIIA with
automatic precision
adjustment controlled by
the Crimp Quality Monitor
(CQM), and the IIE with
manual precision
adjustment.
With CQM, the APT IIIA
assists in achieving 6-sigma
processing capability. In
addition to providing 100%
inspection and automatic
adjustment of crimp heights
as needed, the CQM also
evaluates the quality of
each crimp. If a
questionable crimp is
detected, visual and
audible alarms alert the
operator.
For operations with multiple
wire sizes, the APT IIIA
provides programmable
sequencing of different
crimp-height settings, and
it can store up to 2,000
different programs of 7
different settings each. The
maximum time to auto-
adjust between
programmed crimp heights
is 2 seconds.
The lower cost, manual
adjust IIE is a simpler
version without CQM
capability, with the
advantage of faster set-up
times.
To avoid the need to
change product reels when
wire combinations are
smaller than the CMA range
of the splice or contact, an
optional stuffer (part no.
679323-1 for APT IIIA, part
no. 679323-2 for APT IIE.)
inserts a stuffer wire into
the splice or contact prior
to crimping, increasing
the total CMA to the
recommended range. The
wire stuffer unit is for pigtail
splices only.
APT III A
APT III A with vertical base
(679984-1) for direct connect
terminals APT II E
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
64
AMPLIVAR and Cluster Blocks Application Tooling (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
AMPLIVAR Product
Terminator (APT) (Continued)
Machine Ordering Information
A “Base Part Number” is
selected from the Basic
Machine Part Numbers
table. Then, a dash number
or numbers are selected
from one of the other two
tables depending on the
type of product to be
applied.
Note: The wire stuffer is
available for Pigtail-Type
Splice only and may be
added to the machine after
installation.
679323-1 — APT IIIA
679323-2 — APT IIE
Basic Machine Part Numbers
Machine Features Base Part Number*
Precision Crimp Quality Programmable Pigtail-type Direct
Adjust Monitor Crimp-Height Model Splice Connect
Sequencing Contact
Manual Not included Not included APT IIE** "-1338906- ""-1338907- "
Automatic Included Included APT IIIA "-679453- ""-679457- "
*See tables below for suffix and prefix dash numbers which indicate product to be applied, product crimp width, and
voltage requirement.
**Not upgradable to an APT IIIA
Pigtail-type Crimp 120/240 VAC 120/240 VAC
Splice Width IIE Machine IIIA Machine
Base Number "-1338906-""-679453-"
42775 .110 [2.79] 1-( )-1 3-( )-7
42776
42777 .110 [2.79] 1-( )-2 3-( )-8
42778
42779 .140 [3.56] ( )-8 3-( )-4
62000 .110 [2.79] 1-( )-2 3-( )-8
62001 .140 [3.56] ( )-7 3-( )-3
62001 .180 [4.57] ( )-6 3-( )-2
62201 .140 [3.56] ( )-8 3-( )-4
62002 .180 [4.57] ( )-3 2-( )-9
62040 .110 [2.79] 1-( )-1 3-( )-7
62157 .110 [2.79] 1-( )-2 3-( )-8
62200
62295 .250 [6.35] ( )-1 2-( )-7
62303 .080 [2.03] 1-( )-3 3-( )-9
62304 .110 [2.79] 1-( )-2 3-( )-8
62305
62306 .140 [3.56] 1-( )-0 3-( )-6
62306 .110 [2.79] 1-( )-1 3-( )-7
62307
62308 .140 [3.56] ( )-9 3-( )-5
62308 .180 [4.57] ( )-6 3-( )-2
62309 .220 [5.59] 5-( )-4 5-( )-3
62309 .180 [4.57] ( )-5 3-( )-1
62310 .220 [5.59] ( )-2 2-( )-8
62310 .180 [4.57] ( )-4 3-( )-0
280002 .110 [2.79] 1-( )-1 3-( )-7
280004 .110 [2.79] 1-( )-2 3-( )-8
964156 .110 [2.79] 1-( )-1 3-( )-7
Direct Connect Crimp 120/240 VAC 120/240 VAC
Contact Width IIE Machine IIIA Machine
Base Number "-1338907-""-679457-"
63453 .090 [2.286] ( )-3 ( )-8
63454 .110 [2.79] ( )-2 ( )-7
63455 .140 [3.56] ( )-1 ( )-6
63548 .090 [2.286] ( )-5 1-( )-0
63549 .110 [2.79] ( )-4 ( )-9
63906 .140 [3.56] ( )-1 ( )-6
63907 .110 [2.79] ( )-2 ( )-7
63908 .090 [2.286] ( )-3 ( )-8
1217122 .160 [4.064] 1-( )-1 1-( )-2
1217172 .090 [2.286] ( )-3 ( )-8
1217173 .140 [3.56] ( )-1 ( )-6
1217174 .110 [2.79] ( )-2 ( )-7
1217670 .090 [2.286] ( )-3 ( )-8
1217671 .110 [2.79] ( )-2 ( )-7
1217672 .140 [3.56] ( )-1 ( )-6
AMPLIVAR Pigtail-Type Splice Suffix and Prefix Dash Numbers
(Aluminum base 679984-1 not included)
AMPLIVAR Direct Connect Contact Suffix and Prefix Dash Numbers
(Aluminum base 679984-1 included)
Extraction Tool
Part No. 274186-1
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
65
AMPLIVAR and Cluster Blocks Application Tooling (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
AMPLIVAR and Cluster Blocks
Application Tooling
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
AMP-O-LECTRIC
Termination Machines Model “G”
A totally new design of our
most popular machine for
bench-top operation. It
features a quiet and highly-
reliable direct motor drive,
electronic controls for ease
of setup and operation, and
improved guarding and
lighting for operator
convenience and safety. All
versions also include either
manual or automatic
precision adjustment for
crimp height. For use with
miniature style applicators
only.
(Shown with optional Crimp
Quality Monitor.)
Specifications
Weight — Approximately 240 lb
[110 kg]
Height — 20 [508] without reel
Width — 18.7-25.3 [475-643]
depending on type of applicator used
Depth — 21.5-28.1 [546-713]
depending on type of applicator used
Electrical — 120 or 220 VAC,
50 or 60 Hz
Air — 90-110 psi [6.21-7.59 bar] when
required for use with air-feed applicators
For complete information, request
Catalog 65828.
Crimp Quality Monitor This unique system provides
100% on-the-fly crimp
inspection. It measures the
crimp height of each
termination, and evaluates
the quality of each crimp. If a
crimp is questionable, the
monitor alerts the operator
with both visual and audible
alarms. It also provides ports
for printing and networking.
When used with
AMP-O-LECTRIC Model “G”
Termination Machines, the
monitor is mounted to the
machine. When used with
AMPOMATOR CLS IV Lead
Making Machines, it is
integrated into the machine’s
operating system, with the
information displayed on the
machine’s touch screen.
Model “K”
These machines are used
with standard style
applicators, generally to
apply one size and type of
terminal without the need
for frequent changeovers of
applicators or adjustment of
crimp height. The basic
model is Part Number
1-471273-2. Part Number
1-471273-3 is equipped
with a mechanical feed
assembly for applicators
requiring this type of feed
for advancing the terminal
strip.
Specifications
Weight — Approximately 230 lb
[104 kg]
Height — 24 [610] without reel
Width — 21 [533]
Depth — 20 [508]
Electrical — 120 VAC, 60 Hz, 6 A
Air — 90-110 psi [6.21-7.59 bar] when
required for use with air-feed applicators
Specifications
Height — 4.5 [114]
Width — 8.5 [216]
Depth — 9 [229]
Electrical — 120 VAC, 50 or 60 Hz, or
220 VAC, 50 or 60 Hz
Printer Port — Serial Interface
For further information, request Catalog
82275.
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
66
AMPLIVAR and Cluster Blocks Application Tooling (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Model G Splice Terminating
Machine, P/N 356462-2 &
Applicator
Standard G Splice Applicator
Available for the
AMP-O-LECTRIC Model G
splice terminator only.
Semiautomatic bench
machine crimps reeled
splice product. Uses
Standard G Splice
Applicators to provide
access to both sides of the
splice product. Features a
quiet, reliable motor drive,
microprocessor controls for
ease of setup and operation
and guarding and lighting
designed for operator
convenience. Manual
precision crimp height
adjust is standard and
machine-mounted sensors
are available for crimp
quality monitoring.
Two-piece applicator for
crimping end- or side-feed
reeled splice products.
Provides access to both
sides of splice for increased
ease of use and
productivity. Applicators
use an air feed mechanism.
Specifications
AMP-O-LECTRIC Model “G”
Thru Splice Terminator
Capacity — 5 000 lb [2 224 N]
max. crimp force
Deflection — .003 [0.076] max.
per 1 000 lb [445 N] crimp force
Noise — 76 dB max. at 5 000 lb
[2 224 N] full capacity
Weight — Approx. 240 lb
[109 kg]
Height — 20 [508]
Electrical — 120/220 VAC, 50/60
Hz; Avg. 2.6 A at 120 VAC when
used as a bench-top unit at 2 000
cycles per hour operating rate
Air — 90-110 psi [6.21-7.58 bar],
6 scfm [0.00283 m3/s] (when
required for use with air-feed
applicators)
For more information, order Catalog
889021.
Entry Level Terminator (ELT),
1338600-(x) Semiautomatic Bench
Terminator for side- and
end-feed reeled terminals
and contacts. The ELT uses
a DC motor with gear box
drive. The result is a small-
footprint design that is fast
and quiet. Cycle time is less
than 0.400 sec. with an
operation sound level of
76dBa. With a crimp force
capacity of 3,000 pounds,
the ELT is available for all
but the highest crimp force
applications. Optional
equipment is also available
to meet your specific
application requirements.
Specifications
Width—16.8 [427]
Depth—20.6 [523]
Height—20 [510] w/o reel support
Weight—approx. 150 lb [68 kg]
Electrical—100-240 VAC, 50/60
Hz, 6 A (Note: Avg <1 A at 120 VAC
when used as a bench-top unit at 2,000
cycles per hour operating rate)
Air—90-100 psi [6.21-6.90 bar],
6 scfm [0.00282 m3/s] when
required for use with air-feed
applicators (Note: Optional Air Feed
Valve Assembly Required)
Wire Range—Up to 14 AWG
[2.5 mm2]
For more information, request
catalog 1308382.
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
67
AMPLIVAR and Cluster Blocks Application Tooling (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
AMPLIVAR and Cluster Blocks
Application Tooling
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Applicators End- and Side-Feed
Heavy-Duty Miniature
(HDM) Applicators
AMP applicators are
designed to exacting
specifications to produce
consistent, high-quality
terminations.
HDM applicators are
quickly interchangeable
and easily repaired. They
feature simple dial-in
settings for adjusting crimp
height for terminating differ-
ent wire combinations within
the designated CMA range.
These applicators are used
with both bench machines
and fully-automatic lead
makers. They can also be
used for crimp quality
monitoring on systems
equipped with the CQM
G-Adapter. Call the AMP
Tooling Assistance Center
at 1-800-722-1111 for
further information.
Standard (STD)
Applicators
Standard style applicators
are generally used for long
production runs using
dedicated equipment, or
when splicing a coil, for
example, that needs to be
positioned close to the
crimping area in the
applicator. The crimp height
can be adjusted by raising
or lowering the base mount.
Standard Style Applicator for
Large CMA Splice,
Part Number 566372-2
This applicator was
designed specifically to
apply AMP 5 000-16 000
CMA Splice, Part Number
63625-1. It features a
highly-visible, close-up
crimp area—less than 1
[25] from the front of the
guard. You can easily
splice multiple wires by
simply rotating them down
through the front of the
guard into the crimp area.
It is an air-feed applicator,
and can be used with
Model “K” Part Number
1-471273-3.
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
68
AMPLIVAR and Cluster Blocks Application Tooling (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
AMPOMATOR CLS IV+
Lead-Making Machines, 356500-1, -2 Fully-automatic machines
that measure, cut, strip and
terminate single leads.
Microprocessor-controlled,
and programmed and
operated using an easy-to-
follow, menu-driven
touchscreen. Features
include direct-drive
terminating units with
precision crimp height
adjustment, fully
programmable setups, wire
runout and splice detection,
and motorized pre-feed with
wire straightener. Crimp
quality monitoring is also
available.
Specifications
Width—159 [4 040]
Depth—68 [1 730]
Height—86 [2 185] with
24 [610] dia. reel
Weight—2 000 lb [907 kg]
Electrical—220 VAC, 50 or
60 Hz, single phase, 25 A, with
neutral and ground
Air—90 psi [6.21 bar], 15 scfm
[0.0071 m3/s] sustained
Wire Range—26-10 AWG
[0.12-6 mm2] stranded, 26-16 AWG
[0.12-1.4 mm2] solid
Lead Lengths—3-90
[76.2-2 285], 90-1 000
[2 285-25 400] with long lead
conveyors
For more information, request
Catalog 124324.
Gamma 333 PC Lead-Making Machine, Three Stations,
1-528324-1 With its capacity to
accommodate an additional
processing station on side
1, the Gamma 333 PC can
perform a number of new
processes. It can produce
two-ended crimp leads,
process double crimp
connections with three
different terminals or apply
seals on one end of the
wire. Tinning and ink jet
marking are two further
options. Process monitoring
is integrated into the
system, for accurate
trimming and stripping of
the wires.
Specifications
Length—125 [3137]
Width—54.2 [1377]
Height—70.5 [1790]
Length Range— 2.36 in-32.8 ft
[60-10,000] (optional 30mm)
Cross-Section Range —
AWG 26-AWG 10 [0.125mm2-
5mm2]
Noise Level—<76dB (without
crimping modules)
Electrical—3x208 - 480V,
50-60Hz; 6kVA
Compressed Air—5-6 bar
Air Consumption—6.5m3/h
Weight—1850 lbs [840 kg] with
two crimping modules
For more information, request
Catalog 1307901.
