Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals Product Facts Terminates all magnet wire film insulations Eliminates need for prestripping 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 R Standard MAG-MATE Terminals 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. Applications Motor windings and connections Coil connections Transformer windings and connections Bobbin connections Lighting ballasts Power supplies 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 metalto-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 fullyautomatic applications. 1 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) Typical Plastic Cavities Manufacture only according to Tyco Electronics Specification. 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 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) .355 [ 9.08] Min. .215 [ 5.46] Min. Cavity Size 4, .500 [12.70] Box Height MAG-MATE (Reference Application Spec. 114-2066) 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, .235 [ 5.97] Min. Cavity Size 5, .300 [7.62] Box Height Latch-In MAG-MATE, Narrow Body (Reference Application Spec. 114-2067) Cavity Size 6, .300 [7.62] Box Height MAG-MATE (Reference Application Spec. 114-2046) either manually or by coil winding equipment. quick disconnect FASTON tab terminals. Unraveling is prevented by a slight friction fit, suitable bend or by wrapping the magnet wire around a tie-off post. Excess magnet wire is trimmed flush with the outside of the plastic cavity by a shear blade traveling with the terminal insertion ram. 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 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. 2 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) Standard MAG-MATE Interconnection System How the System Operates Wire Cutter Standard MAG-MATE Terminals Locking Barbs This part cuts off the excess magnet wire and the wire support at the front of the cavity. Terminal retention is secured in the cavity by four locking barbs. Plastic Cavity Insertion 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. Contact Various wire attachments in three different sizes, .187, .300, .500 cavity height (see tables). IDC Slot Production must be in accordance with Tyco Electronics Application Specifications. Consulting Tyco Electronics is required for design in. Cavity Slot for Wire The width has to be in accordance with the wire size (see Application Specification). Magnet Wire The magnet wire is positioned in the "U" 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. Wire Support Block The block supports the magnet wire during the cutting process. The magnet wire is cut flush to the cavity front side. Stripping Shoulders During the insertion process, these shoulders strip the film insulation from the magnet wire in four areas. 11 Anvil The anvil supports the wire during the insertion process. Termination Sequence A = Prepare B = Insert C = Finish Post Trim Blade Insertion Finger Poke-In Contact MAG-MATE Cavity Magnet Wire Support Anvil 11 A B C 3 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 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 125C followed by 30 minutes at -65C Humidity -- Temperature Cycling 10 cycles between 25C and 65C at 95% RH Heat Age -- 33 days at 118C Resistance vs Thermal Shock (Copper Wire) 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. Resistance vs Current Cycles (Copper Wire) 15 AWG 16 AWG 19 AWG 24 AWG 22 AWG 27 AWG 26 AWG T (C) 33 AWG 30 AWG Test Current produces 100C 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) 4 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. 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 Note: For all applications, Tyco Electronics recommends that samples of the magnet wire to be used be submitted for engineering evaluation. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 300 Box Poke-In Terminals .300 [7.62] .300 [7.62] Tin plated brass (See page 2) Copper Magnet Wire Range1 AWG mm C 300 Box Standard IDC Non-Locking Poke-In Lead Wire Range3 AWG mm2 0.16-0.18 20-18 0.5-0.9 33-31 0.18-0.23 20-18 0.5-0.9 31-28 0.23-0.32 20-18 0.5-0.9 Stock Thickness .010 0.25 .010 0.25 .012 0.30 .012 0.30 0.25-0.36 20-18 0.5-0.9 27-23 0.36-0.57 20-18 -- 0.5-0.9 -- .016 0.41 25-222 0.45-0.64 20-18 0.5-0.9 .016 0.41 0.64-0.81 .118 [3.00] B 34-33 22-202 B4 300 Box Standard IDC w/ Strain Relief Slot Locking Poke-In .118 [3.00] A 30-27 A 300 Box Standard IDC Locking Poke-In .135 [3.43] .118 [3.00] Typical Cavity Size 2 Type .300 [7.62] .135 [3.43] .135 [3.43] 20-18 0.5-0.9 -- -- 202 0.81 20-18 0.5-0.9 19-172 0.91-1.15 20-18 0.5-0.9 30 0.25 20-18 0.5-0.9 29-282 0.29-0.32 20-18 0.5-0.9 28-262 0.32-0.40 20-18 0.5-0.9 27-232 0.36-0.57 20-18 0.5-0.9 31-28 0.23-0.32 -- -- Standard MAG-MATE Terminals Material .016 0.41 .016 0.41 .016 0.41 .012 0.30 .012 0.30 .012 0.30 .016 0.41 .012 0.30 30-27 0.25-0.36 -- -- .012 0.30 27-23 0.36-0.57 -- -- .016 0.41 27-26 0.36-0.40 -- -- 25.5-24 0.43-0.51 -- -- 23.5-222 0.54-0.64 -- -- 21.5-202 0.68-0.81 -- -- .016 0.41 .016 0.41 .016 0.41 .016 0.41 C Strip Part Number* L. P. Dual L. P. -- -- 63662-1 62431-1 62527-1 1217234-1 -- -- 62429-1 63636-18 62935-1 63754-15 63658-1 1217084-15 62420-1 62420-46 1217824-11 63725-15 62526-1 -- 63044-1 -- 1217757-1 63591-1 -- 62833-1 -- 62524-1 -- -- -- 63855-1 -- 62842-1 -- -- 62841-1 -- -- -- -- 62912-1 1217736-1 -- -- 1217011-1 -- -- 1217368-1 -- -- 63789-1 -- -- 63786-1 1217026-1 -- -- -- -- -- -- -- -- -- -- -- -- -- -- 1217192-1 -- -- 1217191-1 -- -- 1217190-1 -- -- 1217189-1 -- -- 63590-17 63590-2 63590-36 63551-17 63551-2 63551-36 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger unless otherwise noted. 3 Solid or overcoated stranded lead wire only. Product will also accept Poke-In Tab Terminal shown on page 7. 4 Strain relief slot for high vibration applications. 5 Enhanced anti-overstress behind Poke-In feature for severe applications. Part does not accept lead wires. 6 Finish is tin plated phosphor bronze. 7 Finish is tin over nickel plated brass. 8 Deep 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. 1 2 Preferred part numbers are printed in bold. Chart continued on next page 5 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 300 Box Poke-In Terminals (Continued) .300 [7.62] Material .300 [7.62] .135 [3.43] Tin plated brass .118 [3.00] Typical Cavity Size 2 .455 [11.56] E D (See page 2) .118 [3.00] Copper Magnet Wire Range1 Stock Thickness AWG mm .016 27-26 0.36-0.40 0.41 D4 300 Box .016 25.5-24 0.43-0.51 Standard IDC w/ 0.41 Strain Relief Slot .016 2 23.5-22 0.54-0.64 Non-Locking 0.41 Poke-In .016 0.68-0.81 21.5-202 0.41 .016 30-272 0.25-0.36 0.41 .016 E 2 27-23 0.36 -0.57 0.41 300 Box Standard IDC .016 0.57-0.81 23-202 Tri-Slot 0.41 Non-Locking 0.36-0.57 27-232 Poke-In .016 0.91-1.15 19-172 0.41 182 0.8-0.9 Type Note: Special cavity required for Tri-slot splice terminal. Contact Tyco Electronics Engineering for details. Strip Part Number 1217429-1 . 1217691-13 . 1217428-1 . 1217690-13 1217427-1 . 1217689-13 1217426-1 . 1217688-13 1217221-1 63632-1 1217533-1 63975-1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. Enhanced anti-overstress behind Poke-In feature for severe applications. Part does not accept lead wires. 4 Strain 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. 