Cut
Formed
Crimped
69
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
MTM Crimpband Splices
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Crimpband
Product Facts
■Made from a continuous coil
of “Ribbon Connector”
material
■Magnet wires MTM
Crimpband splices have
machine-piercing serrations
designed for displacing
magnet wire insulation.
■Available in brass, tin-
plated brass, and copper-
nickel alloy material
■Make parallel or pigtail
connections on same
machine
■100% of Crimpband
material is used in scrap
free terminations
■Crimpband material coupled
with appropriate toolsets
accommodate specific
CMA ranges
■Produced in Tyco Electronics
equipment on your
production floor
■Meets UL 486C crimp
tensile requirements
Tyco Electronics features
the AMP MTM Crimpband
system that is comprised of
two key features: the semi-
automatic termination
machine and a reel of MTM
Crimpband material.
In a one-step crimping
operation, the machine
feeds, cuts, forms and
crimps the material to
provide a low-cost, high
reliability crimp connection.
The MTM Crimpband
splices are formed during
the crimping process from
machined longitudinal
grooved material that pierces
magnet wire varnish film
insulation during crimping.
MTM Crimpband splices
are specifically designed to
terminate magnet wire to
itself or in combination with
standard solid or stranded
lead wire.
Three magnet wires
maximum can be
terminated together with
stranded lead wire in one
splice.
Tyco Electronics provides a
wide range of toolset types
and Crimpband splices to
meet various production
requirements.
Depending on your
specific application, MTM
Crimpband splices are
available in 7, 9, 11 and 13
serration versions for
terminations in the 400 to
13,000 CMA range.
When aluminum magnet wire
is used, MTM Crimpband
splices must be tin plated.
Applications
■Motors windings and
connections
■Coil connections
■Transformer windings and
connections
■Lighting ballasts
■Power supplies
Mod I Mod III
70 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
MTM Crimpband Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
➀Feed (Magnet Wire
Connector Material)
Machine feeds strip until
the strip hits the wire stop.
➁Shear (Blank Length)
The strip is cut by the
cutter block former bar
insert tooling.
➂Bend (Crimp Formed)
The former bar drives the
cut strip over the anvil,
bending the cut strip into
an upside down “U”.
➃Wire (Placement)
In Pigtail and Parallel
(Thru) splices magnet
wires must be placed on
top of the lead wire.
➄Crimp (Crimp Formed)
The anvil retracts as the
driver takes the formed
strip down into the
clincher.
MTM Crimpband
Interconnection System
How the System Operates
W
W
Blank
Length
D
TSerrations
Burrs
Lead Wire
Magnet Wires
on top
A
A
Section A-A
➃
➀
➁
➂
➄
Connector Specification Code
See Figure 1 and/or Legend below
Machine B.L. Dim. W Dim. T Dim. Material
Basis Tooling Connector Material Finish Code
Size Width Thickness
L 092 6R 20 T B
Splice No.
Example: L 092 6R 20 T B
Legend Machine Basis
LPG*
Leased Purchase General
* Customer has their own Tooling
Tooling Blank Length
Size Code B/L (Nom.)
032 .167
032/036 .228
036 .224
045 .246
051 .267
061 .292
061/076 .324
076 .339
076/092 .361
092 .379
092/125 .413
125 .446
125/160 .485
125/165 .506
165 .546
Note: For B/L above, .546 consult
Tyco Electronics for tooling size
code.
Connector Width Code W
4R 5 Serrations .138
6R 7 Serrations .154
8R 9 Serrations .194
10R 11 Serrations .234
Material T±.002 D
Thickness Dim. Serration
Code Depth
12 .012 .005
14 .014 .005
16 .016 .007
20 .020 .007
25 .025 .007
UL486C Pull Out
Wire Size Force Requirements
AWG Underwriters
Laboratory (lbs.)
26 3
24 5
22 8
20 10
18 10
16 15
14 25
12 35
10 40
Notes: To insure that the proper Crimpband splice is chosen, Tyco Electronics
recommends the following:
1. Submit 10 samples of wire combinations and/or components to be
crimped with any special requirements to your Tyco Electronics
sales representative.
2. Pull-out force and/or millivolt drop tests will be performed to insure
that the proper Crimpband material, toolset and crimp heights are
recommended.
3. Tooling and testing will be documented on a Material & Tooling
Sheet (M & T sheet).
4. Crimpband material quotes, tooling quotes and samples will be
submitted to the customer.
Material Material/Finish
Code
B CDA 260 Brass
ACDA 725 Copper/
Nickel Alloy
TB Pre-Tin over
CDA 260 Brass
71
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
MTM Crimpband Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Crimpband
11 Serrations
9 Serrations
T
W
T
W
AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive
mm2Solid Dia. Range Thk. (T) Width (W) Number X-ref
24-20 .020-.033 400-1100 .016 .194 Tin Plated 032/036 1601794-1†P032/
0.20-0.50 0.51-0.84 0.41 4.93 Brass 0368R16TB
201⁄2-16 .030-.051 900-2600 .018 .194 Tin Plated 061 1601607-1†L0618R16TB
0.45-1.30 0.76-1.29 0.46 4.93 Brass
201⁄2-16 .030-.051 900-2600 .018 .194 Brass 061 1601608-1 L0618R20B
0.45-1.30 0.76-1.29 0.46 4.93
201⁄2-16 .030-.051 900-2600 .018 .194 Tin Plated 061 1601814-1†P0618R20TB
0.45-1.30 0.76-1.29 0.46 4.93 Brass
18-14 .040-.063 1600-4000 .016 .194 Tin Plated 076 1601824-1 P0768R16TB
0.80-2.00 1.02-1.60 0.41 4.93 Brass
18-14 .040-.063 1600-4000 .020 .194 Tin Plated 076 1601857-1 PO768R20TB
0.80-2.00 1.02-1.60 0.51 4.93 Brass
18-14 .040-.063 1800-4600 .020 .194 Brass 076/092 1601823-1 P076/
0.80-2.00 1.02-1.60 0.51 4.93 0928R20B
18-14 .040-.063 1800-4600 .020 .194 Tin Plated 076/092 1601639-1 L076/
0.80-2.00 1.02-1.60 0.51 4.93 Brass 0928R20TB
16-12 .051-.078 2600-6100 .020 .194 Brass 092/125 1601833-1 P092/
1.30-3.46 1.29-1.98 0.51 4.93 1258R20B
16-12 .051-.078 2600-6100 .020 .194 Tin Plated 092/125 1601677-1 L092/
1.30-3.46 1.29-1.98 0.51 4.93 Brass 1258R20TB
16-12 .051-.078 2600-6100 .025 .194 Brass 092/125 1601678-1†L092/
1.30-3.46 1.29-1.98 0.64 4.93 1258R25B
16-12 .051-.078 2600-6100 .025 .194 Tin Plated 092/125 1601835-1†P092/
1.30-3.46 1.29-1.98 0.64 4.93 Brass 1258R25TB
151⁄2-12 .055-.082 3000-6750 .016 .194 Brass 125 1601717-1†L1258R16B
1.54-3.46 1.40-2.10 0.41 4.93
151⁄2-12 .055-.082 3000-6750 .016 .194 Tin Plated 125 1601718-1 L1258R16TB
1.54-3.46 1.40-2.10 0.41 4.93 Brass
151⁄2-12 .055-.082 3000-6750 .020 .194 Brass 125 1601846-1 P1258R20B
1.54-3.46 1.40-2.10 0.51 4.93
151⁄2-12 .055-.082 3000-6750 .025 .194 Brass 125 1601719-1 L1258R25B
1.54-3.46 1.40-2.10 0.64 4.93
141⁄2-111⁄2.059-.087 3500-7500 .025 .194 Brass 125/165 1601706-1 L125/
1.80-4.00 1.50-2.21 0.64 4.93 1658R25B
141⁄2-111⁄2.059-.087 3500-7500 .025 .194 Tin Plated 125/165 1601707-1 L125/
1.80-4.00 1.50-2.21 0.64 4.93 Brass 1658R25TB
14-11 .063-.092 4000-8500 .025 .194 Tin Plated 165 1601750-1†L1658R25TB
2.00-4.20 1.60-2.34 0.64 4.93 Brass
111⁄2-9 .084-.114 7000-13000 .025 .194 Tin Plated 200/202 1601761-1 L200/
4.00-6.50 2.13-2.90 0.64 4.93 Brass 2028R25TB
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive
mm2Solid Dia. Range Thk. (T) Width (W) Number X-ref
141⁄2-111⁄2.059-.087 3500-7500 .025 .234 Brass 125/165 1601842-1 P125/
1.80-4.00 1.50-2.21 0.64 5.94 16510R25B
141⁄2-111⁄2.059-.087 3500-7500 .025 .234 Tin Plated 125/165 1601705-1 L125/
1.80-4.00 1.50-2.21 0.64 5.94 Brass 16510R25TB
131⁄2-101⁄2.071-.097 4500-9500 .025 .234 Brass 165/200 1601847-1 P165/
2.54-4.50 1.70-2.46 0.64 5.94 20010R25B
131⁄2-101⁄2.071-.097 4500-9500 .025 .234 Tin Plated 165/200 1601848-1 P165/
2.54-4.50 1.70-2.46 0.64 5.94 Brass 20010R25TB
72 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
MTM Crimpband Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
7 Serrations
T
W
AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive
mm2Solid Dia. Range Thk. (T) Width (W) Number X-ref
271⁄2-21 .013-.028 170-800 .012 .154 Brass 032 1601800-1 P0326R12BUF1
0.09-0.40 0.33-0.71 0.30 3.91
24-20 .020-.033 400-1100 .012 .154 Brass 032/036 1601539-1 L032/
0.20-0.50 0.51-0.84 0.30 3.91 0366R12B
24-20 .020-.033 400-1100 .012 .154 Cu Ni 032/036 1601538-1 L032/
0.20-0.50 0.51-0.84 0.30 3.91 0366R12AUF1
24-20 .020-.033 400-1100 .016 .154 Brass 032/036 1601540-1 L032/
0.20-0.50 0.51-0.84 0.41 3.91 0366R16B
24-20 .020-.033 400-1100 .016 .154 Tin Plated 032/036 1601793-1 P032/
0.20-0.50 0.51-0.84 0.41 3.91 Brass 0366R16TB
22-19 .024-.036 600-1300 .016 .154 Brass 045 1601559-1 L0456R16B
0.38-0.60 0.70-0.91 0.41 3.91
22-19 .024-.036 600-1300 .020 .154 Brass 045 1601560-1†L0456R20B
0.38-0.60 0.70-0.91 0.51 3.91
201⁄2-16 .030-.051 900-2600 .016 .154 Brass 061 1601604-1 L0616R16B
0.45-1.30 0.76-1.29 0.41 3.91
201⁄2-16 .030-.051 900-2600 .016 .154 Tin Plated 061 1601606-1 L0616R16TB
0.45-1.30 0.76-1.29 0.41 3.91 Brass
18-14 .040-.063 1600-4000 .016 .154 Brass 076 1601644-1 L0766R16B
0.80-2.00 1.02-1.60 0.41 3.91
18-14 .040-.063 1600-4000 .016 .154 Tin Plated 076 1601646-1†L0766R16TB
0.80-2.00 1.02-1.60 0.41 3.91 Brass
18-14 .040-.063 1600-4000 .020 .154 Brass 076 1601647-1†L0766R20B
0.80-2.00 1.02-1.60 0.51 3.91
171⁄2-131⁄2.042-.068 1800-4600 .016 .154 Brass 076/092 1601637-1 L076/
0.95-2.54 1.07-1.80 0.41 3.91 0926R16BX
161⁄2-13 .047-.072 2200-5200 .016 .154 Tin Plated 092 1601683-1 L0926R16TB
1.10-2.60 1.19-1.83 0.41 3.91 Brass
16-12 .051-.078 2600-6100 .016 .154 Tin Plated 092/125 1601675-1 L092/
1.30-3.46 1.29-1.98 0.41 3.91 Brass 1256R16TB
16-12 .051-.078 2600-6100 .020 .154 Brass 092/125 1601832-1 P092/
1.30-3.46 1.29-1.98 0.51 3.91 1256R20B
151⁄2-12 .055-.082 3000-6750 .012 .154 Brass 125 1601844-1 P1256R12B
1.54-3.46 1.40-2.10 0.30 3.91
151⁄2-12 .055-.082 3000-6750 .016 .154 Brass 125 1601845-1 P1256R16B
1.54-3.46 1.40-2.10 0.41 3.91
151⁄2-12 .055-.082 3000-6750 .016 .154 Tin Plated 125 1601716-1†L1256R16TB
1.54-3.46 1.40-2.10 0.41 3.91 Brass
1UF designates Ultra-Fine serrations which are recommended for applications using wire size 28 AWG [0.32 mm]
or smaller.
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
73
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
RTM Crimpband Splices
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Crimpband
Product Facts
■Made from a continuous coil
of “Ribbon Connector”
material
■RTM Crimpband have
grooved serrations for
improved axial retention.
■Available in brass, tin-plated
brass and copper-nickel
alloy (CA725) material
■Make parallel or pigtail
connections on same
machine
■Used for electrical and non-
electrical connections.
■100% of RTM Crimpband
material is used in scrap
free terminations
■Crimpband material coupled
with appropriate toolsets
accommodate specific CMA
ranges
■Produced in Tyco Electronics
equipment on your
production floor
■Meets UL 486C crimp
tensile requirements
Tyco Electronics features
the AMP RTM Crimpband
system that is comprised of
two key features: the semi-
automatic termination
machine and a reel of RTM
Crimpband material.
In a one-step crimping
operation, the machine
feeds, cuts, forms and
crimps the material to
provide a low-cost, high
reliability crimp connection.
The RTM Crimpband
splices are formed during
the crimping process from
milled longitudinal groove
material that produce rolled,
rounded serrations.
They are designed to
terminate pre-stripped
stranded and solid wire
conductors together as well
as wire conductors to switch
tabs, resistors, printed
circuit board, flex circuit and
light bulb LED and glass
reed switch assemblies, etc.
The flexibility of the RTM
Crimpband system provides
opportunity for use in
custom applications for
either electrical and / or
mechanical connections.
Tyco Electronics provides a
wide range of toolset types
and crimpband splices to
meet various production
requirements.
Depending on your specific
application, RTM Crimpband
splices are available in 3, 6,
7, 8, 9, 10 14 and 20 ridge
serration versions for
terminations in the 170 to
13,000 CMA range.
Applications
■Stranded and solid wire-to-
wire connections
■Light bulb LED assembly
■Switch lead assembly
■Resistor lead assembly
■Printed circuit board lead
assembly
■Flex-film lead assembly
■Glass reed switch lead
assembly
Cut
Formed
Crimped
Mod I Mod III
74 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
RTM Crimpband Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
➀Feed (Ribbon
Connector Material)
Machine feeds strip until
the strip hits the wire stop.
➁Shear (Blank Length)
The strip is cut by the
cutter block former bar
insert tooling.
➂Bend (Crimp Formed)
The former bar drives the
cut strip over the anvil,
bending the cut strip into
an upside down “U”.
➃Wire (Placement)
Pigtail and Parallel (Thru)
splice terminations are
made on the same
machine.
➄Crimp (Crimp Formed)
The anvil retracts as the
driver takes the formed
strip down into the
clincher.
RTM Crimpband
Interconnection System
How the System Operates
Legend Machine Basis
LP
Leased Purchase
Tooling Blank Length
Size Code B/L (Nom.)
032 .167
032/036 .228
036 .224
045 .246
051 .267
061 .292
061/076 .324
076 .339
076/092 .361
092 .379
092/125 .413
125 .446
125/160 .485
125/165 .506
165 .546
Note: For B/L above, .546 consult
factory for tooling size code
Connector WN
Width Dim. No. of
Code Ridges
B .076 3
C .138 6
D .154 7
E .185 8
F .216 9
G .234 10
H .247 10
L .086 3
M .330 14
N .500 20
P .114 5
Material T±.002
Thickness Dim.
Code
12 .012
16 .016
18 .018
20 .020
22 .022
24 .024
25 .025
Material Material/Finish
Code
B CDA 260 Brass
ACDA 725 Copper/
Nickel Alloy
TB Pre-Tin over
CDA 260 Brass
TCRS 1010 Cold Rolled
Steel, Tin Plated
SS 301 or 302
Stainless Steel
ST Stainless Steel,
Tin Plated
UL486C Pull Out
Wire Size Force Requirements
AWG Underwriters
Laboratory (lbs.)
26 3
24 5
22 8
20 10
18 10
16 15
14 25
12 35
10 40
Notes: To insure that the proper Crimpband splice is chosen, Tyco Electronics
recommends the following:
1. Submit 10 samples of wire combinations and/or components to be
crimped with any special requirements to your Tyco Electronics
sales representative.
2. Pull-out force and/or millivolt drop tests will be performed to insure
that the proper Crimpband material, toolset and crimp heights are
recommended.
3. Tooling and testing will be documented on a Material & Tooling
Sheet (M & T sheet).
4. Crimpband material quotes, tooling quotes and samples will be
submitted to the customer.
W
W
Blank
Length
TRidges
Lead Wires
A
A
Section A-A
➃
➀
➁
➂
➄
Connector Specification Code
See Figure 1 and/or Legend below
Machine B.L. Dim. W Dim. T Dim.
Basis Tooling Connector Material Material
Size Width Thickness
L 092 F 20 TCRS
Splice No.
Example: L 092 F 20 TCRS
75
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
RTM Crimpband Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Crimpband
20 Ridges
T
W
AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive
mm2Solid Dia. Range Thk. (T) Width (W) Number X-ref
111⁄2-9 .084-.114 7000-13000 .020 .500 Tin Plated 200/202 1601771-1 L200/202N20TB
4.00-6.50 2.13-2.90 0.51 12.70 Brass
14 Ridges
T
W
AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive
mm2Solid Dia. Range Thk. (T) Width (W) Number X-ref
22-19 .024-.036 600-1300 .012 .330 Cu Ni 045 1601577-1†L045M12A
0.38-0.60 0.61-0.91 0.30 8.38
22-19 .024-.036 600-1300 .012 .330 Brass 045 1601578-1 L045M12B
0.38-0.60 0.61-0.91 0.30 8.38
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
10 Ridges
T
W
AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive
mm2Solid Dia. Range Thk. (T) Width (W) Number X-ref
22-19 .024-.036 600-1300 .012 .234 Brass 045 1601575-1 L045G12B
0.38-0.60 0.61-0.91 0.30 5.94
21-181⁄2.028-.039 800-1500 .016 .234 Cu Ni 051 1601593-1†L051G16A
0.40-0.75 0.71-0.99 0.41 5.94
201⁄2-16 .030-.051 900-2600 .012 .234 Brass 061 1601632-1†L061G12B
0.45-1.30 0.76-1.29 0.30 5.94
201⁄2-16 .030-.051 900-2600 .020 .234 Brass 061 1601633-1 L061G20B
0.45-1.30 0.76-1.29 0.51 5.94
111⁄2-9 .084-.114 7000-13000 .020 .234 Brass 200/202 1601853-1 P200/
4.00-6.50 2.13-2.90 0.51 5.94 202G20B
111⁄2-9 .084-.114 7000-13000 .025 .234 Brass 200/202 1601769-1 L200/
4.00-6.50 2.13-2.90 0.64 5.94 202G25BX
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
76 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
RTM Crimpband Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
9 Ridges
T
W
AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive
mm2Solid Dia. Range Thk. (T) Width (W) Number X-ref
22-19 .024-.036 600-1300 .012 .216 Stainless 045 1601807-1 P045F12SS
0.38-0.60 0.61-0.91 0.30 5.49 Steel
201⁄2-16 .030-.051 900-2600 .012 .216 Stainless 061 1601520-1 G061F12SS
0.45-1.30 0.76-1.29 0.30 5.49 Steel
8 Ridges
T
W
AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive
mm2Solid Dia. Range Thk. (T) Width (W) Number X-ref
24-20 .020-.033 400-1100 .012 .185 Cu Ni 032/036 1601553-1 L032/
0.20-0.50 0.51-0.84 0.30 4.70 036E12A
18-14 .040-.063 1600-4000 .018 .185 Tin Plated 076 1601669-1 L076E18TCRS
0.80-2.00 1.02-1.60 0.46 4.70 CRS
111⁄2-9 .084-.114 7000-13000 .024 .185 Brass 200/202 1601768-1 L200/
4.00-6.50 2.13-2.90 0.61 4.70 202E24B
7 Ridges
T
W
AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive
mm2Solid Dia. Range Thk. (T) Width (W) Number X-ref
24-20 .020-.033 400-1100 .012 .154 Brass 032/036 1601550-1 L032/
0.20-0.50 0.51-0.84 0.30 3.91 036D12B
24-20 .020-.033 400-1100 .016 .154 Cu Ni 032/036 1601551-1 L032/
0.20-0.50 0.51-0.84 0.41 3.91 036D16A
24-20 .020-.033 400-1100 .016 .154 Brass 032/036 1601797-1 P032/
0.20-0.50 0.51-0.84 0.41 3.91 036D16B
24-20 .020-.033 400-1100 .016 .154 Tin Plated 032/036 1601798-1 P032/
0.20-0.50 0.51-0.84 0.41 3.91 Brass 036D16TB
22-19 .024-.036 600-1300 .012 .154 Brass 045 1601572-1 L045D12B
0.38-0.60 0.61-0.91 0.30 3.91
22-19 .024-.036 600-1300 .016 .154 Cu Ni 045 1601573-1 L045D16A
0.38-0.60 0.61-0.91 0.41 3.91
77
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
RTM Crimpband Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Crimpband
7 Ridges (Continued)
T
W
AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive
mm2Solid Dia. Range Thk. (T) Width (W) Number X-ref
22-19 .024-.036 600-1300 .016 .154 Brass 045 1601507-1†G045D16B
0.38-0.60 0.61-0.91 0.41 3.91
21-181⁄2.028-.039 800-1500 .012 .154 Brass 051 1601587-1 L051D12B
0.40-0.75 0.71-0.99 0.30 3.91
21-181⁄2.028-.039 800-1500 .016 .154 Brass 051 1601588-1 L051D16B
0.40-0.75 0.71-0.99 0.41 3.91
21-181⁄2.028-.039 800-1500 .020 .154 Nickel Plated 051 1601591-1 L051D20NPS
0.40-0.75 0.71-0.99 0.51 3.91 Steel
21-181⁄2.028-.039 800-1500 .020 .154 Tin Plated 051 1601811-1†P051D20TCRS
0.40-0.75 0.71-0.99 0.51 3.91 CRS
201⁄2-16 .030-.051 900-2600 .012 .154 Cu Ni 061 1601818-1†P061D12A
0.45-1.30 0.76-1.29 0.30 3.91
201⁄2-16 .030-.051 900-2600 .012 .154 Brass 061 1601620-1†L061D12B
0.45-1.30 0.76-1.29 0.30 3.91
201⁄2-16 .030-.051 900-2600 .012 .154 Tin Plated 061 1601514-1†G061D12TB
0.45-1.30 0.76-1.29 0.30 3.91 Brass
201⁄2-16 .030-.051 900-2600 .016 .154 Cu Ni 061 1601819-1 P061D16A
0.45-1.30 0.76-1.29 0.41 3.91
201⁄2-16 .030-.051 900-2600 .016 .154 Brass 061 1601820-1 P061D16B
0.45-1.30 0.76-1.29 0.41 3.91
201⁄2-16 .030-.051 900-2600 .016 .154 Tin Plated 061 1601623-1 L061D16TB
0.45-1.30 0.76-1.29 0.41 3.91 Brass
201⁄2-16 .030-.051 900-2600 .018 .154 Brass 061 1601625-1 L061D18B
0.45-1.30 0.76-1.29 0.46 3.91
201⁄2-16 .030-.051 900-2600 .018 .154 Tin Plated 061 1601628-1 L061D18TB
0.45-1.30 0.76-1.29 0.46 3.91 Brass
201⁄2-16 .030-.051 900-2600 .020 .154 Cu Ni 061 1601629-1 L061D20A
0.45-1.30 0.76-1.29 0.51 3.91
201⁄2-16 .030-.051 900-2600 .020 .154 Brass 061 1601630-1 L061D20B
0.45-1.30 0.76-1.29 0.51 3.91
201⁄2-16 .030-.051 900-2600 .020 .154 Tin Plated 061 1601631-1 L061D20TBX
0.45-1.30 0.76-1.29 0.51 3.91 Brass
20-15 .033-.057 1100-3200 .016 .154 Brass 061/076 1601601-1 L061/076D16B
0.60-1.60 0.84-1.45 0.41 3.91
191⁄2-141⁄2.035-.061 1200-3700 .016 .154 Brass 061/092 1601603-1 L061/092D16B
0.60-1.80 0.89-1.54 0.41 3.91
18-14 .040-.063 1600-4000 .012 .154 Cu Ni 076 1601828-1 P076D12A
0.80-2.00 1.02-1.60 0.30 3.91
18-14 .040-.063 1600-4000 .012 .154 Brass 076 1601655-1†L076D12B
0.80-2.00 1.02-1.60 0.30 3.91
18-14 .040-.063 1600-4000 .016 .154 Cu Ni 076 1601656-1 L076D16A
0.80-2.00 1.02-1.60 0.41 3.91
18-14 .040-.063 1600-4000 .016 .154 Brass 076 1601829-1 P076D16B
0.80-2.00 1.02-1.60 0.41 3.91
18-14 .040-.063 1600-4000 .016 .154 Tin Plated 076 1601658-1 L076D16TB
0.80-2.00 1.02-1.60 0.41 3.91 Brass
18-14 .040-.063 1600-4000 .018 .154 Cu Ni 076 1601660-1 L076D18AX
0.80-2.00 1.02-1.60 0.46 3.91
18-14 .040-.063 1600-4000 .018 .154 Brass 076 1601661-1 L076D18B
0.80-2.00 1.02-1.60 0.46 3.91
18-14 .040-.063 1600-4000 .018 .154 Tin Plated 076 1601664-1 L076D18TB
0.80-2.00 1.02-1.60 0.46 3.91 Brass
18-14 .040-.063 1600-4000 .020 .154 Brass 076 1601665-1 L076D20B
0.80-2.00 1.02-1.60 0.51 3.91
18-14 .040-.063 1600-4000 .020 .154 076 1601667-1 L076D20TCRS
0.80-2.00 1.02-1.60 0.51 3.91
18-14 .040-.063 1600-4000 .024 .154 Brass 076 1601668-1 L076D24B
0.80-2.00 1.02-1.60 0.61 3.91
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