1 2 3 500 Box Poke-In Terminals Material .505 [12.83] Tin plated brass .505 [12.83] .281 [7.14] Typical Cavity Size 4 .118 [3.00] (See page 2) A B Copper Magnet Wire Range1 Stock Type Thickness AWG mm .016 23-19.5 0.57-0.86 A 0.41 500 Box .016 19-17 0.91-1.15 Standard IDC 0.41 Non-Locking .016 Poke-In 16-15 1.29-1.45 0.41 .016 23-21.5 0.57-0.68 0.41 .016 B3 21-19.5 0.72-0.86 0.41 500 Box Standard IDC w/ .016 19-17 0.91-1.15 Strain Relief Slot 0.41 Non-Locking .016 16-15 1.29-1.45 Poke-In 0.41 .016 14-132 1.61-1.83 0.41 1 2 3 .118 [3.00] .281 [7.14] Strip Part Number 1217069-1 1217068-1 1217067-1 1217358-1 1217357-1 1217356-1 1217355-1 1217579-1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. Strain relief slot for high vibration applications. These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 6 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) Poke-In Tab Terminals Standard MAG-MATE Terminals Materials Optional Slot for #20 AWG [0.8 mm] Dia. Solid Copper Diode Slot Tin plated brass A B C .208 [5.28] .340 [8.64] .312 [7.92] D .245 [6.22] .312 [7.92] .135 [3.43] .135 [3.43] F E Type A 90 Up B 90 Up w/Ins. Sup. C Straight D Straight w/Ins. Sup. Poke-In System .110 .370 [2.79] [9.40] E 90 Down F 90 Down w/Ins. Sup. G Flag - 300 Box only H Flag - 500 Box only H G Lead Wire Size1 AWG mm2 22-18 0.3-0.9 Ins. O.D. -- 22-18 0.3-0.9 18-14 0.8-2.0 .060-.100 1.52-2.54 .090-.140 2.29-3.56 22-18 0.3-0.9 -- 18-14 0.8-2.0 -- Stock Thickness .018 0.46 .020 0.51 .018 0.46 .020 0.51 .020 0.51 .020 0.51 22-18 0.3-0.9 .060-.100 1.52-2.54 .018 0.46 18-14 0.8-2.0 .090-.140 2.29-3.56 22-18 0.3-0.9 -- .020 0.51 .018 0.46 18-14 0.8-2.0 .090-.140 2.29-3.56 20-16 0.5-1.4 -- 18-14 0.8-2.0 .080-.120 2.03-3.05 Stranded, fused stranded or solid lead wire. Shallow tab serrations. 3 Tab serration on top of tab only. 4 No serrations on tab. 5 Includes diode slot for 20 AWG [0.8 mm] diameter solid copper diode wire. 6 Special serration location for deeper poke-in. 1 2 .540 [13.72] .285 .347 [7.24] [8.81] Strip Part Number 62895-1* 63410-1 62896-1* 1217132-12 63218-1 62897-1* 63775-1 62898-1* 63574-13 63631-14, 1217470-15 63397-1 63364-1 .020 0.51 63458-1 1217214-16 .020 0.51 .032 0.81 1217406-17 1217875-1 1217324-1 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. 7 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 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) .300 [7.62] .455 [11.56] A B Range1 Copper Magnet Wire AWG mm Type Note: Special cavity required for Tri-slot splice terminal. Contact Tyco Electronics Engineering for details. A 300 Box Standard IDC Splice B 300 Box Standard IDC Tri-Slot Splice .120 [3.05] Dim. C Stock Thickness 33-31 0.18-0.23 31-28 0.23-0.32 27-24 0.36-0.50 20-183 0.81-1.02 .070 1.78 .070 1.78 .070 1.78 .120 3.05 28-24 0.32-0.51 -- 23-202 0.57-0.81 -- .012 0.30 .012 0.30 .012 0.30 .020 0.51 .016 0.41 .016 0.41 27-23 184 19-172 25-223 184 23.5-202 0.36-0.57 0.8-0.9 0.91-1.15 0.45-0.64 0.8-0.9 0.54-0.81 -- -- Part Number Strip L. P. -- 63531-1 -- 63532-1 -- 63533-1 62903-1 -- 1217858-1 -- 1217853-1 -- .016 0.41 1217613-1 -- .016 0.41 1217209-1 -- Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. 3 Bare wire only. 4 Single solid or fused stranded lead wire only. These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 Dual Connection Terminals Material Tin plated brass Note: Special cavity required. Contact Tyco Electronics Engineering for details. A Type Copper Magnet Wire Range1 AWG mm A 165 Box Standard IDC Splice 1 Solid Lead Wire Range AWG mm 32-31 0.20-0.23 26-24 0.40-0.51 30-28 0.25-0.32 26-24 0.40-0.51 30-27 0.25-0.36 26-24 0.40-0.51 Stock Thickness .012 0.30 .012 0.30 .012 0.30 Strip Part Number 63005-1 63087-1 62766-1 Two magnet wires may be terminated in the same terminal lower slot if diameters are equal. part numbers are available upon special request; contact Tyco Electronics Engineering for details. These 8 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) Dual Connection Terminals (Continued) Standard MAG-MATE Terminals Material .345 [8.76] .185 [4.70] Tin plated phos. bronze .110 [2.79] Note: Special cavity required. Contact Tyco Electronics Engineering for details. .070 [1.78] B Copper Magnet Wire Range1 AWG mm Type B 185 Box Standard IDC Tab Receptacle 1 32-31 0.20-0.23 30-28 0.25-0.32 29-28 0.29-0.32 Mating Tab Stock Thickness .070 x .020 1.78 x 0.51 .070 x .020 1.78 x 0.51 .070 x .020 1.78 x 0.51 .010 0.25 .010 0.25 .010 0.25 Strip Part Number 1217538-1 1217457-1 1217458-1 Two magnet wires may be terminated in the same slot if diameters are equal. 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) A Type Copper Magnet Wire Range1 AWG mm 33-31 A 300 Box Standard IDC F-Crimp 0.18-0.23 31-28 0.23-0.32 30-27 0.25-0.36 28-24 0.32-0.51 27-24 0.36-0.51 27-23 0.36-0.57 25-22 0.45-0.64 22-202 0.64-0.81 Dim. C Lead Wire Range3 AWG mm2 .070 1.78 .120 3.05 .070 1.78 .120 3.05 .120 3.05 .070 1.78 .120 3.05 .070 1.78 .120 3.05 22-18 0.3-1.0 24-20 0.2-0.6 22-18 0.3-1.0 24-20 0.2-0.6 24-20 0.2-0.6 22-18 0.3-1.0 24-20 0.2-0.6 22-18 0.3-1.0 24-20 0.2-0.6 Stock Thickness .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .016 0.41 .012 0.30 .016 0.41 Strip Part Number L. P. 63235-1 -- 63420-1 -- 63236-1 -- 62992-1 -- 63641-1 -- 63237-1 -- 62459-1 62666-1 63690-1 -- 62458-1 62665-1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. Stranded, fused stranded or solid lead wire. These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 3 9 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 187 Box F-Crimp Terminals .187 [4.75] .360 .187 [9.14] [4.75] Material Tin plated brass .187 [4.75] Series Box Typical Cavity Size 1 (See page 2) .070 [1.78] .090 [2.29] .467 [11.86] .070 [1.78] .090 [2.29] A Type Copper Magnet Wire Range1 AWG mm A 187 Box Standard IDC F-Crimp B 187 Box F-Crimp w/ Ins Sup. B Lead Wire Range3 AWG mm2 Stock Thickness .010 0.25 Ins. O.D. 33-31 0.18-0.23 26-22 0.12-0.3 -- 30-28 0.25-0.32 26-22 0.12-0.3 -- 27-25 0.36-0.46 26-22 0.12-0.3 -- 26-24 0.40-0.51 22-18 0.3-1.0 -- 24-222 0.51-0.64 26-22 0.12-0.3 -- .012 0.30 .012 0.30 .012 0.30 27-25 0.36-0.46 22-18 0.3-1.0 .071-.088 1.80 -2.23 .012 0.30 Strip Part Number 63039-1 63039-23,5 63036-1 62608-14 62608-34 62609-14 62609-34 .012 0.30 1217146-1 62610-14 63856-1 63856-2 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. 3 Stranded, fused stranded or solid lead wire. 4 Strip rereeled to feed through mini-applicator to crimp lead wire first, magnet wire termination is secondary operation. 1 2 300 Box Posted PCB Terminals .042 [1.07] Solder Terminal L L Material .300 [7.62] Tin over copper plated brass Typical Cavity Size .070 [1.78] .135 [3.43] (See page 2) Type A--Cavity Size 2 Type B--Cavity Size 6 A Type A 300 Box Standard IDC PCB Post B PCB Post Shallow Box Copper Magnet Wire Range1 AWG mm B Dim. L 33-31 0.18-0.23 31-28 0.23-0.32 29-26 0.29-0.40 27-23 0.36-0.57 22-202 0.64-0.81 19-172 0.91-1.15 .540 13.72 .540 13.72 .540 13.72 .460 11.68 .460 11.68 .460 11.68 33-31 0.18-0.23 .475 12.07 Stock Thickness Tab Section Mag Wire .010 .010 0.25 0.25 .010 .010 0.25 0.25 .012 .012 0.30 0.30 .016 .016 0.41 0.41 .016 .016 0.41 0.41 .016 .016 0.41 0.41 .020 0.51 .012 0.30 Strip Part Number 63253-1 62928-1* 62958-1* 63659-1 63660-1 63661-1 1217302-1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. * Recognized under the Component Program of Underwriters Laboratories, Inc. Note: PC Board hole size .050 [1.27]. 1 10 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 187 Box Posted PCB Terminals Tin plated brass, except where noted 33-31 0.18-0.23 Typical Cavity Size 1 (See page 2) 30-28 A 187 Box Standard IDC PCB Post L 0.25-0.32 27-25 0.36-0.46 24-222 0.51-0.64 Dim. L Stock Thickness .267 6.78 .330 8.38 .267 6.78 .287 7.29 .330 8.38 .330 8.38 .287 7.29 .010 0.25 .010 0.25 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .330 8.38 Part Number Strip L.P. .012 0.30 63565-10 -- 62938-10 62938-23 62934-1 . -- 63160-10 -- 63818-10 -- 62430-10 62430-23 62438-10 62438-20 62874-1 . -- Standard MAG-MATE Terminals Copper Magnet Wire Range1 AWG mm Type Material -- 63819-10 -- 62439-10 62439-24 62439-33 63645-1 -- -- Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. Reverse reeled version of -1. 4 Finish is tin over nickel plated brass. These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 3 A 187 Box Tab Terminals Material Left Right Tin plated brass, except when noted L L Typical Cavity Size 1 (See page 2) L .187 [4.75] .187 [4.75] .187 [4.75] .090 [2.29] .070 [1.78] .090 [2.29] .070 [1.78] .090 [2.29] .070 [1.78] A Type Copper Magnet Wire AWG mm A 187 Box Standard IDC Straight Tab 1 2 3 B Range1 30-28 0.25-0.32 29-27 0.29-0.36 30 0.25 25-222 0.46-0.64 B 187 Box Standard IDC Offset Tab-R.H. 27-25 0.36-0.45 C 187 Box Standard IDC Offset Tab-L.H. 27-25 0.36-0.45 C Dim. L Tab Size .432 10.97 .432 10.97 .550 14.00 .700 17.78 .565 14.36 .700 17.78 .565 14.36 .700 17.78 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .071 x .025 1.80 x 0.63 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 Stock Thickness Tab Section Mag Wire .020 .012 0.51 0.30 .020 .012 0.51 0.30 .025 .012 0.63 0.30 .032 .012 0.81 0.30 .032 .012 0.81 0.30 .032 .012 0.81 0.30 .032 .012 0.81 0.30 .032 .012 0.81 0.30 Strip Part Number 63702-1 1217196-13 1217405-1 1217013-1 1217641-1 1217459-1 1217642-1 1217460-1 Two magnet wires may be terminated in the same terminal if diameters are equal. Single magnet wire only. Finish is tin over nickel plated brass. 11 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 300 Box Tab Terminals Material Tin plated brass Typical Cavity Size 2 (See page 2) L L .300 [7.62] .135 [3.43] A 300 Box Standard IDC Straight Tab 20 B 300 Box Standard IDC Offset Tab-R.H. C 300 Box Standard IDC Offset Tab-L.H. D 300 Box Standard IDC Universal Offset Tab .135 [3.43] 0.23 33-31 0.18-0.23 30 0.25 33-31 0.18-0.23 .300 [7.62] .135 [3.43] .120 [3.05] .120 [3.05] .120 [3.05] .120 [3.05] A B C D 0.79 31 L .300 [7.62] .135 [3.43] Copper Magnet Wire Range1 AWG mm Type L .300 [7.62] Dim. L Tab Size .750 19.05 .895 22.73 .870 22.10 .660 16.76 .669 17.75 .669 17.75 .660 16.76 .669 17.75 .669 17.75 .063 x .025 1.60 x 0.63 .063 x .025 1.60 x 0.63 .062 x .032 1.57 x 0.81 .071 x .025 1.80 x 0.63 .091 x .025 2.31 x 0.63 .091 x .025 2.31 x 0.63 .071 x .025 1.80 x 0.63 .091 x .025 2.31 x 0.63 .091 x .025 2.31 x 0.63 Stock Thickness Tab Section Mag Wire .025 .016 0.63 0.41 .025 .016 0.63 0.41 .032 .010 0.81 0.25 .025 .010 0.63 0.25 .025 .010 0.63 0.25 .025 .010 0.63 0.25 .025 .010 0.63 0.25 .025 .010 0.63 0.25 .025 .010 0.63 0.25 Part Number Strip L.P. 63965-12 -- 1217595-12 -- 63810-1 -- 63909-1 -- 63927-1 -- 1217052-12 -- 63910-1 63910-23 -- -- 63926-1 -- 1217051-13 -- 30 0.25 31-28 0.23-0.32 1.230 31.25 .071 x .025 1.80 x 0.63 .025 0.63 .012 0.30 63773-1 -- 32 0.20 1.098 27.90 .118 x .025 3.00 x 0.63 .025 0.63 .010 0.25 63247-1 63247-23 1217032-1 -- Two magnet wires may be terminated in the same terminal slot if diameters are equal. Tinsel wire only. 3 Reverse reeled version of -1. 1 2 Type Copper Magnet Wire Range1 AWG mm E 300 Box Standard IDC Twisted Tab C E 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) 1 2 33-31 0.18-0.23 31-28 0.23-0.32 27-24 0.36-0.50 212 0.72 19.52 0.86 Dim. C Tab Size .070 1.78 .070 1.78 .070 1.78 .120 3.05 .120 3.05 .125 x .020 3.17 x 0.51 .125 x .020 3.17 x 0.51 .125 x .020 3.17 x 0.51 .118 x .030 3.00 x 0.76 .118 x .030 3.00 x 0.76 Stock Thickness Tab Section Mag Wire .020 .012 0.51 0.30 .020 .012 0.51 0.30 .020 .012 0.51 0.30 .030 .016 0.76 0.41 .030 .016 0.76 0.41 Strip Part Number 63806-1 63807-1 63808-1 63463-1 63216-1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. 12 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 300 Box Tab Terminals (Continued) Standard MAG-MATE Terminals Material Tin plated brass L Typical Cavity Size 2 L (See page 2) .300 [7.62] .310 [7.87] .120 [3.05] .132 [3.35] .135 [3.43] .120 [3.05] F Type G Copper Magnet Wire Range AWG mm F 300 Box Standard IDC Timer Tab Tab Size .585 14.86 .585 14.86 .585 14.86 .585 14.86 .585 14.86 .585 14.86 .775 19.68 .585 14.86 .585 14.86 .118 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 .125 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 .125 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 0.45-0.64 .665 16.89 .118 x .020 3.00 x 0.51 .020 0.51 .016 0.41 1217210-1 1217210-23 0.54 0.81 .665 16.89 .118 x .020 3.00 x 0.51 .020 0.51 .016 0.41 1217211-1 33-31 0.18-0.23 30 -28 0.25-0.32 27-23 0.36-0.57 25-222 0.45-0.64 23.5-21.52 0.54-0.68 23-202 0.57-0.81 19-172 0.91-1.15 18 Lead2 G4 25-222 300 Box Standard IDC Poke-In 23.5-202 Combination Tab Stock Thickness Tab Section Mag Wire .020 .010 0.51 0.25 .020 .010 0.51 0.25 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 Dim. L 1.02 Strip Part Number 1217746-1 1217745-1 63973-1 63489-1 1217596-1 1217593-1 63899-1 63972-1 63974-1 63974-23 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. 3 Reverse reeled version of -1. 4 Poke-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. 1 2 13 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) .092 Dia. [2.34] .092 Dia. [2.34] Pin Receptacle Terminals with Right or Left Hand Diode Lead Slot Material Tin plated brass .913 [23.20] .913 [23.20] Typical Cavity Size 2 (See page 2) .300 [7.62] .300 [7.62] .135 [3.43] .135 [3.43] .120 [3.05] .120 [3.05] B A Range1 Copper Magnet Wire AWG mm Type A 300 Box Diode Offset- R.H. B 300 Box Diode Offset- L.H. Diode Lead AWG mm Mating Pin Dia. Stock Thickness I/O Mag Wire Strip Part Number 32-31 0.20-0.23 22 0.64 .094 2.39 .014 0.36 .010 0.25 63208-1 63326-1 31-27 0.23-0.36 22 0.64 .094 2.39 .014 0.36 .010 0.25 63209-1 63308-1 1 Two 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. 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) .060 [1.52] .789 [20.29] .300 [7.62] .120 [3.05] .120 [3.05] A Type C 300 Box Offset Pin-L.H. D 500 Box Straight Pin 1 2 3 14 .120 [3.05] .120 [3.05] B Copper Magnet Wire Range1 AWG mm A 300 Box Straight Pin B 300 Box Offset Pin-R.H. .280 [7.11] .135 [3.43] .135 [3.43] .135 [3.43] C D Pin Dia. Stock Thickness I/O Mag Wire Part Number Strip L.P. 27-23 . 0.36-0.57 .060 1.52 .010 0.25 .010 0.25 63722-1 -- 33-31 0.18-0.23 .048 1.22 .010 0.25 .010 0.25 63443-1 -- 33-31 0.18-0.23 63569-1 63879-1 27-23 0.36-0.57 63570-1 63880-1 25-222 0.45-0.64 63788-1 -- 27-23 0.86-1.15 63278-13 -- 22-20 0.64-0.81 .010 0.25 .010 0.25 .016 0.25 .016 0.41 .016 0.41 .016 0.41 -- 0.23-0.32 .010 0.25 .010 0.25 .010 0.25 .010 0.25 .016 0.41 .016 0.41 63444-1 31-28 .048 1.22 .048 1.22 .048 1.22 .048 1.22 .090 2.29 .090 2.29 63277-13 -- Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. Varnish resist coating. Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 110 Series FASTON Tab Terminals Standard MAG-MATE Terminals Optional Slot for 22 AWG [0.64 mm] Dia. Solid Copper Diode Wire (2 Wires Max.) Material Tin plated brass Typical Cavity Size 2 (See page 2) A Copper Magnet Wire Range1 AWG mm Type A 300 Box Standard IDC .110 [2.79] Tab w/ Optional Diode Slot 1 33-31 Diode Lead AWG mm Stock Thickness Strip Tab Mag Wire Part Number Tab Size -- -- .110 x .025 2.79 x 0.64 .025 0.64 .010 0.25 63110-1 22 0.64 .110 x .025 2.79 x 0.64 .025 0.64 .010 0.25 63376-1 0.18-0.23 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Diode Lead Slot L L A Type A 300 Box Standard IDC .110 [2.79] FASTON w/ Diode Slot Offset-R.H. B 300 Box Standard IDC .110 [2.79] FASTON w/ Diode Slot Offset-L.H. 1 Copper Magnet Wire Range1 AWG mm 31-27 30-27 31-27 30-27 B Diode Lead AWG mm 22 0.64 20 0.81 20 0.81 20 0.81 22 0.64 20 0.81 20 0.81 20 0.81 0.23-0.36 0.25-0.36 0.23-0.36 0.25-0.36 Tab Size Dim. L .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .965 24.51 .965 24.51 .965 24.51 .895 22.73 .965 24.51 .965 24.51 .965 24.51 .895 22.73 Stock Thickness Tab Mag Wire .032 .010 0.81 0.25 .032 .010 0.81 0.25 .032 .014 0.81 0.36 .032 .014 0.81 0.36 .032 .010 0.81 0.25 .032 .010 0.81 0.25 .032 .014 0.81 0.36 .032 .014 0.81 0.36 Part Number Strip L.P. 63319-1 -- 63331-1 63434-1 -- 63529-1 63177-1 -- 63276-1 -- 63330-1 63433-1 -- 63530-1 63178-1 -- Two 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. Note: .110 [ 2.79] Tab Terminals mate with compatible FASTON receptacles. Request AMP Catalog 82004. 