78 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
RTM Crimpband Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
7 Ridges (Continued)
T
W
AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive
mm2Solid Dia. Range Thk. (T) Width (W) Number X-ref
171⁄2-13 .042-.068 1800-4600 .016 .154 Brass 076/092 1601642-1 L076/
0.95-2.54 1.07-1.80 0.41 3.91 092D16BX
161⁄2-13 .047-.072 2200-5200 .016 .154 Cu Ni 092 1601689-1 L092D16ASP
1.10-2.60 1.19-1.83 0.41 3.91
161⁄2-13 .047-.072 2200-5200 .016 .154 Brass 092 1601691-1 L092D16B
1.10-2.60 1.19-1.83 0.41 3.91
161⁄2-13 .047-.072 2200-5200 .016 .154 Tin Plated 092 1601693-1 L092D16TB
1.10-2.60 1.19-1.83 0.41 3.91 Brass
161⁄2-13 .047-.072 2200-5200 .018 .154 Cu Ni 092 1601694-1 L092D18A
1.10-2.60 1.19-1.83 0.46 3.91
161⁄2-13 .047-.072 2200-5200 .018 .154 Brass 092 1601695-1 L092D18B
1.10-2.60 1.19-1.83 0.46 3.91
161⁄2-13 .047-.072 2200-5200 .018 .154 Tin Plated 092 1601841-1 P092D18TB
1.10-2.60 1.19-1.83 0.46 3.91 Brass
161⁄2-13 .047-.072 2200-5200 .020 .154 Brass 092 1601528-1†G092D20B
1.10-2.60 1.19-1.83 0.51 3.91
16-12 .051-.078 2600-6100 .020 .154 Cu Ni 092/125 1601680-1 L092/
1.30-3.46 1.29-1.98 0.51 3.91 125D20A
16-12 .051-.078 2600-6100 .020 .154 Brass 092/125 1601681-1 L092/
1.30-3.46 1.29-1.98 0.51 3.91 125D20B
16-12 .051-.078 2600-6100 .020 .154 Tin Plated 092/125 1601682-1 092/
1.30-3.46 1.29-1.98 0.51 3.91 CRS 125D20TCRS
151⁄2-12 .055-.082 3000-6750 .016 .154 Brass 125 1601529-1 G125D16B
1.54-3.46 1.40-2.10 0.41 3.91
151⁄2-12 .055-.082 3000-6750 .018 .154 Cu Ni 125 1601531-1 G125D18A
1.54-3.46 1.40-2.10 0.46 3.91
151⁄2-12 .055-.082 3000-6750 .018 .154 Brass 125 1601726-1 L125D18B
1.54-3.46 1.40-2.10 0.46 3.91
151⁄2-12 .055-.082 3000-6750 .018 .154 Tin Plated 125 1601729-1 L125D18TBX
1.54-3.46 1.40-2.10 0.46 3.91 Brass
151⁄2-12 .055-.082 3000-6750 .020 .154 Brass 125 1601730-1 L125D20B
1.54-3.46 1.40-2.10 0.51 3.91
151⁄2-12 .055-.082 3000-6750 .020 .154 Tin Plated 125 1601731-1 L125D20TB
1.54-3.46 1.40-2.10 0.51 3.91 Brass
151⁄2-12 .055-.082 3000-6750 .020 .154 125 1601733-1 L125D20TCRS
1.54-3.46 1.40-2.10 0.51 3.91
141⁄2-111⁄2.059-.087 3500-7500 .018 .154 Tin Plated 125/165 1601709-1 L125/
1.80-4.00 1.50-2.21 0.46 3.91 Brass 165D18TB
141⁄2-111⁄2.059-.087 3500-7500 .020 .154 Cu Ni 125/165 1601710-1 L125/
1.80-4.00 1.50-2.21 0.51 3.91 165D20A
141⁄2-111⁄2.059-.087 3500-7500 .020 .154 Brass 125/165 1601711-1 L125/
1.80-4.00 1.50-2.21 0.51 3.91 165D20B
141⁄2-111⁄2.059-.087 3500-7500 .020 .154 Tin Plated 125/165 1601712-1 L125/
1.80-4.00 1.50-2.21 0.51 3.91 Brass 165D20TB
14-11 .063-.092 4000-8500 .020 .154 Cu Ni 165 1601754-1†L165D20A
2.00-4.20 1.60-2.34 0.51 3.91
14-11 .063-.092 4000-8500 .020 .154 Brass 165 1601755-1 L165D20B
2.00-4.20 1.60-2.34 0.51 3.91
131⁄2-101⁄2.071-.097 4500-9500 .020 .154 Brass 165/200 1601532-1 G165/
2.54-4.50 1.70-2.46 0.51 3.91 200D20B
111⁄2-9 .084-.114 7000-13000 .016 .154 Brass 200/202 1601764-1 L200/
4.00-6.50 2.13-2.90 0.41 3.91 202D16B
111⁄2-9 .084-.114 7000-13000 .020 .154 Cu Ni 200/202 1601765-1 L200/
4.00-6.50 2.13-2.90 0.51 3.91 202D20A
111⁄2-9 .084-.114 7000-13000 .020 .154 Brass 200/202 1601852-1 P200/
4.00-6.50 2.13-2.90 0.51 3.91 202D20B
111⁄2-9 .084-.114 7000-13000 .020 .154 Tin Plated 200/202 1601766-1 L200/
4.00-6.50 2.13-2.90 0.51 3.91 Brass 202D20TB
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
79
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
RTM Crimpband Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Crimpband
6 Ridges
T
W
AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive
mm2Solid Dia. Range Thk. (T) Width (W) Number X-ref
24-20 .020-.033 400-1100 .012 .138 Tin Plated 032/036 1601548-1 L032/
0.20-0.50 0.51-0.84 0.30 3.51 Brass 036C12TB
24-20 .020-.033 400-1100 .016 .138 Brass 032/036 1601549-1 L032/
0.20-0.50 0.51-0.84 0.41 3.51 036C16B
22-19 .024-.036 600-1300 .012 .138 Brass 045 1601566-1 L045C12B
0.38-0.60 0.61-0.91 0.30 3.51
22-19 .024-.036 600-1300 .016 .138 Cu Ni 045 1601569-1 L045C16A
0.38-0.60 0.61-0.91 0.41 3.51
22-19 .024-.036 600-1300 .016 .138 Brass 045 1601571-1 L045C16B
0.38-0.60 0.61-0.91 0.41 3.51
21-181⁄2.028-.039 800-1500 .012 .138 Brass 051 1601808-1†P051C12B
0.40-0.75 0.71-0.99 0.30 3.51
21-181⁄2.028-.039 800-1500 .016 .138 Cu Ni 051 1601809-1 P051C16A
0.40-0.75 0.71-0.99 0.41 3.51
21-181⁄2.028-.039 800-1500 .016 .138 Brass 051 1601810-1 P051C16B
0.40-0.75 0.71-0.99 0.41 3.51
21-181⁄2.028-.039 800-1500 .018 .138 Brass 051 1601586-1†L051C18B
0.40-0.75 0.71-0.99 0.46 3.51
201⁄2-16 .030-.051 900-2600 .016 .138 Cu Ni 061 1601614-1 L061C16A
0.45-1.30 0.76-1.29 0.41 3.51
201⁄2-16 .030-.051 900-2600 .016 .138 Brass 061 1601511-1 G061C16B
0.45-1.30 0.76-1.29 0.41 3.51
201⁄2-16 .030-.051 900-2600 .016 .138 Tin Plated 061 1601617-1 L061C16TB
0.45-1.30 0.76-1.29 0.41 3.51 Brass
201⁄2-16 .030-.051 900-2600 .018 .138 Cu Ni 061 1601618-1 L061C18AX
0.45-1.30 0.76-1.29 0.46 3.51
201⁄2-16 .030-.051 900-2600 .018 .138 Brass 061 1601619-1 L061C18B
0.45-1.30 0.76-1.29 0.46 3.51
201⁄2-16 .030-.051 900-2600 .020 .138 Brass 061 1601513-1†G061C20B
0.45-1.30 0.76-1.29 0.51 3.51
20-15 .033-.057 1100-3200 .016 .138 Brass 061/076 1601597-1 L061/
0.60-1.60 0.84-1.45 0.41 3.51 076C16B
20-15 .033-.057 1100-3200 .016 .138 Tin Plated 061/076 1601599-1 L061/
0.60-1.60 0.84-1.45 0.41 3.51 Brass 076C16TB
20-15 .033-.057 1100-3200 .018 .138 Brass 061/076 1601600-1†L061/
0.60-1.60 0.84-1.45 0.46 3.51 076C18B
18-14 .040-.063 1600-4000 .016 .138 Cu Ni 076 1601650-1 L076C16A
0.80-2.00 1.02-1.60 0.41 3.51
18-14 .040-.063 1600-4000 .016 .138 Brass 076 1601651-1 L076C16B
0.80-2.00 1.02-1.60 0.41 3.51
18-14 .040-.063 1600-4000 .018 .138 Cu Ni 076 1601652-1†L076C18A
0.80-2.00 1.02-1.60 0.46 3.51
18-14 .040-.063 1600-4000 .018 .138 Brass 076 1601827-1 P076C18B
0.80-2.00 1.02-1.60 0.46 3.51
18-14 .040-.063 1600-4000 .018 .138 076 1601654-1†L076C18TCRS
0.80-2.00 1.02-1.60 0.46 3.51
171⁄2-13 .042-.068 1800-4600 .016 .138 Brass 076/092 1601640-1 L076/
0.95-2.54 1.07-1.80 0.41 3.51 092C16B
161⁄2-13 .047-.072 2200-5200 .016 .138 Cu Ni 092 1601837-1 P092C16AX
1.10-2.60 1.19-1.83 0.41 3.51
161⁄2-13 .047-.072 2200-5200 .016 .138 Brass 092 1601687-1 L092C16B
1.10-2.60 1.19-1.83 0.41 3.51
151⁄2-12 .055-.082 3000-6750 .016 .138 Tin Plated 125 1601721-1 L125C16TB
1.54-3.46 1.40-2.10 0.41 3.51 Brass
151⁄2-12 .055-.082 3000-6750 .018 .138 Cu Ni 125 1601722-1 L125C18A
1.54-3.46 1.40-2.10 0.46 3.51
151⁄2-12 .055-.082 3000-6750 .018 .138 Brass 125 1601723-1 L125C18B
1.54-3.46 1.40-2.10 0.46 3.51
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
80 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
RTM Crimpband Splices (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive
mm2Solid Dia. Range Thk. (T) Width (W) Number X-ref
271⁄2-21 .013-.028 170-800 .012 .076 Brass 032 1601555-1 L032B12B
0.09-0.40 0.33-0.71 0.30 1.93
24-20 .020-.033 400-1100 .012 .076 Cu Ni 032/036 1601542-1 L032/
0.20-0.50 0.51-0.84 0.30 1.93 036B12A
24-20 .020-.033 400-1100 .012 .076 Brass 032/036 1601795-1 P032/
0.20-0.50 0.51-0.84 0.30 1.93 036B12B
24-20 .020-.033 400-1100 .016 .076 Brass 032/036 1601545-1 L032/
0.20-0.50 0.51-0.84 0.41 1.93 036B16B
24-20 .020-.033 400-1100 .016 .076 Tin Plated 032/036 1601546-1 L032/
0.20-0.50 0.51-0.84 0.41 1.93 Brass 036B16TB
24-20 .020-.033 400-1100 .018 .076 Brass 032/036 1601547-1†L032/
0.20-0.50 0.51-0.84 0.46 1.93 036B18B
22-19 .024-.036 600-1300 .016 .076 Cu Ni 045 1601503-1 G045B16A
0.38-0.60 0.61-0.91 0.41 1.93
22-19 .024-.036 600-1300 .016 .076 Brass 045 1601562-1 L045B16B
0.38-0.60 0.61-0.91 0.41 1.93
22-19 .024-.036 600-1300 .016 .076 Tin Plated 045 1601504-1†G045B16TB
0.38-0.60 0.61-0.91 0.41 1.93 Brass
22-19 .024-.036 600-1300 .016 .076 Tin Plated 045 1601564-1 L045B16TBSP
0.38-0.60 0.61-0.91 0.41 1.93 Brass
21-181⁄2.028-.039 800-1500 .016 .076 Cu Ni 051 1601580-1†L051B16A
0.40-0.75 0.71-0.99 0.41 1.93
21-181⁄2.028-.039 800-1500 .016 .076 Brass 051 1601582-1†L051B16B
0.40-0.75 0.71-0.99 0.41 1.93
21-181⁄2.028-.039 800-1500 .016 .076 Tin Plated 045 1601583-1†L051B16TB
0.40-0.75 0.71-0.99 0.41 1.93 Brass
21-181⁄2.028-.039 800-1500 .020 .076 Brass 051 1601584-1 L051B20B
0.40-0.75 0.71-0.99 0.51 1.93
201⁄2-16 .030-.051 900-2600 .016 .076 Tin Plated 061 1601612-1†L061B16TB
0.45-1.30 0.76-1.29 0.41 1.93 Brass
201⁄2-16 .030-.051 900-2600 .016 .076 Cu Ni 061 1601610-1 L061B16A
0.45-1.30 0.76-1.29 0.41 1.93
201⁄2-16 .030-.051 900-2600 .016 .076 Brass 061 1601611-1 L061B16B
0.45-1.30 0.76-1.29 0.41 1.93
201⁄2-16 .030-.051 900-2600 .016 .076 Brass 061 1601635-1 L061L16B
0.45-1.30 0.76-1.29 0.41 1.93
20-15 .033-.057 1100-3200 .016 .076 Tin Plated 061/076 1601596-1 L061/
0.60-1.60 0.84-1.45 0.41 1.93 Brass 076B16TBX
18-14 .040-.063 1600-4000 .016 .076 Brass 076 1601825-1 P076B16B
0.80-2.00 1.02-1.60 0.41 1.93
18-14 .040-.063 1600-4000 .020 .076 Brass 076 1601649-1 L076B20B
0.80-2.00 1.02-1.60 0.51 1.93
†These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
3 Ridges
T
W
81
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Crimpband Application Tooling
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Crimpband
Product Facts
■High Speed Operation —
Many times faster than
soldering, up to 2,000
crimps per hour
■Reliable — Creates uniform
connection, unlike soldering
■Dependable — The
connection is stronger than
the wires being crimped
■Clean — No heat or noxious
solder fumes
■Scrap Free — No leftover
scrap material
■Easy Operation — Simple
operator training
■Economical — Proven
reduction in assembly costs
Tyco Electronics offers
solderless crimping systems
to handle a wide range of
wire connections including
solid and stranded lead
wire, insulated magnet wire,
and component leads. Each
system is comprised of
continuous, serrated
Crimpband material and a
crimping machine. The
Tyco Electronics solution
allows the flexibility to create
a shape and size, which
optimizes the crimp’s
electrical and mechanical
performance.