15 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 110 Series FASTON Tab Terminals (Continued) Material .625 [15.88] Tin plated brass Typical Cavity Size 2 (See page 2) .300 [7.62] .135 [3.43] Note: .110 [2.79] Tab Terminals mate with compatible FASTON receptacles. Request AMP Catalog 82004. .120 [3.05] B A Type Copper Magnet Wire AWG mm A5 300 Box Standard IDC .110 [2.79] FASTON Tab B5,6 300 Box Single IDC w/ Strain Relief Slot C4,5 Poke-In Combination Tab Range1 30-27 0.25-0.36 27-23 0.36-0.57 23-202 0.45-0.64 19-17 0.91-1.15 27-23 0.36-0.57 23.5-202 0.54-0.81 28-24 0.32-0.51 25-222 0.45-0.64 C Tab Size .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 Stock Thickness Tab Mag Wire .020 .012 0.51 0.30 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .020 0.51 0.51 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .012 0.51 0.30 .020 .012 0.51 0.30 Part Number Strip L.P. 63777-1 -- 63746-1 -- 63486-1 -- 63145-1 -- 63827-1 -- 1217783-1 -- 63062-13 1217430-13 63063-13 -- -- 63063-2 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. Varnish resist coating. 4 Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] Solid or overcoated stranded lead wire or 90 Poke-In tab. 5 After insertion into plastic cavity, tab portion must be bent over 45-90 or potted in to prevent pullout when mating receptacle is disconnected. 6 Strain relief slot for high vibration applications. These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 3 16 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 187 Series FASTON Tab Terminals Standard MAG-MATE Terminals Material Tin plated brass Typical Cavity Sizes (See page 2) Type A--Cavity Size 2 A Type Copper Magnet Wire Range1 AWG mm Dim. L 33-31 .630 16.00 .660 16.76 0.18-0.23 30-27 0.25-0.36 .630 16.00 Tab Feature Dimple Hole Dimple Dimple Dimple 27-23 0.36-0.57 .630 16.00 Hole -- 23 0.57 A4 300 Box Standard IDC .187 [4.75] 22-202 FASTON Tab .660 16.76 .630 16.00 Hole -- Dimple 0.64-0.81 .630 16.00 Hole Dimple Hole 21-193 Aluminum 0.72-0.91 20-182 0.81-1.02 19-172 0.91-1.15 18.5-16.53 Aluminum 0.97-1.22 .630 16.00 .630 16.00 .630 16.00 .630 16.00 Dimple Hole Dimple Hole Dimple Hole Dimple Hole Tab Size .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 Stock Thickness Part Number Tab Mag. Wire Section Section Strip L. P. .020 .010 62513-1* 62663-1 0.51 0.25 .020 .012 63584-1 -- 0.51 0.30 .020 .012 62512-1* -- 0.51 0.30 63510-15, -- .032 .012 62678-1* 1217178-1 0.81 0.30 .020 .016 62514-1* 63852-1 0.51 0.41 62514-25* -- -- .020 .016 63664-15 0.51 0.41 63664-2 -- .020 .016 63461-1 -- 0.51 0.41 1217243-16 -- .020 .016 63585-1 -- 0.51 0.41 .020 .016 63776-1 -- 0.51 0.41 .020 .016 62511-1* 62661-1 0.51 0.41 62511-25 -- -- .020 .016 63663-15 0.51 0.41 63663-2 -- .032 .016 1217065-1 -- 0.81 0.41 .032 .016 1217128-1 -- 0.81 0.41 .020 .016 -- 63293-1 0.51 0.41 .020 .016 -- 63669-1 0.51 0.41 .020 .020 -- 62904-17 0.51 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .016 0.41 .016 0.41 63670-1 -- 63273-1 63511-15 63829-1 -- 63665-15 -- 63494-1 -- 63668-1 -- Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. 3 Single aluminum magnet wire only. 4 After insertion into plastic cavity, tab portion must be bent over 45-90 or potted in to prevent pullout when mating receptacle is disconnected. 5 Varnish resist coating. 6 Special wide body cut off for added stability. 7 Single 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. 1 2 Note: .187 [4.75] Tab Terminals mate with compatible FASTON receptacles. Request AMP Catalog 82004. Chart continued on next page 17 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) .187 [4.75] 187 Series FASTON Tab Terminals (Continued) Hole or Dimple Material Dimple L Tin plated brass .300 [7.62] Typical Cavity Sizes (See page 2) Type B--Cavity Size 5 Type C--Cavity Size 5 Type D--Cavity Size 3 .135 [3.43] B 187 Series Combination Poke-In FASTON Terminals Type Material Tin plated brass C Copper Magnet Wire Range1 AWG mm 33-31 0.18-0.23 31-28 0.23-0.32 30-27 0.25-0.36 27-23 0.36-0.57 Typical Cavity Sizes (See page 2) Type E--Cavity Size 2 Type F--Cavity Size 3 B 300 Box Standard IDC Narrow Body Latch Type 23-202 0.57-0.81 0.54-0.81 .016 0.41 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .010 0.25 .010 0.25 .012 0.30 .012 0.30 .012 0.30 .016 0.41 Hole -- Hole -- Hole Dimple Hole Poke-In 33-31 Combination Tab F4 Poke-In Combination Tab 28-24 Wide Body Latch Type 0.81-0.23 .630 16.00 Hole .187 x .020 4.75 x 0.51 .020 0.51 .010 0.25 0.32-0.51 .630 16.00 Hole .187 x .032 4.75 x 0.81 .032 0.51 .016 0.41 31-28 30-27 0.18-0.23 0.23-0.32 0.25-0.36 E4,5 Note: .187 [4.75] Tab Terminals mate with compatible FASTON receptacles. Request AMP Catalog 82004. .020 0.51 Hole 0.36-0.57 .187 [4.75] F .187 x .020 4.75 x 0.51 Hole 27-23 D 300 Box Standard IDC Wide Body Latch Type .120 [3.05] Dimple Hole .630 16.00 .730 18.54 .630 16.00 .630 16.00 .730 18.54 .630 16.00 E .135 [3.43] .630 16.00 .630 16.00 0.80-0.92 Stock Thickness Tab Mag. Wire Section Section .020 .010 0.51 0.25 .020 .010 0.51 0.25 .020 .012 0.51 0.30 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 -- .630 16.00 0.91-1.15 mm2 Tab Size .630 16.00 .630 16.00 19-172 lead2 Tab Feature D .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .630 16.00 33-31 L .630 16.00 .630 16.00 .630 16.00 0.64-0.81 C3 Narrow Body 2 Latch Type w/ 23.5-20 Strain Relief Slot .310 [7.87] Dim. L 22-202 18 .120 [3.05] .120 [3.05] Dimple Hole Dimple .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 Hole Hole Dimple Hole Hole Strip Part Number 63108-1 62743-1 63109-1 63107-1 1217493-1 63340-1 1217493-1 63429-1 63429-26 62888-1 62888-26 63782-1 1217592-1 1217004-1 63255-1 63544-1 63505-1 63760-1 63254-1 63478-1 63447-1 63256-2 63018-1 1217857-1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. Strain relief slot for high vibration applications. Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] solid, fused stranded lead wire or 90 poke-in tab terminal. After insertion into plastic cavity, tab portion must be bent over 45-90 or potted in to prevent pullout when mating receptacle is disconnected. 6 Splice free reeling. These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 3 4 5 Chart continued on next page 18 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 187 Series FASTON Tab Terminals .187 [4.75] (Continued) Hole L Material Standard MAG-MATE Terminals .187 [4.75] L .505 [12.83] Tin plated brass .505 [12.83] Typical Cavity Sizes .281 [7.14] (See page 2) Type G--Cavity Size 4 Type H--Cavity Size 4 Type J--Cavity Size 4 .120 [3.05] G H Copper Magnet Wire Range1 AWG mm Type Dim. L 22-20 0.64-0.81 19-17 0.91-1.15 .830 21.08 .830 21.08 1.09-1.29 .830 21.08 Tab Feature Dimple Hole Hole 17.5-16 G3 500 Box Standard IDC Hole Hole Hole 16-15 1.29-1.45 .830 21.08 Hole Dimple 14.5-132 1.54-1.83 27-23 0.36-0.57 22-20 0.64-0.81 H3,5 500 Box Single IDC w/ Strain Relief Slot 19-17 J 500 Box Standard IDC Latch Type .281 [7.14] 0.91-1.15 16-15 1.29-1.45 22-20 0.64-0.81 19-17 0.91-1.15 .830 21.08 .830 21.08 .830 21.08 .830 21.08 .830 21.08 .830 21.08 .830 21.08 Dimple Hole Hole Hole Hole Hole Hole -- -- .120 [3.05] J Tab Size .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 Stock Thickness Part Number Tab Mag. Wire Section Section Strip L. P. .020 .020 -- .. 63708-14 0.51 0.51 .020 .020 63643-1 -- 0.51 0.51 .020 .020 63667-14 63599-14 0.51 0.51 .020 .020 -- 63427-1 0.51 0.51 .032 .020 1217075-1 -- 0.81 0.51 .020 .020 -- 63666-14 0.51 0.51 .020 .020 63762-1 -- 0.51 0.51 .020 .020 63353-1 -- 0.51 0.51 .020 .016 63428-1 -- 0.51 0.41 .020 .020 1217042-1 -- 0.51 0.51 .020 .020 63983-1 -- 0.51 0.51 .032 .020 1217339-1 -- 0.81 0.51 .020 .020 63995-1 -- 0.51 0.51 .032 .020 1217090-1 -- 0.81 0.51 .020 .020 63996-1 -- 0.51 0.51 .020 .020 1217491-1 -- 0.51 0.51 .020 .020 1217492-1 -- 0.51 0.51 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. 3 After insertion into plastic cavity, tab portion must be bent over 45-90 or potted in to prevent pullout when mating receptacle is disconnected. 4 Varnish resist coating. 5 Strain relief slot for high vibration applications. These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 19 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 250 Series FASTON Tab Terminals Hole or Dimple Material Dimple Hole or Dimple L L L Tin plated brass .300 [7.62] Typical Cavity Sizes .135 [3.43] (See page 2) Type A--Use Cavity Size 2 Type B--Use Cavity Size 5 Type C--Use Cavity Size 3 .135 [3.43] .120 [3.05] A Type Note: .250 [6.35] tab terminals mate with compatible FASTON receptacles. Request AMP Catalog 82004. 30-27 A3 300 Box Standard IDC .250 [6.35] FASTON Tab 28-24 27-23 Dim. L Tab Feature .750 0.18-0.231 19.05 Dimple Dimple .750 0.25-0.361 19.05 Hole Dimple & Hole .750 0.32-0.511 19.05 Hole Dimple Dimple 0.36-0.571 .750 Dimple 19.05 Dimple Hole B Narrow Body Latch Type Material Tin plated brass Typical Cavity Sizes 3 (Type D) (See page 2) C Wide Body Latch Type Hole 1 0.18-0.23 .750 19.05 30-28 .750 0.23-0.321 19.05 .750 0.25-0.321 19.05 30-27 0.25-0.361 .750 19.05 27-23 .750 0.36-0.571 19.05 31-28 .250 [6.35] .750 0.64-0.81 19.05 20-182 .750 1 Bare Wire 0.81-1.02 19.05 .750 33-31 0.18-0.231 19.05 .750 30-27 0.25-0.361 19.05 .750 27-23 0.36-0.57 19.05 .750 23-202 0.57-0.81 19.05 33-31 L .310 [7.87] 22-202 .135 [3.43] .120 [3.05] D 19-172 D5 Poke-In Combination Tab 28-24 Wide Body Latch Type .120 [3.05] .750 0.64-0.811 19.05 .750 0.91-1.151 19.05 .750 0.32-0.51 19.05 C Stock Thickness Tab Mag. Wire Section Section .250 x .032 .032 .010 6.35 x 0.81 0.81 0.25 Tab Size .250 x .032 6.35 x 0.81 .032 0.81 .012 0.30 .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .020 0.51 .010 0.25 .012 0.30 .016 0.41 .016 0.41 .250 x .032 6.35 x 0.81 .032 0.81 .010 0.25 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .032 0.81 .032 0.81 .012 0.30 .012 0.30 .250 x .032 6.35 x 0.81 .032 0.81 .012 0.30 .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 Hole .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .032 0.81 .032 0.81 .016 0.41 .016 0.41 Hole .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 1 22-202 250 Series Combination Poke-In FASTON Tab Terminal .135 [3.43] .120 [3.05] B Copper Magnet Wire Range1 AWG mm 33-31 Locking Latch (2) .300 [7.62] .300 [7.62] Dimple Dimple Dimple Dimple Dimple Dimple Dimple Hole Hole Hole Dimple Hole Dimple Dimple Dimple Hole Hole Hole Hole Dimple Dimple Dimple Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. After insertion into plastic holder, tab portion must be bent over 45-90 or potted in to prevent pullout when mating receptacle is disconnected. 4 Varnish resist coating. 5 Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] solid, fused stranded lead wire or 90 Poke-In tab 1 2 3 Part Number Strip L. P. 62600-1* 62655-1 62600-27 --. 62651-1* 62656-1 63055-1 --. 63328-1 --. . 63607-1 -- 62652-17* 62657-1 62652-26,7 --. 62939-13,4, -- . 63920-17,9 --. --. 63159-17, 62653-1* 62658-1 7 62653-2 1217031-17 62653-36 --. . 63200-1 -- 63026-1 -- 63027-1 -- 1217860-1 -- 1217870-1 -- 63133-1 63309-1 63309-27 63618-18 63403-2 1217152-1 . 63132-1 63132-210 63132-34 63499-1 63499-27 63571-1 63571-27 63128-1 63128-37 63601-1 63601-27 63614-1 1217856-2 . . . . --. --. --. --. . -- -- . 63203-1 --. --. 63898-1 --. --. --. 63207-1 --. --. --. . -- --. terminal. 6 Reverse reeled version of -1. 7 Half hard temper brass. 8 Special key hole wire slot block. 9 Special 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 Chart continued on next page 20 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals (Continued) 250 Series FASTON Tab Terminals Standard MAG-MATE Terminals (Continued) Material L Tin plated brass L Typical Cavity Sizes (See page 2) Type E--Use Cavity Size 4 Type F--Use Cavity Size 4 E Type Copper Magnet Wire Range1 AWG mm 22-20 E3 500 Box Standard IDC Wide Neck F3 500 Box Standard IDC Narrow Neck 0.64-0.81 F Dim. L .952 24.18 .952 24.18 .952 24.18 Tab Feature Hole 19-17 0.91-1.15 16-15 1.29-1.45 14-132 1.61-1.83 .952 24.18 22-20 0.64-0.81 .952 24.18 Dimple 19-17 0.91-1.15 .952 24.18 Dimple 16-15 1.29-1.45 14-132 1.61-1.83 122 2.05 .952 24.18 .952 24.18 .952 24.18 Hole Hole Dimple Hole Dimple Dimple Dimple Tab Size .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 Stock Thickness Tab Mag. Wire Section Section .032 .020 0.81 0.51 .032 .020 0.81 0.51 .032 .020 0.81 0.51 .032 .020 0.81 0.51 .032 .020 0.81 0.51 .032 .020 0.81 0.51 .250 x .032 6.35 x 0.81 .032 0.81 .020 0.51 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .032 0.81 .032 0.81 .032 0.81 .020 0.51 .020 0.51 .020 0.51 Part Number Strip L. P. 63495-14 63882-1 -- 63464-2 63464-34 63598-1 63459-2 63881-1 63459-34 -- 63460-14, 63883-1 -- 1217588-1 63816-1 -- 63816-24 -- 63155-14 62923-14 62923-24,5 62923-34.6 63064-14 63336-1 -- -- -- 63263-1 63465-1 63371-14 -- -- 63425-14 -- Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. 3 After insertion into plastic holder, tab portion must be bent over 45-90 or potted in to prevent pullout when mating receptacle is disconnected. 4 Varnish resist coating. 5 Box-up reversed reel version of -1. 6 Box-up reeled version of -1. These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 21 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Slim Line MAG-MATE Terminals Product Facts Terminates all magnet wire film insulations Eliminates need for prestripping 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 [0.180.57 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 R 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. Typical Plastic Cavity Not for design, Tyco Electronics will supply required dimensions of cavity for each customer application. Residual spring energy in the terminal causes the side walls of each IDC slot to function as opposing cantilever beams. .375 [9.53] Min. This constant pressure results in an intimate metalto-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 fullyautomatic applications. .270 Min. [6.86] .115 Min. [2.92] 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 22 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Slim Line MAG-MATE Terminals (Continued) 187 Series FASTON Tab Terminals Slim Line MAG-MATE Terminals Material Tin Plated Brass Type .187 [4.75] .020 [0.51] Hole or Dimple A .187 [4.75] FASTON Tab Copper Magnet Wire Range1 AWG mm Dim. L 33-31 .630 16.00 0.18-0.23 30-28 0.25-0.32 27-24 0.36-0.51 Tab Feature .630 16.00 .630 16.00 .760 19.31 L 23-202 .135 [3.43] 0.57-0.81 0.91-1.15 19-172 .016 [0.41] .630 16.00 .630 16.00 Hole Dimple Hole Hole Dimple Hole Dimple Plain Hole Dimple Hole Hole Dimple Tab Size .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 Stock Thickness Part Number Tab Mag. Wire Section Section Strip L. P. .020 .012 63710-2 -- 0.51 0.30 63738-2 -- .032 .012 1217666-1 -- 0.81 0.30 .020 .012 63711-2 -- 0.51 0.30 63737-2 -- .020 .016 63712-2 -- 0.51 0.41 63736-2 -- .020 .016 1217497-1 -- 3 0.51 0.41 1217497-2 -- .020 .016 63713-2 1217714-1 0.51 0.41 63735-2 -- .032 .016 1217516-1 -- 0.81 0.41 .020 .016 63714-2 -- 0.51 0.41 63734-2 -- Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64] or larger. 3 Reverse reeled version of -1. 1 2 A 250 Series FASTON Tab Terminals Material Tin Plated Brass .250 [6.35] Type .032 [0.81] Hole or Dimple B .250 [6.35] FASTON Tab Copper Magnet Wire Range1 AWG mm 33-31 0.18-0.23 30-28 0.25-0.32 27-24 0.36-0.51 23-202 0.57-0.81 19-172 0.91-1.15 L 1 2 .135 [3.43] Dim. L Tab Feature Tab Size .752 19.10 .752 19.10 .752 19.10 .752 19.10 .752 19.10 Hole Dimple Hole Dimple Hole Dimple Hole Dimple Hole Dimple .