The Tyco Electronics
crimping system produces a
very economical and reliable
interconnection. Utilizing a
continuous Crimpband
material the machine will
feed, cut form, and crimp
your application resulting in
a very strong and uniform
interconnect crimp.
Whether your application
required a wire-to-wire, wire
to component leads, wire to
terminals, or magnet wire
splice termination, the very
flexible and dependable
crimping machine will
provide high-speed scrap
free interconnects.
Substantial increase in
production interconnection
rates can be realized
versus traditional soldering.
Not to mention it completely
eliminates the noxious fumes.
The Mod I crimping system
is used when running
standard RTM and MTM
Crimpband product. In
addition, left and right horn
termination machines are
available when your
application requires
additional working envelope.
The Mod III crimping system
is used when stainless steel
splices or when large wire
gauge applications warrant
additional force
requirements.
Mod I Mod III
Tooling and Equipment Selector
Volume To Be Crimped Recommended Equipment
CMA in2/mm2Toolset Size Machine
140-800 .003-.016 032 Mod I
0.07 - 0.40
400-1200 .008-.024 032/036 Mod I
0.20 - 0.60
600-1600 .012-.032 045 Mod I
0.30 - 0.81
900-2600 .018-.052 061 Mod I
0.45 - 1.31
1600-4000 .032-.080 076 Mod I
0.81 - 2.02
2200-5200 .044-.104 092 Mod I
1.11 - 2.63
3000-6750 .060-.135 125 Mod I
1.52 - 3.42
4000-8500 .080-.170 165 Mod III
2.02 - 4.31
5000-11000 .010-.219 200 Mod III
2.53 - 5.57
6000-13000 .120-.259 200/202 Mod III
3.04 - 6.58
1. Calculate the combined volume of the wires or components in a crimp.
2. Select Tooling and Machine.
3. Submit samples for test and equipment conditioning.
4. Toolsets are easily interchangeable within same machine type.
82 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
COPALUM Terminals and Splices
(For Solid and Stranded Aluminum or Copper Wire)
Product Facts
■COPALUM terminates film
insulated solid aluminum,
film insulated solid copper,
or uninsulated stranded
copper conductors — indi-
vidually or in combination
■Round wire — up to 10
wires can be terminated in
a single terminal or splice
■Stripping of film insulated
solid conductors not
required when the insula-
tion piercing technique/
tooling are utilized
■Eliminates messy inhibitors
■Available for a broad range
of wire sizes — from 16 to
4/0 AWG [1.25 to 105 mm2]
■Provides stable electrical
and mechanical perfor-
mance in a low-cost reliable
termination
Applications
■Transformers
■Coil windings
■Motors
■Regulators
Cross Section of
Insulation Piercing Crimp
COPALUM terminals and
splices provide reliable, low
cost terminations for film
insulated solid aluminum,
film insulated solid copper,
or uninsulated stranded
copper conductors.
Stranded solid, round and
rectangular conductors can
be terminated in the same
wire barrel, individually or in
combinations falling within a
specified CMA range.
The combination of an insu-
lation displacement crimp
configuration and an inte-
gral perforated inner sleeve
design penetrates the film
insulation, creating an elec-
trical interface between the
conductor and terminal.
Adequate surface contact is
achieved due to the high-
density hole pattern of the
sleeve.
The crimp shears the film
insulation and the conduc-
tor extrudes into the perfo-
rated sleeve, producing a
hermetic seal. These termi-
nations can be exposed to
the typical gaseous and oil
environments found in oil
and air-cooled transformers
or air and fluid-cooled
motors.
A secondary mechanical
crimp section flanks the
electrical crimp and pro-
vides a robust interface
which optimizes the
mechanical properties
(tensile strength, vibration,
resistance, flex life) of the
electrical crimp. The insula-
tion piercing crimp design
permits parallel, butt or
pigtail splicing.
The crimp design allows
solid copper, solid
aluminum and stranded
copper to be terminated in
the same wire barrel if
certain restrictions regard-
ing size, number and total
CMA of conductors being
terminated are observed.
COPALUM
83
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
COPALUM Terminals and Splices
(For Solid and Stranded Aluminum or Copper Wire) (Continued)
Test Results of Insulation
Piercing Crimp Terminations
3.5
3.0
2.5
2.0INITIAL AFTER
CURRENT
CYCLING
VOLTAGE DROP IN MILLIVOLTS
Typical Millivolt Drop (Current Cycling/Thermal Shock) Performance
MAX. INDIVIDUAL CONNECTOR READINGS
AVG. INDIVIDUAL CONNECTOR READINGS
MIN. INDIVIDUAL CONNECTOR READINGS
301430114
AFTER 5
CYCLES
SHOCK
AFTER 10
CYCLES
SHOCK
AFTER 15
CYCLES
SHOCK
AFTER 20
CYCLES
SHOCK
AFTER 25
CYCLES
SHOCK
Current Cycling — 100 cycles
@ 35 amperes, AC; each cycle
consisting of 15 min. “on cur-
rent” and 15 min. “off current”
Thermal Shock — 0.5 hr. @
+150°C and 0.17 hr. in ice
water per cycle; 5 amperes, DC
Products Tested —
COPALUM parallel splices,
wire size 8 AWG [8 mm2]
using two 14 AWG [2 mm2]
solid aluminum conductors
(unstripped) and one 14 AWG
[2 mm2] stranded copper wire
conductor (stripped). Graph
curves represent individual
conductor readings.
Technical Documents
Product Specification —
108-13013
Application Specification —
114-02121
Test Reports —
110-13506 — Copper lead wire
to aluminum
magnet wire in a
COPALUM paral-
lel splice
502-1084 — COPALUM butt
splice perfor-
mance in several
copper lead wire
to copper magnet
wire combina-
tions
502-1085 — Performance
comparison:
COPALUM butt
splice vs. brazing
process
General Application
Guidelines
To assist you in obtaining
the optimum COPALUM
insulation piercing crimp
termination for solid copper,
solid aluminum and strand-
ed copper in the same wire
barrel, the following guide-
lines regarding size, num-
ber and total CMA of con-
ductors being terminated
are recommended:
1. A maximum of 10 equal
size round wires, or a
maximum of 6 equal
square wires may be
crimped without insula-
tion removal.
2. Four rectangular wires
(where T ≥1/4W) or 2
rectangular wires (where
T ≤1/4W) may be
crimped without insula-
tion removal.
3. When crimping different
size solid conductors,
size should not vary by
more than 1 wire gauge,
and preferably by no
more than 1/2 wire
gauge.
4. To use parallel splices
with round magnet wire,
the CMA of the lead wire
should be less than the
sum of the magnet wire
CMA, and the total num-
ber of conductors (lead
and magnet) must be
less than six.
5. To use a butt splice
when the lead wire CMA
is ≥the combined mag-
net wire CMA.
6. In a solid (or combina-
tion of solids) aluminum
and stranded copper
application, the maxi-
mum amount of CMA fill
for the copper conductor
should not exceed 40%
of the total CMA being
crimped.
7. Due to the closed barrel,
it may not be possible
for a particular CMA
loading to fit in the nor-
mally recommended
connector. In instances
where 7 or more equal
round conductors or a
combination of solid alu-
minum and stranded
copper is used, and the
total CMA is at least 50%
of the maximum CMA of
the next larger size con-
nector, this larger size
connector may be used.
8. For applications using
wire combinations not
covered by guidelines
above, consult
Tyco Electronics
Engineering.
Warning: Not approved for
reconnection of residential
aluminum branch circuit
wiring. (Refer to Catalog
82205.)
84 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
COPALUM Terminals and Splices
(For Solid and Stranded Aluminum or Copper Wire) (Continued)
L
L
Butt Splices
Wire Size Range —
Aluminum — AWG 16 to 10
[1.25 to 5.0 mm2], CMA 2,050
to 13,100
Copper — AWG 18 to 12
[0.8 to 3 mm2], CMA 1,290 to
8,230
Wire Size Range —
Aluminum — AWG 8 to 4/0
[8.0 to 105 mm2], CMA 13,100
to 231,000
Copper — AWG 12 to 3/0
[5.0 to 85 mm2], CMA 5,180 to
190,000
Wire Size Dim. Part Numbers
[mm2]LHand Heads for
Circular Mils Max. Tool Pneumatic Tools Splice
Aluminum Copper 626 Tooling 68068
16-14 18-16 .701
[1.25] [0.8] 17.81 68140-1 189447-1 68100 52001
2050-5180 1290-3260
12-10 14-12 .799 68100
[5.0] [3.0] 20.29 68141-1 189444-1 68101 52004
5180-13100 3260-8230
Wire Size Dim. Part Numbers
[mm2]LHeads for Tooling for
Circular Mils Max. Pneumatic Tools Power Unit 69120 Splice
Aluminum Copper 626 Tooling 69015 68068 Head Die Insert
8 12-10 1.195 68101-1
[8.0] [5.0] 30.35 662546-1 68081 68192-1 69099 68084 51826
13100-20800 5180-13100
68
1.340
[14] [8.0] 34.04 — 68082 68102-1 69099 68085 51941
20800-33100 13100-20800
46
1.630
[21] [14] 41.4 — 68038 — 69099 68086 51942
33100-52600 20800-33100
24
1.995
[35] [21] 50.67 — — — 69099 68130 52007
52600-83700 33100-52600
1/0 2 1.985
[50] [35] 50.42 — — — 69099 68131 52010
83700-119500 52600-83700
2/0 1/0 1.985
[70] [50] 50.42 — — — 69099 68132 52013
119500-150500 83700-119500
3/0 2/0 1.985
[85] [70] 50.42 — — — 69099 68133 52016
150500-190000 119500-150500
4/0 3/0 1.985
[105] [85] 50.42 — — — 69082 68129 52019
190000-231000 150500-190000
COPALUM
85
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
COPALUM Terminals and Splices
(For Solid and Stranded Aluminum or Copper Wire) (Continued)
Part Numbers
Wire Size Dim. Hand Heads for Tooling for
[mm2]L
Tool Pneumatic Tools Power Unit 69120 Splice
Circular Mils Max. 69015 626 Tooling 68068 Head Die Insert
16-14 .283
[1.25] 7.19 68140-1 — 189447-1 68100 — — 52791
2050-5180
12-10 .375 68100
[5.0] 9.53 68141-1 — 189444-1 68101 — — 52792
5180-13100
8.437 68101-1
[8.0] 11.1 — 68081 662546-1 68192-1 69099 68084 52745
13100-20800
6.450
[14] 11.43 — 68082 — 68102 69099 68085 52746
20800-33100
4.562
[21] 14.27 — 68038 — — 69099 68086 52747
33100-52600
2.781
[35] 19.84 — — — — 69099 68130 52748
52600-83700
1/0 .734
[50] 18.64 — — — — 69099 68131 52749
83700-119500
2/0 .734
[70] 18.64 — — — — 69099 68132 52750
11950-150500
3/0 .749
[85] 19.02 — — — — 69099 68133 52751
150500-190000
4/0 .765
[105] 19.43 — — — — 69082 68129 52752
190000-231000
Important:
When two or more wires are used in a parallel splice, the combined cross-section area
must be within the CMA range listed.