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 Stock Thickness Tab Mag. Wire Section Section .032 .012 0.81 0.30 .032 .012 0.81 0.30 .032 .016 0.81 0.41 .032 .016 0.81 0.41 .032 .016 0.81 0.41 Strip Part Number 63716-2 63744-2 63717-2 63743-2 63718-2 63742-2 63719-2 63741-2 63720-2 63740-2 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64] or larger. .016 [0.41] B 23 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Slim Line MAG-MATE Terminals (Continued) Tab Terminals .139 [3.53] Material .032 [0.81] Tin Plated Brass .059 [1.50] .135 [3.43] L .220 [5.59] .013 [0.33] C Type C Combination Diode Slot/Tab 1 Copper Magnet Wire Range1 AWG mm 33-31 0.18-0.23 33-31 0.18-0.23 33-31 0.18-0.23 Dim. L Diode Size Tab Size .725 18.42 .725 18.42 .760 19.29 #20 0.8 #22.5 0.6 #22.5 0.6 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 Stock Thickness Tab Mag. Wire Section Section 0.032 0.012 0.81 0.30 0.032 0.012 0.81 0.30 0.032 0.012 0.81 0.30 Strip Part Number 63888-1 63903-1 1217709-1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 24 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Mini MAG-MATE Terminals Product Facts Terminates all fine gauge magnet wire film insulations Eliminates need to prestripping 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 R Applications Ignition coils Small motors Synchronist timers Electric meter coils Solenoids Relays Mini MAG-MATE Terminals 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 [0.2540.198 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. Typical Plastic Cavity Not for design, Tyco Electronics will supply required dimensions of cavity for each customer application. 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. Reference Application Spec. 114-2047 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 25 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Mini MAG-MATE Terminals (Continued) Termination Sequence Terminal Removed from Carrier Terminal Inserted Termination Complete Poke-In Tab Terminal Material .010 [0.25] tin plated brass B A Type A Lead Wire Poke-In B Tab Poke-In Copper Magnet Wire Range Lead Wire Range1 AWG mm AWG mm2 52-42 0.02-0.06 22-18 44-36 0.05-0.13 22-18 38-30 0.10-0.25 22-18 52-42 0.02-0.06 -- 44-36 0.05-0.13 -- 38-30 0.10-0.25 -- Stock Thickness Strip Poke-In Beam Mag Wire Part Number 0.010 0.010 0.3-0.9 -- 62781-1 0.25 0.25 0.010 0.010 0.3-0.9 -- 62780-1 0.25 0.25 0.010 0.010 0.3-0.9 -- 62606-1 0.25 0.25 .050 x .020 0.010 0.010 -- 63613-13 1.27 x 0.51 0.25 0.25 .060 x .020 0.010 0.010 63795-12 -- 1.52 x 0.51 0.25 0.25 63845-12,3 .060 x .020 0.010 0.010 -- 63844-12,3 1.52 x 0.51 0.25 0.25 Mating Tab Solid or overcoated stranded lead wire only. 2 Radius on beam leaf tip. 3 Finish is select gold plated on lead tip. 1 26 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Mini MAG-MATE Terminals (Continued) Posted Terminal .138 [3.51] .138 [ 3.51] .060 [1.52] .060 [1.52] Mini MAG-MATE Terminals Material Tin over premilled brass .169 [4.29] .770 [19.56] .540 [13.72] A B Copper Magnet Wire Range AWG mm Type A PCB Post B Solder Post C Wire Wrap Post 44-36 0.05-0.13 38-30 0.10-0.25 44-36 0.05-0.13 38-30 0.10-0.25 38-30 0.10-0.25 C Post Size .024 x .020 0.62 x 0.51 .024 x .020 0.62 x 0.51 .150 x .020 3.81 x 0.51 .150 x .020 3.81 x 0.51 .070 x .020 1.78 x 0.51 Stock Thickness Post Mag Wire .020 .010 0.51 0.25 0.020 0.010 0.51 0.25 0.020 0.010 0.51 0.25 0.020 0.010 0.51 0.25 0.020 0.010 0.51 0.25 Strip Part Number 1217804-1 63675-4 63955-1 63956-1 63041-1 These part numbers are available upon special request; contact Tyco Electronics Engineering for details. FASTON Tab Terminals .138 [3.51] .060 [1.52] Material Tin over premilled brass .880 [22.35] A B Copper Magnet Wire Range AWG mm Type A .110 [2.79] FASTON Tab B .187 [4.75] FASTON Tab C .250 [6.35] FASTON Tab 38-30 0.10-0.25 44-36 0.05-0.13 38-30 0.10-0.25 44-36 0.05-0.13 38-30 0.10-0.25 C Tab Size Stock Thickness Post Mag Wire .110 x .020 2.79 x 0.51 .020 0.51 .010 0.25 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .020 0.51 .020 0.51 .032 0.81 .032 0.81 .010 0.25 .010 0.25 .010 0.25 .010 0.25 Strip Part Number 63161-1 63778-1 62816-1 1217529-1 1217000-1 63999-1 Crimp Wire Barrel Terminal Material Tin plated brass Type A Crimp Wire Barrel 1 Copper Magnet Wire Range AWG mm Lead Wire Range AWG mm2 52-42 0.02-0.06 26-22 0.12-0.30 44-36 0.05-0.13 26-22 0.12-0.30 38-30 0.10-0.25 22-18 0.3-0.9 Stock Thickness Crimp Barrel Mag Wire 0.010 0.010 0.25 0.25 0.010 0.010 0.25 0.25 0.010 0.010 0.25 0.25 Strip Part Number 63828-1 1217830-11, 63199-11 1217231-1 Wire 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. A 27 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 SIAMEZE Terminals Product Facts Terminates all copper magnet wire film insulations Eliminates need for prestripping conductors Moving Beam contact design connects a wide range of magnet wire sizes with a single terminal Standard range terminals connect 34-18 AWG [0.161.0 mm] magnet wire Fine range terminals connect 36-27 AWG [0.130.38 mm] magnet wire Medium range terminals connect 23-12 AWG [0.562.03 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 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. R Applications Motor windings and connections Coil connections Transformer windings and connections Ballasts Power supplies Solenoids Actuators Fine Range SIAMEZE terminals terminate 36-27 AWG [0.13-0.38 mm] copper magnet wires. During this operation the small stripping devices penetrate the film insulation from the magnet wire. Medium Range and Heavy Range SIAMEZE terminals terminate 23-12 AWG [0.562.03 mm] copper magnet wires. Residual spring energy in the terminal causes the side walls of the IDC slot to function as opposing cantilever beams. 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. This constant pressure results in an intimate metalto-metal interface, providing a reliable, long-term connection. 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. 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 semiautomatic bench machine or integrated in production lines for fully-automatic applications. 28 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 SIAMEZE Terminals (Continued) 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. 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 tieoff 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 Cavity Part Number 1601421 .104 [2.63] Min. Cavity Part Number 1601425 .276 [7.01] Min. .140 [3.56] Min. Cavity Part Number 1601423 .380 [9.65] Min. .276 [7.01] Min. Tyco Electronics can provide design and mold engineering resources to manufacture most specifically designed SIAMEZE cavity housings. .270 [6.86] Min. .350 [8.89] Min. .204 [5.18] Min.* Excess magnet wire is trimmed flush with the outside of the plastic cavity by a shear blade traveling with the terminal insertion ram. .570 [14.48] Min. .380 [9.65] Min. .276 [7.01] Min. disconnect FASTON tab terminals. SIAMEZE Terminals 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. Cavity Part Number 1601424 .330 [8.38] Min. .305 [7.75] Min. .276 [7.01] Min. .276 [7.01] Min. .104 [2.63] Min. Cavity Part Number 1601427 .104 [2.63] Min. .116 [2.95] Min. Cavity Part Number 1601431 * Minimum dimension with Lead Lok slot. 29 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 SIAMEZE Terminals (Continued) Typical Plastic Cavity -- Pockets (Continued) .380 [9.65] Min. .380 [9.65] Min. .473 [12.01] Min. .116 [2.95] Min. Cavity Part Number 1601432 .490 [12.60] Min. .446 [11.33] Min. .135 [3.44] Min. Cavity Part Number 1601435 .135 [3.44] Min. Cavity Part Number 1601438 .410 [10.41] Min. .167 [4.24] Min. Cavity Part Number 1601462 Cavity Part Number 1601434 .350 [8.89] Min. .580 [14.72] Min. .135 [3.44] Min. Cavity Part Number 1601436 .716 [18.19] Min. .050 [1.27] .204 [5.18] Min.