Parallel Splices
Wire Size Range —
Aluminum — AWG 16 to 4/0
[1.25 to 105 mm2], CMA 2,050
to 231,000
Copper — AWG 18 to 3/0
[0.8 to 85 mm2] , CMA 1,290 to
190,000
L
86 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
COPALUM Terminals and Splices
(For Solid and Stranded Aluminum or Copper Wire) (Continued)
Tongue Dimensions Part Numbers
Wire Size Thickness Stud Heads for
[mm2]Max. Size WLEC
Hand Pneumatic Tools Terminal
Circular Mils Max. Max. Min. Tool 626 Tooling 68068
16-14 .033 1/4 .531 1.107 .839 .564
[1.25] 0.84 M6 13.49 28.12 21.31 14.33 68140-1 189447-1 68100 52587-1
2050-5180 6 .375 .835 .645 .302 -1 68100 51979-1
M3.5 9.53 21.21 16.38 7.67 68141-1 189444-1 68101
8 .375 .835 .645 .302 168100 51979-1
M4 9.53 21.21 16.38 7.67 68141-1 189444-1 68101
12-10 10 .375 .835 .645 .302 168100 51979-2
[5.0] .042 — 9.53 21.21 16.38 7.67 68141-1 189444-1 68101
5180-13100 1.07 1/4 .375 .835 .645 .302 -1 68100 51979-3
M6 9.53 21.21 16.38 7.67 68141-1 189444-1 68101
1/4 .593 1.173 .874 .531 168100 52590-1
M6 15.06 29.79 22.20 13.49 68141-1 189444-1 68101
5/16 .593 1.173 .874 .531 -1 68100 52590-2
M8 15.06 29.79 22.20 13.49 68141-1 189444-1 68101
Tongue Dimensions Part Numbers
Wire Size Thickness Stud Heads for Heads & Die Inserts
[mm2]Max. Size WLER Pneumatic Tools for Power Unit 69120 Terminal
Circular Mils Max. Max. Max. 626 Tooling 69015 68068 Head Die Insert
10 .500 1.384 1.131 .560 662546-1 68101-1 150720-1
— 12.70 35.15 28.73 14.22 68081 68192-1 69099 68084
81/4 .500 1.384 1.131 .560 662546-1 68101-1 150720-1
[8.0] .048 M6 12.70 35.15 28.73 14.22 68081 68192-1 69099 68084
13100-20800 1.22 5/16 .625 1.446 1.131 .560 662546-1 68101-1 150720-2
M8 15.88 36.73 28.73 14.22 68081 68192-1 69099 68084
10MM .625 1.446 1.131 .560 662546-1 68101-1 184076-1
— 15.88 36.73 28.73 14.22 68081 68192-1 69099 68084
10 .500 1.415 1.162 .580 —150719-1
— 12.70 35.94 29.51 14.73 68082 68102 69099 68085
1/4 .500 1.415 1.162 .580 —150719-1
M6 12.70 35.94 29.51 14.73 68082 68102 69099 68085
6.051 5/16 .679 1.504 1.162 .580 —150719-2
[14] 1.30 M8 17.25 38.20 29.51 14.73 68082 68102 69099 68085
20800-33100 3/8 .679 1.504 1.162 .580 —150719-3
— 17.25 38.20 29.51 14.73 68082 68102 69099 68085
10MM .679 1.504 1.162 .580 — 184079-1
— 17.25 38.20 29.51 14.73 68082 68102 69099 68085
E
C
LW
E
R
L
W
Ring Tongue Terminals
Wire Size Range —
Aluminum — AWG 16 to 10
[1.25 to 5.0 mm2], CMA 2,050
to 13,100
Copper — AWG 18 to 12
[0.8 to 3.0 mm2], CMA 1,290
to 8,230
Wire Size Range —
Aluminum — AWG 8 to 6
[8.0 to 14 mm2], CMA 13,100
to 33,100
Copper — AWG 12 to 8
[3.0 to 8.0 mm2], CMA 1,290
to 13,100
COPALUM
87
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
COPALUM Terminals and Splices
(For Solid and Stranded Aluminum or Copper Wire) (Continued)
Ring Tongue Terminals
Wire Size Range —
Aluminum — AWG 4 to 4/0
[21 to 105 mm2], CMA 33,100
to 231,000
Copper — AWG 6 to 3/0
[14 to 85 mm2], CMA 20,800 to
190,000
Tongue Dimensions Part Numbers
Wire Size Thickness Stud Heads & Die Inserts
[mm2]Max. Size WLER for Power Unit 69120 Terminal
Circular Mils Max. Max. Max. Head Die Insert
10 .531 1.630 1.362 .625 150717-1
— 13.49 41.40 34.59 15.88 69099 68086
1/4 .531 1.630 1.362 .625 150717-1
M6 13.49 41.40 34.59 15.8 69099 68086
45/16 .531 1.630 1.362 .62 150717-2
.060 M8 13.49 41.40 34.59 15.88 69099 68086
[21] 1.52 3/8 .675 1.702 1.362 .625 150717-3
33100-52600 — 17.15 43.23 34.59 15.88 69099 68086
1/2 .675 1.702 1.362 .625 150717-5
— 17.15 43.23 34.59 15.88 69099 68086
10MM .675 1.702 1.362 .625 184082-1
— 17.15 43.23 34.59 15.88 69099 68086
1/4 .675 1.859 1.541 .625 151982-1
M6 17.15 47.22 39.14 15.88 69099 68130
5/16 .675 1.859 1.541 .625 151982-1
2M8 17.15 47.22 39.14 15.88 69099 68130
[35] .060 3/8 .675 1.859 1.541 .625 151982-2
52600-83700 1.52 — 17.15 47.22 39.14 15.88 69099 68130
1/2 .807 1.925 1.541 .625 151982-3
— 20.50 48.90 39.14 15.88 69099 68130
10MM .807 1.925 1.541 .625 184084-1
— 20.50 48.90 39.14 15.88 69099 68130
1/4 .675 1.859 1.541 .625 151986-1
M6 17.15 47.22 39.14 15.88 69099 68131
5/16 .675 1.859 1.541 .625 151986-1
1/0 M8 17.15 47.22 39.14 15.88 69099 68131
[50] .073 3/8 .675 1.859 1.541 .625 151986-2
83700-119500 1.85 — 17.15 47.22 39.14 15.88 69099 68131
1/2 .807 1.925 1.541 .625 151986-3
— 20.50 48.90 39.14 15.88 69099 68131
10MM .807 1.925 1.541 .625 184087-1
— 20.50 48.90 39.14 15.88 69099 68131
5/16 .926 1.930 1.560 .625 151989-1
M8 23.52 49.02 39.62 15.88 69099 68132
2/0 3/8 .926 1.930 1.560 .625 151989-2
[70] .083 — 23.52 49.02 39.62 15.88 69099 68132
119500-150500 2.11 1/2 .926 1.930 1.560 .625 151989-3
— 23.52 49.02 39.62 15.88 69099 68132
10MM .926 1.930 1.560 .625 184090-1
— 23.52 49.02 39.62 15.88 69099 68132
7/16 1.020 2.112 1.645 .625 151992-2
3/0 — 25.91 53.64 41.66 15.88 69099 68133
[85] .094 1/2 1.020 2.112 1.645 .625 151992-3
150500-190000 2.39 — 25.91 53.64 41.66 15.88 69099 68133
10MM 1.020 2.112 1.645 .625 184092-1
— 25.91 53.64 41.66 15.88 69099 68133
4/0 1/2 1.087 2.178 1.676 .625
[105] .105 — 27.61 55.32 42.57 15.88 69082 68129 151995-2
190000-231000 2.67 10MM 1.087 2.178 1.676 .625 184094-1
— 27.61 55.32 42.57 15.88 69082 68129
E
R
L
W
88 Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
COPALUM Application Tooling
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Power Unit Style Power Unit Part Number
Hand Actuated 189721-1*
Foot Actuated 189722-1*
*Change to -2 suffix to order Power Unit for use with “C” Head die set adapter.
Notes:
1. Power Units with a ‘1 suffix can be converted to -2 by ordering Booster Addition Kit part no. 189720-1
2. 10 ft [3.05] Air Supply Hose, part no. 38111, is included with each power unit
3. Order Tool Holders, Crimping Heads/Adapters separately.
Tool Holder
w/Ratchet Control w/o Ratchet Control
356302-1 189767-1
Crimp Heads AWG Part Number
16-14 189447-1
12-10 189444-1
8 602546-1
626 Pneumatic Tool System
Bench Mount Assembly
Part Number 856402-1*
Lightweight, air-operated
modular tooling system.
Accepts a wide variety of
interchangeable heads for
crimping various types of
contacts, terminals and
splices onto wires ranging
6-26 AWG [13-0.12 mm2],
plus coaxial and fiber optic
cable. Available with either
hand- or foot-actuation
switch. Optional ratchet
control available to provide
complete crimp cycle.
Specifications
Outside Diameter—1.83 [46.5]
Length—11.6-12.9 [295-327]
Grip Span—2.19 [55.6] over
button/handle
Weight—2.3-3.3 lb [1.0-1.5 kg]
Air—90-100 psi [6.21-6.89 bar],
11.14 in3[0.00018 m3]
Cycle Time—0.7-0.8 sec
(16-14 AWG [1.3-2 mm2] PIDG
Terminals)
For more information, request
Catalog 124208.
Fully adjustable stand allows
operator free use of both hands —
recommended for maximum pro-
ductivity.
Specifications
Base Size — 8 x 8 [200 x 200]
Weight — 6.5 lb [2.9 kg]
Bench Mounting Dimensions —
Base has two, 1/4 - 20 tapped holes on
6 [150] centerlines
*Note: Not for use in the European
Community
89
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
COPALUM Application Tooling (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
COPALUM
Accessories for DYNA-CRIMP Power Units 69120-1 (115 V) or 69120-2 (230 V)
Accessory Part No. Description
59907-7 7 ft. [2.13m] Handle Control Assembly — Hose and Cord*
1-59907-5 15 ft. [4.57m] Handle Control Assembly — Hose and Cord*
2-59907-1 21 ft. [6.4m] Handle Control Assembly — Hose and Cord*
2-59908-1 21 ft. [6.4 m] Handle Control Assembly — Cord w/o Hose*
2-59907-8 28 ft [8.53m] Handle Control Assembly — Hose and Cord*
68284-1 15 ft. [4.57m] Foot Switch Assembly (requires hose assembly)
59909-3 3 ft [0.91m] Hose Assembly**
59909-7 7 ft. [2.13m] Hose Assembly**
1-59909-5 15 ft. [4.57m] Hose Assembly**
2-59909-1 21 ft. [6.4m] Hose Assembly**
59220 3-Way Multi-Directional Valve (for use with foot switch only)
59220-2 3-Way Multi-directional valve (for use with foot switch only)
* Pressure release on Power Unit only
** 311470-1 Quick Disconnect Coupling (Hose Half) and 68284-1 Foot Switch Assembly required
Specifications
Width—9.5 [240]
Depth—11.5 [292]
Height—18.2 [464]
Weight—65 lb [29 kg]
Electrical—120 VAC, 60 Hz
(69120-1); 220 VAC, 50 or 60 Hz
(69120-2); 3 240 VA max.
For more information, request
Instruction Sheet 408-1965.
Wire range: — 16 AWG to 6 AWG
(68068), 8 AWG to 4 AWG (69015)
CMA range: — 2,050 to 33,100
(68068), 20,800 to 52,600 (69015)
Note: Part Number 68068-3, tool with foot
pedal, can be bench mounted.
Power units for crimping
large terminals and splices,
including AMPOWER and
SOLISTRAND terminals,
onto wires ranging from
8 AWG [8 mm2] through
1 000 kcmil [507 mm2].
Heads and die sets are
interchangeable. Available
with either hand- or foot-
actuation switch, and
hose/coupling assemblies
up to 28 ft [8.5 m] in length.
Designed for medium pro-
duction, these semi-auto-
matic power tools offer the
convenience of hand tools
plus the effortless precision
and speed of machines.
They are built for long,
rugged service and are
equipped with removable
crimping dies for terminat-
ing a variety of AMP prod-
ucts.
DYNA-CRIMP Electric-
Hydraulic Power Units,
69120-1, -2, plus Heads
Pneumatic Power Units,
68068, 69015
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
90
Power Splice
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Product Facts
■Compression crimp
eliminates cold solder
points, weld burns and wire
enbrittlement usually
connected with thermal-type
terminations
■Precisely controlled crimp
termination helps eliminate
human error, for maximum
reliability
■Excellent tensile strength,
up to 90 lbs axial retention,
vibration resistant
■Provides a superior
electrical connection that is
free of many contaminates
such as stripper residue and
solder flux
■8000 - 38,000 CMA nominal
capacity
■Accepts up to six magnet
wires and two standard
solid or stranded lead wires
■Superior test results: low
resistance, high stability
■High termination rates, low
wire consumption and the
elimination of rejects
caused by solder flux or
heat damage results in the
lowest applied costs
Tyco Electronics features
the AMP Power Splice
terminal that is specifically
designed to terminate a
wide range of lead and
magnet wire combinations.
The splice contains two
cavities that separate and
cradle magnet wire and
stripped lead wires prior to
crimping.
The outer saddle accepts
up to six-magnet wire
allowing for a CMA range of
15,000 to 30,000.
The inner saddle accepts
pre-stripped lead wires that
total up to 10,900 CMA.
In a one step automatic
operation, the magnet wire
film insulation is multiple
ring-stripped as it is forced
into the serrations while the
lead wire is simultaneously
terminated during the
precisely controlled crimp
The outer saddle has
machined, sharp edges
made by a special
production process that
pierces the insulating layer
of the magnet wire in a
manner that provides a
large contact area.
The resulting termination
produces a high tensile
strength, air sealed
connection that is as
resistant to corrosion as the
insulated conductor with up
to 90 lbs axial retention.
As many as six magnet
wires can be terminated
simultaneously in one splice
in combination with up to
two pre-stripped standard
solid or stranded lead wire.
A semi-automatic machine
provides high output per
hour terminations.
Applications
■Hermetic/Compressor
motors
■Squirrel Cage DC motors
■Capacitor Start motors
■Gear & Traction motors
■Power supplies
■Liner, Torroid & RF
transformers
■Circuit breakers & welders
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
93
93
Technical Information
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Technical Information
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
C. F. C. F. C. F. C. F.
–80 –112.0 9 48.2 47 116.6 85 185.0
–70 –94.0 10 50.0 48 118.4 86 186.8
–60 –76.0 11 51.8 49 120.2 87 188.6
–50 –58.0 12 53.6 50 122.0 88 190.4
–45 –49.1 13 55.4 51 123.8 89 192.2
–40 –40.0 14 57.2 52 125.6 90 194.0
–35 –31.0 15 59.0 53 127.4 91 195.8
–30 –22.0 16 60.8 54 129.2 92 197.6
–25 –13.0 17 62.6 55 131.0 93 199.4
–20 –04.0 18 64.4 56 132.8 94 201.2
–19 –02.2 19 66.2 57 134.6 95 203.0
–18 –00.4 20 68.0 58 136.4 96 204.8
–17 1.4 21 69.8 59 138.2 97 206.6
–16 3.2 22 71.6 60 140.0 98 208.4
–15 5.0 23 73.4 61 141.8 99 210.2
–14 6.8 24 75.2 62 143.6 100 212.0
–13 8.6 25 77.0 63 145.4 110 230.0
–12 10.4 26 78.8 64 147.2 120 248.0
–11 12.2 27 80.6 65 149.0 130 266.0
–10 14.0 28 82.4 66 150.8 140 284.0
–09 15.8 29 84.2 67 152.6 150 302.0
–08 17.6 30 86.0 68 154.4 160 320.0
–07 19.4 31 87.8 69 156.2 170 338.0
–06 21.2 32 89.6 70 158.0 180 356.0
–05 23.0 33 91.4 71 159.8 190 374.0
–04 24.8 34 93.2 72 161.6 200 392.0
–03 26.6 35 95.0 73 163.4 220 428.0
–02 8.4 36 96.8 74 165.2 240 464.0
–01 30.2 37 98.6 75 167.0 260 500.0
0 32.0 38 100.4 76 168.8 280 536.0
1 33.8 39 102.2 77 170.6 300 572.0
2 35.6 40 104.0 78 172.4 400 752.0
4 39.2 42 107.6 80 176.0 600 1112.0
5 41.0 43 109.4 81 177.8 700 1292.0
6 42.8 44 111.2 82 179.6 800 1472.0
7 44.6 45 113.0 83 181.4 900 1652.0
8 46.4 46 114.8 84 183.2 1000 1832.0
C =5/9 (F. −32)
F =9/5C. +32
Tensile Strength
of Magnet Wire1
Nominal Nominal
Wire Dia. Dia.
Size Copper Aluminum
(lbs.) (lbs.)
8 438 142
9 340 113
10 269 89
11 213 71
12 189 56
13 134 44
14 106 35
15 84 28
16 66 22
17 53 17
18 42 14
19 33 11
20 6 8
21 21 7
22 16 5
23 13 4
24 10 3
25 8 2.7
26 6 2.1
27 5 1.7
28 4 1.3
29 3 1.1
30 2 .86
31 2 .68
32 1 .55
33 1 .43
34 1 .34
35 .81 .27
36 .65 .21
37 .65 .21
38 .42 .13
39 .32 .10
40 .25 .083
41 .20 .067
42 .16 .054
43 .12 .041
44 .10 .034
45 .08 .027
46 .06 .022
47 .05 .017
48 .04 .013
49 .03 .010
50 .02 .009
51 .02 .007
52 .01 .005
1Magnet wire tensile will change as
the psi of magnet wire changes.
Note: Copper magnet wire is
calculated at 33,000 psi. Aluminum
magnet wire is calculated at 11,000
psi (EC grade). Magnet wire should
be tensiled on each coil. After
termination of the AMPLIVAR splice,
the tensile strength will be 70%
(min.) of the original magnet wire
tensile values.
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
94
Technical Information (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
AWG Bare Wire CMA Single Film CMA Heavy Film CMA
Bare Dia. Bare Coated Dia. Single Film Coated Dia. Heavy Film
Wire in. mm in. mm Coated in. mm Coated
52 .0008 .020 0.6 .0010 .025 1.0 .0011 .028 1.2
51 .0009 .023 0.8 .0011 .028 1.2 .0012 .031 1.5
50 .0010 .025 1.0 .0012 .031 1.5 .0013 .033 1.7
49 .0011 .028 1.2 .0013 .033 1.7 .0014 .035 2.0
48 .0012 .031 1.5 .0014 .035 2.0 .0015 .038 2.2
47 .0014 .035 2.0 .0016 .040 2.5 .0018 .045 3.1
46 .0016 .040 2.5 .0017 .043 2.9 .0019 .048 3.6
45 .0018 .045 3.1 .0019 .048 3.6 .0021 .053 4.4
44 .0020 .050 4.0 .0022 .056 4.8 .0025 .063 6.2
43 .0022 .056 4.8 .0025 .063 6.2 .0027 .069 7.3
42 .0025 0.06 6.3 .0028 0.07 8.0 .0030 0.08 9.0
41 .0028 0.07 7.8 .0031 0.08 10.0 .0034 0.09 12.0
40 .0031 0.08 9.6 .0035 0.09 12.0 .0038 0.10 14.0
39 .0035 0.09 12.0 .0039 0.10 15.0 .0043 0.11 18.0
38 .0040 0.10 16.0 .0045 0.11 20.0 .0049 0.12 24.0
37 .0045 0.11 20.0 .0050 0.13 25.0 .0055 0.14 30.0
36 .0050 0.13 25.0 .0056 0.14 31.0 .0060 0.15 36.0
35 .0056 0.14 31.0 .0062 0.16 38.0 .0067 0.17 45.0
35 .0056 0.14 31.0 .0062 0.16 38.0 .0067 0.17 45.0
34 .0063 0.16 40.0 .0069 0.18 48.0 .0075 0.19 56.0
33 .0071 0.18 50.0 .0077 0.20 59.0 .0085 0.22 72.0
32 .0080 0.20 64.0 .0084 0.21 71.0 .0095 0.24 90.0
31 .0089 0.23 79.0 .0092 0.23 85.0 .0105 0.27 110.0
301/2.0095 0.24 90.0 .0099 0.25 98.0 .0111 0.28 123.0
30 .0100 0.25 100.0 .0106 0.27 112.0 .0116 0.29 135.0
291/2.0107 0.27 115.0 .0114 0.29 130.0 .0123 0.31 151.0
29 .0113 0.29 128.0 .0120 0.30 144.0 .0130 0.33 169.0
281/2.0120 0.30 144.0 .0126 0.32 159.0 .0137 0.35 187.0
28 .0126 0.32 159.0 .0136 0.35 185.0 .0144 0.37 207.0
271/2.0134 0.34 180.0 .0144 0.37 207.0 .0153 0.39 234.0
27 .0142 0.36 202.0 .0152 0.39 231.0 .0161 0.41 259.0
261/2.0151 0.38 225.0 .0160 0.41 256.0 .0170 0.43 289.0
26 .0159 0.40 258.0 .0170 0.43 289.0 .0179 0.45 320.0
251/2.0169 0.43 289.0 .0180 0.46 324.0 .0190 0.48 361.0
Circular Mil Area
(CMA) and Diameter
for Magnet Wires
(AWG Wire Size
Range 52–251/2)
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
95
95
Technical Information (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Technical Information
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Circular Mil Area
(CMA) and Diameter
for Magnet Wires
(AWG Wire Size
Range 25–8)
AWG Bare Wire CMA Single Film CMA Heavy Film CMA
Bare Dia. Bare Coated Dia. Single Film Coated Dia. Heavy Film
Wire in. mm in. mm Coated in. mm Coated
25 .0179 0.45 320 .0190 0.48 361 .0200 0.51 400
241/2.0190 0.48 361 .0200 0.51 400 .0212 0.54 449
24 .0201 0.51 404 .0213 0.54 455 .0223 0.57 497
231/2.0214 0.54 458 .0226 0.57 511 .0236 0.60 557
23 .0226 0.57 511 .0238 0.60 566 .0249 0.63 620
221/2.0240 0.61 576 .0252 0.64 635 .0263 0.67 692
22 .0253 0.64 640 .0266 0.68 708 .0277 0.70 767
211/2.0269 0.68 724 .0282 0.72 795 .0293 0.74 858
21 .0285 0.72 812 .0298 0.76 888 .0310 0.79 961
201/2.0303 0.77 918 .0315 0.80 992 .0328 0.83 1,076
20 .0320 0.81 1,024 .0334 0.85 1,116 .0346 0.88 1,197
191/2.0340 0.86 1,156 .0353 0.90 1,246 .0365 0.93 1,340
19 .0359 0.91 1,289 .0373 0.95 1,391 .0386 0.98 1,490
181/2.0381 0.97 1,452 .0395 1.00 1,560 .0409 1.04 1,673
18 .0403 1.02 1,624 .0418 1.06 1,747 .0431 1.09 1,858
171/2.0428 1.09 1,832 .0443 1.13 1,962 .0456 1.16 2,079
17 .0453 1.15 2,052 .0468 1.19 2,190 .0482 1.22 2,323
161/2.0481 1.22 2,314 .0496 1.26 2,460 .0510 1.30 2,601
16 .0508 1.29 2,581 .0524 1.33 2,746 .0583 1.37 2,894
151/2.0540 1.37 2,916 .0560 1.42 3,136 .0570 1.45 3,249
15 .0571 1.45 3,260 .0587 1.49 3,446 .0602 1.53 3,624
141/2.0606 1.54 3,672 .0622 1.58 3,869 .0639 1.62 4,082
14 .0641 1.63 4,109 .0658 1.67 4,330 .0675 1.71 4,556
131/2.0681 1.73 4,638 .0698 1.77 4,872 .0711 1.81 5,055
13 .0720 1.83 5,184 .0738 1.87 5,446 .0749 1.90 5,670
121/2.0764 1.94 5,837 .0783 1.99 6,131 .0793 2.01 6,188
12 .0808 2.05 6,529 .0827 2.10 6,839 .0838 2.13 7,090
111/2.0858 2.18 7,362 .0877 2.23 7,691 .0888 2.26 7,885
11 .0907 2.30 8,226 .0927 2.35 8,593 .0938 2.38 8,892
101/2.0963 2.35 9,274 .0983 2.50 9,663 .0994 2.52 9,880
10 .1019 2.59 10,384 .1040 2.64 10,820 .1050 2.67 11,151
9 .1144 2.91 13,087 .1166 2.96 13,600 .1177 2.99 13,971
8 .1285 3.26 16,512 .1307 3.32 17,080 .1318 3.35 17,530
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
96
Technical Information (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Circular Mil Area
(CMA) and Diameter
for Lead Wires
(AWG Wire Size
Range 30–8)
Wire Strands Wire Area
in
Size No. Dia. (Mils) Circ. Mils
30 7 4.0 112
30 1 10.0 100
28 7 5.0 175
28 19 3.1 181
28 1 12.6 159
27 7 5.6 219
27 1 14.2 202
26 6 6.3 238
26 10 5.0 250
26 16 4.0 256
26 8 5.6 251
26 1 15.9 253
26 26 3.1 250
26 7 6.3 278
26 3 10.0 300
26 AN 12 5.0 300
25 10 5.6 314
25 8 6.3 318
25 1 17.9 320
24 10 6.3 397
24 8 7.1 403
24 16 5.0 400
24 4 10.0 400
24 1 20.1 404
24 26 4.0 416
24 13 5.6 408
24 7 8.0 448
24 56 2.8 439
24 AN 19 5.0 475
23 10 7.1 504
23 8 8.0 512
23 1 22.6 511
— 21 5.0 525
22 6 10.0 600
22 8 8.9 634
22 16 6.3 635
22 10 8.0 640
22 1 25.3 640
22 7 10.0 700
22 AN 19 6.3 754
20 10 10.0 1,000
20 1 10.0 1,024
20 26 6.3 1,032
20 7 12.6 1,111
20 AN 19 7.9 1,186
18 19 9.2 1,608
— 16 10.0 1,600
18 1 40.3 1,624
18 7 15.2 1,617
18 65 5.0 1,625
18 7 15.3 1,639
Wire Strands Wire Area
in
Size No. Dia. (Mils) Circ. Mils
— 41 6.3 1,627
— 7 16.0 1,792
18 AN 19 10.0 1,900
18 AN 19 11.3 2,426
16 7 19.2 2,580
16 1 50.8 2,581
16 65 6.3 2,580
16 19 11.7 2,601
16 105 5.0 2,625
— 26 10.0 2,600
16 7 20.0 2,800
14 AN 19 14.2 3,831
14 37 10.5 4,079
14 7 24.2 4,099
14 19 14.7 4,106
14 1 64.4 4,109
— 41 10.0 4,100
14 105 6.3 4,167
14 168 5.0 4,200
14 84 71 4,234
— 7 25.3 4,481
12 19 17.9 6,088
12 AN 19 17.9 6,088
12 259 5.0 6,475
12 19 18.5 6,503
12 7 30.5 6,512
12 37 13.3 6,545
12 1 80.8 6,529
12 165 6.3 6,549
12 84 8.9 6,654
10 7 36.0 9,072
— 37 16.0 9,472
10 414 5.0 10,350
10 37 16.7 10,319
10 1 101.9 10,384
10 7 38.5 10,376
10 19 23.4 10,404
— 41 15.9 10,365
10 105 10.0 10,500
9 7 43.0 12,943
9 1 114.4 13,087
9 525 5.0 13,125
8 7 45.0 14,175
8 133 11.1 16,386
8 37 21.1 16,472
8 1 128.5 16,512
8 7 48.6 16,533
8 19 29.5 16,534
8 49 18.4 16,589
8 AN 133 11.3 16,982
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
97
97
Terminal Stud Hole Size
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Technical Information
The chart shows sizes and
dimensions of various studs
and the corresponding
terminal stud hole sizes
used with AMP devices.
For example, with stud #5
(.125 [3.18] Diameter), use
AMP device listed for #5
stud (.129 [3.28] Hole
Diameter).
Terminal stud hole sizes
may easily be checked by
fitting sample terminal to
black circle.