* Cavity Part Number 1601440 .050 Min. [1.27] Wrap Post Part Number 1601447 .380 [9.65] Min. .276 [7.01] Min. .640 [16.26] Min. .404 [10.26] Min. .167 [4.24] Min. Cavity Part Number 1601463 .135 [3.44] Cavity Part Number 1601437 .380 [9.65] Min. .380 [9.65] Min. .276 [7.01] Min. .104 [2.63] Min. .630 [16.00] Min. .520 [13.21] Min. .410 [10.41] Min. .276 [7.01] Min. .204 [5.18] Min.* Cavity Part Number 1601433 .535 [13.59] Min. .293 [7.44] Min. .152 [3.85] Min. Cavity Part Number 1601470 * Minimum dimension with Lead Lok slot. 30 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 SIAMEZE Terminals (Continued) SIAMEZE Interconnection System How the System Operates Trim Blade Plastic 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. Terminal 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. Contact Cavity Slot for Wire The width has to be in accordance with the wire size (see cavity drawings). Magnet Wire Various wire attachments in standard, fine, medium and heavy duty terminals are available (See tables). IDC Slot The IDC slot in the terminal will terminate a wide range of magnet wire sizes. Locking Barbs Terminal retention is provided in the cavity by single or multiple locking barbs. The magnet wire is positioned in "U" slot manually or automatically by coil winding equipment. Wire 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. Stripping Burrs During the insertion process, these burrs strip the film insulation from the magnet wire. SIAMEZE Terminals The trim blade cuts the excess magnet wire and the wire cutoff block at the front of the cavity. 11 Terminal Insertion Complete The magnet wire termination is complete when the terminal is fully seated in the cavity. 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" 11 Thermal Shock -- 10 cycles with each cycle consisting of 30 minutes at 150C followed by 30 minutes at 21C Humidity -- Temperature Cycling 10 cycles between 25C and 65C at 80 to 100% RH 31 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 SIAMEZE Terminals (Continued) Wire-to-Wire Terminals Material Brass .300 [7.62] .300 [7.62] .300 [7.62] .146 [3.71] .146 [3.71] .146 [3.71] .020 [0.51] .020 [0.51] .020 [0.51] A B C .550 [13.97] .300 [7.62] .146 [3.71] .280 [7.11] .020 [0.51] .032 [0.81] D Copper Magnet Wire Range AWG mm2 Lead Wire Range AWG mm2 27-26 0.36-0.13 18-226 0.8-0.3 18-34 1.02-0.16 18-226 0.8-0.3 18-34 1.02-0.16 20 0.5 18-34 1.02-0.16 18 0.8 1601117-1 2-1601117-11 1601000-1 1601000-25 1601056-1 2-1601056-11 1601074-1 2-1601074-11 1601433 1601440 18-34 1.02-0.16 18-226 0.8-0.3 1601046-1 2-1601046-11 4-1601046-12,5 6-1601046-13,5 8-1601046-14,5 1601433 27-36 0.36-0.13 20 0.5 1601125-1 2-1601125-11 4-1601125-12,5 3 6-1601125-1 ,5 1601436 12-23 2.06-0.56 16-20 1.3-0.5 1601136-1 2-1601136-11 4-1601136-12,5 6-1601136-13 Type Recommended Pocket7 A Moving Beam 1601421 1601462 1601463 B Wire Specific 1601421 C High Carry D High Carry Specific E Medium Range E Part Number Reeled Loose 4-1601117-12,5 4-1601000-12,5 4-1601000-22,5 4-1601056-12,5 4-1601074-12,5 ,5 ,5 Reversed Reeled--Consult Tyco Electronics drawing for orientation. Loose Single. 3 Loose Bussed Pair. 4 Loose Bussed Triple. 5 Finish is Post Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). 6 Lead wire may be stranded, solid or bonded with 105C PVC insulation. Contact Tyco Electronics Engineering when using other types of insulation. 7 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 1 2 32 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 SIAMEZE Terminals (Continued) 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 SIAMEZE Terminals 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-towire 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. This constant pressure results in an intimate metalto-metal interface, providing a reliable, long-term connection. 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. Perpendicular and parallel lead wire strain relief retention forces in excess of 20 lbs are achieved. Residual spring energy in the terminal causes the side walls of the IDC slot to function as opposing cantilever beams. The AMP Lead Lok Inserter may be a secondary station in the AMP SIAMEZE Wireto-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 millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 SIAMEZE Terminals (Continued) Lead Lok Interconnection System .250 [6.35] How the System Operates .150 [3.81] 1 2 Type Recommended Pocket A Lead Lok 1601421 1601433 1601440 .025 [0.64] Lead Wire Range AWG mm2 18-222 0.8-0.3 Part Number Reeled 1601140-1 2-1601140-11 Loose 4-1601140-1 Reverse Reeled--Consult Tyco Electronics drawing for orientation. Lead wire may be stranded, solid or bonded with 105C PVC insulation. Contact Tyco Electronics Engineering when using other types of insulation. Lead 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. Lead Lok Terminal The Lead Lok terminal provides maximum lead wire retention in the cavity. Locking Barbs The Lead Lok multiple locking barbs provide retention in the cavity. Lead Wire Stranded, solid and bonded lead wire with 105C PVC insulation can be used. Contact Tyco Electronics Engineering for other lead wires and insulation under consideration. IDC Slot The IDC slot will pierce the lead wire during insertion. Lead Wire Insertion Complete The lead wire termination is complete when the Lead Lok is fully seated in the cavity. 34 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 SIAMEZE Terminals (Continued) Posted Terminals Material Brass SIAMEZE Terminals L L L L L L .146 [3.71] .146 [3.71] .146 [3.71] .020 [0.51] A Type A PC Tab B Extended PC Tab C Long Narrow Width Blade .146 [3.71] .146 [3.71] .020 [0.51] B Recommended Pocket7 C 27-36 0.36-0.13 18-34 1.02-0.16 16-176 1.27-1.15 296 0.29 27-36 0.36-0.13 18-34 1.02-0.16 1601425 D Tab Pair with Diode Slot 1601425 E Long Medium Width Blade 1601425 F Long Medium Blade Medium Range 1601438 18-34 1.02-0.16 27-36 0.36-0.13 18-34 1.02-0.16 18-34 1.02-0.16 12-23 0.56-2.06 .032 [0.81] .020 [0.51] D 1601424 1601431 .020 [0.51] .020 [0.51] Copper Magnet Wire Range AWG mm2 .280 [7.11] E F Part Number L Dim. Tab SIze .345 8.76 .345 8.76 .345 8.76 .345 8.76 .485 12.32 .485 12.32 .456 11.57 .754 19.16 .669 17.00 .756 19.21 .904 22.96 1.005 25.53 .974 24.74 .710 18.03 .710 18.03 .837 21.26 .837 21.26 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .047 x .032 1.20 x. 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .071 x .025 1.80 x 0.64 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .118 x .025 3.00 x 0.51 .118 x .032 3.00 x 0.81 Reeled 2-1601120-231, 2-1601120-21,3 2-1601009-221, 2-1601009-21,2 2-1601147-231, 2-1601147-21,3 2-1601155-221, 2-1601155-21,2 2-1601128-231, 2-1601128-21,3 2-1601041-221, 2-1601041-21,2 2-1601095-241, 2-1601095-21,4 2-1601110-241, 2-1601110-21,4 2-1601099-11,6 2-1601099-11,6 2-1601063-251, 2-1601063-21,5 2-1601037-251, 2-1601037-21,5 2-1601066-241, 2-1601066-21,4 2-1601104-251, 2-1601104-21,5 2-1601121-241, 2-1601121-21,4 2-1601065-241, 2-1601065-21,4 2-1601008-241, 2-1601008-241, 2-1601051-241, 2-1601051-21,4 .872 22.15 .130 x .032 3.30 x 0.81 1601138-1 2-1601138-11,0 Loose 4-1601120-23 4-1601009-22 4-1601147-23 4-1601155-22 4-1601128-23 4-1601041-22 4-1601095-24 4-1601110-24 4-1601099-1 . 4-1601063-25 4-1601037-25 4-1601066-24 4-1601104-25 -- -- 4-1601008-24 4-1601051-24 4-1601138-1 . 1 2 Finish is Post Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). Reverse Reeled--Consult Tyco Electronics drawing for orientation. Finish is Post Plated Tin over Nickel (Consult Tyco Electronics drawing for specifics). 