Stud Size Minimum Terminal
U.S. Cust. Metric Stud Dia. Hole Diameter
5/8" M16 .625 .651
3/4" .750 .776
7/8" M22 .875 .901
1" 1.000 1.026
1-1/8" 1.125 1.151
1-1/4" 1.250 1.276
Stud Size Minimum Terminal
U.S. Cust. Metric Stud Dia. Hole Diameter
#0 .060 .064
#1 .073 .077
#2 M2 .086 .090
#3 .099 .103
#4 .112 .116
#5 M3 .125 .129
#6 M3.5 .138 .142
#8 M4 .164 .168
#10 .190 .194
#12 .216 .220
#14 .242 .247
1/4" M6 .250 .260
5/16" M8 .312 .323
3/8" .375 .385
7/16" .437 .448
1/2" M12 .500 .510
Use to Select Proper Size
Terminal
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
98
Part Number Index
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
41765 50
41766 50
41770 50
41899 50
41900 50
41904 50
42076 50
42119 50
42192 50
42776 50
42778 50
42779 50
42780 50
50717 87
50719 86
50720 86
51826 84
51941 84
51942 84
51979 86
51982 87
51986 87
51989 87
51992 87
51995 87
52001 84
52004 84
52007 84
52010 84
52013 84
52016 84
52019 84
52587 86
52590 86
52745 85
52746 85
52747 85
52748 85
52749 85
52750 85
52751 85
52752 85
52791 85
52792 85
60177 57
60318 53
60319 53
60320 53
60321 53
60322 53
60323 53
60325 53
60384 56
60385 56
60752 54
61074 50
61151 54
61166 51
61440 55
61442 55
61603 55
61604 55
Part No. Page 61710 54
62000 49
62001 49
62002 49
62040 49
62044 51
62069 56
62080 56
62131 60
62157 49
62194 51
62200 49
62201 49
62243 62
62244 62
62295 49
62303 49
62304 49
62305 49
62306 49
62307 49
62308 49
62309 49
62310 49
62311 49
62341 51
62381 58
62420 5
62429 5
62430 11
62431 5
62438 11
62439 11
62445 55
62447 55
62458 9
62459 9
62511 17
62512 17
62513 17
62514 17
62524 5
62526 5
62527 5
62600 20
62606 26
62608 10
62609 10
62610 10
62651 20
62652 20
62653 20
62655 20
62656 20
62657 20
62658 20
62661 17
62663 17
62665 9
62666 9
62670 51
62678 17
Part No. Page 62743 18
62755 53
62766 8
62780 26
62781 26
62816 27
62833 5
62835 53
62841 5
62842 5
62874 11
62888 18
62895 7
62896 7
62897 7
62898 7
62903 8
62904 17
62912 5
62922 55
62923 21
62928 10
62934 11
62935 5
62938 11
62939 20
62958 10
62992 9
63005 8
63018 18
63026 20
63027 20
63036 10
63039 10
63041 27
63044 5
63055 20
63062 16
63063 16
63064 21
63087 8
63107 18
63108 18
63109 18
63110 15
63128 20
63132 20
63133 20
63136 56
63140 56
63145 16
63147 53
63155 21
63159 20
63160 11
63161 27
63165 56
63177 15
63178 15
63199 27
63200 20
63203 20
Part No. Page
Note: This index lists all cataloged parts
by base no. only. Complete part nos.
(with prefixes and/or suffixes) are shown
on the page(s) indicated.
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
99
99
Part Number Index (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Part Number Index
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
63207 20
63208 14
63209 14
63216 12
63218 7
63235 9
63236 9
63237 9
63247 12
63253 10
63254 18
63255 18
63256 18
63263 21
63273 17
63276 15
63277 14
63278 14
63293 17
63308 14
63309 20
63319 15
63326 14
63328 20
63330 15
63331 15
63336 21
63340 18
63353 19
63364 7
63371 21
63376 15
63397 7
63399 53
63403 20
63410 7
63420 9
63425 21
63427 19
63428 19
63429 18
63431 51
63433 15
63434 15
63443 14
63444 14
63446 53
63447 18
63448 60
63453 62
63454 62
63455 62
63458 7
63459 21
63460 21
63461 17
63463 12
63464 21
63465 21
63478 18
63480 58
63484 55
Part No. Page 63486 16
63489 13
63494 17
63495 21
63499 20
63505 18
63506 57
63510 17
63511 17
63529 15
63530 15
63531 8
63532 8
63533 8
63544 18
63551 5
63561 50
63562 50
63564 50
63565 11
63569 14
63570 14
63571 20
63574 7
63584 17
63585 17
63590 5
63591 5
63598 21
63599 19
63601 20
63607 20
63612 53
63613 26
63614 20
63618 20
63621 51
63622 56
63623 56
63631 7
63632 6
63636 5
63641 9
63643 19
63645 11
63649 53
63658 5
63659 10
63660 10
63661 10
63662 5
63663 17
63664 17
63665 17
63666 19
63667 19
63668 17
63669 17
63670 17
63675 27
63690 9
63702 11
Part No. Page 63708 19
63710 23
63711 23
63712 23
63713 23
63714 23
63716 23
63717 23
63718 23
63719 23
63720 23
63722 14
63725 5
63734 23
63735 23
63736 23
63737 23
63738 23
63740 23
63741 23
63742 23
63743 23
63744 23
63746 16
63754 5
63760 18
63762 19
63773 12
63775 7
63776 17
63777 16
63778 27
63782 18
63786 5
63788 14
63789 5
63795 26
63806 12
63807 12
63808 12
63810 12
63816 21
63818 11
63819 11
63827 16
63828 27
63829 17
63844 26
63845 26
63852 17
63855 5
63856 10
63864 54
63870 55
63871 55
63879 14
63880 14
63881 21
63882 21
63883 21
63888 24
63889 55
Part No. Page 63898 20
63899 13
63903 24
63906 62
63907 62
63908 62
63909 12
63910 12
63920 20
63926 12
63927 12
63940 57
63941 57
63942 57
63944 57
63955 27
63956 27
63964 58
63965 12
63972 13
63973 13
63974 13
63975 6
63983 19
63995 19
63996 19
63999 27
184076 86
184079 86
184082 87
184084 87
184087 87
184090 87
184092 87
184094 87
281006 60
350571 54
360033 60
360050 60
360051 61
360052 61
466010 56
466510 55
466816 56
485044 53
485079 53
505036 54
505044 54
505071 53
505072 53
505075 53
505079 54
520995 61
521078 60
566410 57
566411 57
567343 56
567451 56
640212 54
680353 57
680421 57
770642 55
Part No. Page
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
100
Part Number Index (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
964156 49
1217000 27
1217004 18
1217011 5
1217013 11
1217026 5
1217029 55
1217031 20
1217032 12
1217039 55
1217042 19
1217051 12
1217052 12
1217065 17
1217067 6
1217068 6
1217069 6
1217072 55
1217073 55
1217075 19
1217084 5
1217090 19
1217122 62
1217128 17
1217132 7
1217146 10
1217152 20
1217172 62
1217173 62
1217174 62
1217175 62
1217176 62
1217178 17
1217181 61
1217186 61
1217187 61
1217189 5
1217190 5
1217191 5
1217192 5
1217196 11
1217200 61
1217209 8
1217210 13
1217211 13
1217214 7
1217221 6
1217231 27
1217234 5
1217243 17
1217261 61
1217262 60
1217263 60
1217264 60
1217302 10
1217324 7
1217339 19
1217355 6
1217356 6
1217357 6
1217358 6
1217368 5
Part No. Page 1217384 50
1217405 11
1217406 7
1217417 57
1217426 6
1217427 6
1217428 6
1217429 6
1217430 16
1217457 9
1217458 9
1217459 11
1217460 11
1217470 7
1217491 19
1217492 19
1217493 18
1217497 23
1217516 23
1217529 27
1217533 6
1217538 9
1217579 6
1217588 21
1217592 18
1217593 13
1217595 12
1217596 13
1217613 8
1217624 57
1217641 11
1217642 11
1217666 23
1217670 62
1217671 62
1217672 62
1217688 6
1217689 6
1217690 6
1217691 6
1217709 24
1217714 23
1217736 5
1217745 13
1217746 13
1217757 5
1217783 16
1217804 27
1217824 5
1217830 27
1217835 56
1217853 8
1217856 20
1217857 18
1217858 8
1217860 20
1217870 20
1217875 7
1601000 32
1601002 38
1601003 38
1601004 37
Part No. Page 1601005 36
1601006 37
1601008 35
1601009 35
1601011 37
1601013 37
1601018 37
1601020 37
1601021 37
1601028 38
1601033 37
1601035 37
1601037 35
1601039 36
1601040 37
1601041 35
1601044 38
1601045 36
1601046 32
1601049 37
1601051 35
1601052 38
1601056 32
1601058 37
1601059 36
1601061 38
1601063 35
1601064 36
1601065 35
1601066 35
1601068 37
1601072 37
1601073 36
1601074 32
1601075 39
1601077 39
1601085 36
1601095 35
1601097 36
1601099 35
1601104 35
1601110 35
1601112 36
1601115 38
1601116 36
1601117 32
1601118 38
1601120 35
1601121 35
1601125 32
1601128 35
1601130 39
1601131 39
1601133 36
1601136 32
1601137 39
1601138 35
1601139 38
1601140 34
1601142 37
1601147 35
1601149 39
Part No. Page 1601151 36
1601155 35
1601159 38
1601161 38
1601421 29, 32, 34, 39
1601423 29, 37, 38
1601424 29, 35, 39
1601425 29, 35-39
1601427 29, 37
1601431 29, 35, 36
1601432 30, 39
1601433 30, 32, 34
1601434 30, 37
1601435 30, 38
1601436 30, 32
1601437 30
1601438 30, 35, 38
1601440 30, 32, 34
1601447 30, 32, 35-39
1601462 30, 32
1601463 30, 32
1601470 30, 39
1601503 80
1601504 80
1601507 77
1601511 79
1601513 79
1601514 77
1601520 76
1601528 78
1601529 78
1601531 78
1601532 78
1601538 72
1601539 72
1601540 72
1601542 80
1601545 80
1601546 80
1601547 80
1601548 79
1601549 79
1601550 76
1601551 76
1601553 76
1601555 80
1601559 72
1601560 72
1601562 80
1601564 80
1601566 79
1601569 79
1601571 79
1601572 76
1601573 76
1601575 75
1601577 75
1601578 75
1601580 80
1601582 80
1601583 80
1601584 80
Part No. Page
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
101
101
Part Number Index (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Part Number Index
1601586 79
1601587 77
1601588 77
1601591 77
1601593 75
1601596 80
1601597 79
1601599 79
1601600 79
1601601 77
1601603 77
1601604 72
1601606 72
1601607 71
1601608 71
1601610 80
1601611 80
1601612 80
1601614 79
1601617 79
1601618 79
1601619 79
1601620 77
1601623 77
1601625 77
1601628 77
1601629 77
1601630 77
1601631 77
1601632 75
1601633 75
1601635 80
1601637 72
1601639 71
Part No. Page 1601640 79
1601642 78
1601644 72
1601646 72
1601647 72
1601649 80
1601650 79
1601651 79
1601652 79
1601654 79
1601655 77
1601656 77
1601658 77
1601660 77
1601661 77
1601664 77
1601665 77
1601667 77
1601668 77
1601669 76
1601675 72
1601677 71
1601678 71
1601680 78
1601681 78
1601682 78
1601683 72
1601687 79
1601689 78
1601691 78
1601693 78
1601694 78
1601695 78
1601705 71
Part No. Page 1601706 71
1601707 71
1601709 78
1601710 78
1601711 78
1601712 78
1601716 72
1601717 71
1601718 71
1601719 71
1601721 79
1601722 79
1601723 79
1601726 78
1601729 78
1601730 78
1601731 78
1601733 78
1601750 71
1601754 78
1601755 78
1601761 71
1601764 78
1601765 78
1601766 78
1601768 76
1601769 75
1601771 75
1601793 72
1601794 71
1601795 80
1601797 76
1601798 76
1601800 72
Part No. Page 1601807 76
1601808 79
1601809 79
1601810 79
1601811 77
1601814 71
1601818 77
1601819 77
1601820 77
1601823 71
1601824 71
1601825 80
1601827 79
1601828 77
1601829 77
1601832 72
1601833 71
1601835 71
1601837 79
1601841 78
1601842 71
1601844 72
1601845 72
1601846 71
1601847 71
1601848 71
1601852 78
1601853 75
1601857 71
1601953 91
111-000-001 91
Part No. Page
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Engineering Notes
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
102
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
91
Power Splice (Continued)
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Power Splice
Magnet Wire
Insulation
Piercing
Serrations
Inner saddle for lead wire
(CMA 4,200-10,900)
Outer saddle accepts up to 6 Magnet Wires
(CMA 15,000-30,000) #20 AWG minimum
Magnet wires smaller
than #18 AWG (1.0 mm)
are placed here
Direction of Feed .408
[10.36] .430
[10.92] Max.
Cut-off
.385
[9.78]
.430 ± .010
[10.92 ± 0.25]
.118
[3.00]
R .060
[1.52]
R .024
[0.61]
.296
[7.52]
Part Number 111-000-001
Type Magnet Wire Range Lead Wire Range Part Number
CMA CMA Reeled
A 15,000-30,000 4200-10,900 1601953-11
1Total combined CMA not to exceed 38000.
.375
[9.53]
.408
[10.36]
.425
[10.80]
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
92
Application Tooling
Magnet Wire Terminals and Termination Systems Catalog 82221
Revised 10-02
Power Splice Machine for
Mag Wire/Lead Wire Pigtail
Splice Termination
Product Facts
■Terminate Mag Wire and
Lead Wire Together
■Maximum 38,000 CMA
Crimp
■Servo-Driven 5-Ton
Terminator
■Heavy Duty Air-Feed
Applicator
■One Control Cabinet
Operates 2 Terminators
■Programmable Crimping
Ram Stroke
■Hand Held Control Pendent
■Crimp Force Monitoring
■Crimp Height Sequencing
For quick, easy and reliable
pigtail splice termination of
magnet wire and solid or
stranded lead wire, Tyco
Electronics offers the new
Power Splice terminator and
applicator.
The Power Splice terminator
and applicator will terminate
pigtail splices consisting up
to two (2) solid or stranded
copper lead wires in wire
size from 10-14 AWG and
having a Circular Mil Area
(CMA) of 4,200-10,000. The
splice will simultaneously
accept combinations of
multiple copper magnet
wires in a range of 11-20
AWG. Total magnet wire
CMA can fall in the range of
8,000-30,000. Total CMA
capable of being crimped in
the Power Splice terminal is
between 8,000-38,000.
The Power Splice terminator
incorporates a servo motor
drive 5-ton terminator with
an air feed applicator to
create a high quality crimp.
The application equipment
is controlled through a
handheld pendent and
incorporates crimp force
monitoring, crimp height
sequencing, and a
programmable ram stroke.
A special machine guard to
facilitate proper wire
placement into the terminal
is also provided to ease
terminal loading and
provide operator safety.
Solderless Pigtail Splice
Terminations
■No need to pre-strip the
magnet wire
■No wire embrittlement
due to solder
■No Solder fumes
■Compact clean
termination