4 Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). 5 Finish is Pre-Plated Tin (Consult Tyco Electronics drawing for specifics). 6 Two magnet wires may be terminated in the same slot if diameters are equal. 7 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 3 35 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 SIAMEZE Terminals (Continued) 110 Series FASTON Tab Terminals Material Brass L L L L .146 [3.71] .146 [3.71] .146 [3.71] .020 [0.51] .020 [0.51] A Type A Single Barb Recommended Copper Magnet Wire Range Pocket7 AWG mm C Multi-Barb D Multi-Barb w/ 90 Twist B C D 1.02-0.16 .925 23.50 Hole .110 x .020 2.79 x 0.51 18-34 1.02-0.16 .945 24.00 -- .110 x .032 2.79 x 0.81 2-1601097-23,0 2-1601097-21,3 27-36 0.36-0.13 1.240 31.50 -- .110 x .032 2.79 x 0.81 18-34 1.02-0.16 .655 16.63 Hole .110 x .020 2.79 x 0.51 .630 15.99 1.240 31.50 -- .915 23.24 -- 2-1601133-22,5 2-1601133-21,2,5 2-1601039-1,00 2-1601039-11,0 2-1601039-23,0 2-1601039-21,3,0 2-1601064-1,00 2-1601064-11,0 2-1601112-22,5 2-1601112-21,2,5 2-1601151-23,0 Tab Feature Tab Size Hole .110 x .020 2.79 x 0.51 Hole .110 x .020 2.79 x 0.51 27-36 0.36-0.13 .640 16.26 18-34 1.02-0.16 .640 16.26 -- Hole 1.02-0.16 1601425 1601425 .020 [0.51] 18-34 L Dim. 1601425 1601431 .020 [0.51] Part Number Reeled Loose 2-1601116-1,00 ,0 4-1601116-1 1,0 2-1601116-1 2-1601005-1,00 4-1601005-1 ,0 2-1601005-11,0 2-1601005-23,0 4-1601005-23 , 2-1601005-21,3,0 3,0 2-1601085-1 4-1601085-13 , 2-1601085-11,3,0 ,00 2-1601045-1 4-1601045-1 ,0 2-1601045-11,0 2-1601059-1,00 4-1601059-1 ,0 2-1601059-11,0 2-1601059-24,0 4-1601059-24,0 2-1601059-21,400 2-1601073-1,00 4-1601073-1 ,0 2-1601073-11,0 18-34 B Single Barb Low Transition .146 [3.71] 18-34 1.02-0.16 18-34 1.02-0.16 21-246 .51-.72 .846 21.49 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 -- .110 x .020 2.79 x 0.51 -- .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .020 2.79 x 0.51 2-1601151-21,3 4-1601097-23 , 4-1601133-22 , 4-1601039-1 ,0 4-1601039-23 4-1601064-1 , ,0 4-1601112-22 4-1601151-23 , , Reversed Reeled--Consult Tyco Electronics drawing for orientation. Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). is Pre-Plated Tin (Consult Tyco Electronics drawing for specifics). 4 Finish is Pre-Plated Silver over Nickel (Consult Tyco Electronics drawing for specifics). 5 Dual Carrier Strip. 6 Two magnet wires may be terminated in the same slot if diameters are equal. 7 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 1 2 3 Finish 36 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 SIAMEZE Terminals (Continued) 187 Series FASTON Tab Terminals Material Brass SIAMEZE Terminals L L L L L L .146 [3.71] .146 [3.71] .146 [3.71] .020 [0.51] A Type B C Recommended Copper Magnet Wire Range Pocket6 AWG mm A Single Barb B Single Barb Short Pocket C Multi-Barb 1601425 1601427 1601425 18-34 18-34 18-34 1.02-0.16 1.02-0.16 1.02-0.16 L Dim. .605 15.37 .505 12.83 .590 14.99 .985 25.02 .618 15.70 .655 16.64 .791 20.09 .832 21.14 .655 16.64 D Multi-Barb Short Profile E Multi-Barb .187/.250 Profile F Latch D E Hole .187 x .020 4.75 x 0.51 1601006-23 2-1601006-21,3,0 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 1601011-1,0 2-1601011-11,0,0 1601018-22,5 2-1601018-21,2,5,0 1601033-22,5 2-1601033-21,2,5,0 1601021-22, 2-1601021-21,2,0,0 1601013-1,0 2-1601013-11,0,0 1601072-22, 2-1601072-21,2,0 1601068-22, 2-1601068-21,2,0 1601035-1,0 2-1601035-11,0,0 1601035-23, 2-1601035-21,3,0 1601040-1,0 2-1601040-11,0,0 1601142-1,,0 2-1601142-11,0,0 1601058-22,4 2-1601058-21,2,4 Hole -- -- -- Hole -- -- Hole .187 x .032 4.75 x 0.81 1601434 .492 12.50 Hole .187 x .032 4.75 x 0.81 Hole 1601425 1.02-0.16 .655 16.64 .187 x .020 4.75 x 0.51 1.02-0.16 .805 20.45 .775 19.68 1601423 18-34 18-34 F Part Number Tab Size Hole 0.58-0.81 .020 [0.51] Tab Feature .745 18.92 .655 16.64 20-23** .020 [0.51] .020 [0.51] .020 [0.51] .020 [0.51] .146 [3.71] .146 [3.71] .146 [3.71] Hole Hole Hole .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 Reeled Loose , 1601020-1,0 2-1601020-11,0,0 1601020-23, 2-1601020-21,3,0 1601049-23, 2-1601049-21,3,0 1601004-1,0 2-1601004-11,0,0 4-1601006-23,0,0 4-1601011-1 ,0,0 4-1601018-22 ,0 4-1601033-22 ,0 4-1601021-22 ,0 4-1601013-1 ,0,0 4-1601072-22 ,0 4-1601068-22, 0 4-1601035-1 ,0,0 , 0 4-1601035-23 4-1601040-1 ,0,0 4-1601142-1 ,0,0 4-1601058-22,4 ,0,0 4-1601020-1 4-1601020-23 4-1601049-23 ,0 ,0 4-1601004-1 ,0,0 Reverse Reeled--Consult Tyco Electronics drawing for orientation. Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). Finish is Pre-Plated Tin (Consult Tyco Electronics drawing for specifics). 4 Extra Short Tab-Does not meet UL & NEMA length requirements. 5 Carrier strip not in retention barb area as shown. 6 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 1 2 3 37 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 SIAMEZE Terminals (Continued) 250 Series FASTON Tab Terminals Material Brass L L L L .280 [7.12] .315 [8.00] .032 [0.81] A Type A Single Barb Medium Range B Single Barb Heavy Range C Multi-Barb D Latch 1601435 12-23 2.03-0.56 12-20 2.03-0.8 16-175 1.27-1.15 14-155 1.60-1.40 27-36 0.36-0.13 .885 22.48 .885 22.48 .885 22.48 .745 18.92 .745 18.92 1601425 1601423 L Dim. .778 19.76 18-34 18-34 .146 [3.71] B Recommended Copper Magnet Wire Range Pocket6 AWG mm 1601438 .032 [0.81] 1.02-0.16 1.02-0.16 .146 [3.71] .020 [0.51] C Tab Feature Tab Size D Part Number Reeled Loose -- .250 x .032 6.35 x 0.81 1601139-23........ 2-1601139-21,3...... 4-1601139-23 Hole .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 1601115-1........ 2-1601115-11...... 1601159-1........ 2-1601159-11...... 1601161-1........ 2-1601161-11...... 1601118-23...... 2-1601118-21,3... 1601002-23...... 2-1601002-21,3... 1601028-23...... 2-1601028-21,3... 1601028-1... 2-1601028-113...... 1601061-23...... 2-1601061-21,3... 1601044-1........ 2-1601044-11 .... 1601052-22,4... 2-1601052-21,2,4 1601003-1... 2-1601003-11...... 4-1601115-1 Hole Hole Hole Hole Hole .250 x .032 6.35 x 0.81 Dimple .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .805 20.45 1.000 25.4 1.281 32.53 .850 21.59 .020 [0.51] Hole Hole Hole 4-1601159-1 4-1601161-1 4-1601118-2,3 4-1601002-23 4-1601028-23 4-1601028-1 . 4-1601061-23 4-1601044-1 4-1601052-22 4-1601003-12 Reverse Reeled--Consult Tyco Electronics drawing for orientation. Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). Finish is Pre-Plated Tin (Consult Tyco Electronics drawing for specifics). 4 Double Carrier Strip. 5 Two magnet wires may be terminated in the same slot if diameters are equal. 6 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 1 2 3 38 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 SIAMEZE Terminals (Continued) Pin Terminals .084 Dia. [2.13] .039 Dia. [1.00] L .020 [0.51] .146 [3.71] Type Copper Magnet Wire Range AWG mm2 B 1601424 18-34 1.02-0.16 .718 18.24 .084 2.13 Part Number Reeled Loose 1601077-1 4-1601077-1 2-1601077-11 1601432 27-36 0.36-0.13 .855 21.71 .039 1.00 1601130-22,3 2-1601131-22,3,4 Recommended Pocket5 A Round Pin B Pseudo Round Pin with Diode Slot .020 [0.51] .146 [3.71] A SIAMEZE Terminals L L Dim. Pin Dia. -- Reverse Reeled--Consult Tyco Electronics drawing for orientation. Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). Diameter is approximate as Pin is not perfectly round. 4 Reverse Reeled Mirror Image--Consult Tyco Electronics drawing for orientation. 5 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 1 2 3 .199 [5.04] Receptacle Terminals .715 [18.15] .300 [7.62] .032 [0.81] A A Edge Contact In Line B Edge Contact Off Line C Blind Mate Full Surround 1 2 3 Recommended Pocket3 .031 [0.79] .315 [8.00] .020 [0.51] Type .146 [3.71] .310 [7.87] .480 [12.19] .146 [3.71] B Copper Magnet Wire Range AWG mm2 1601425 18-34 1.02-0.16 1601421 15-23 1.47-0.56 1601470 21.5 0.71 C L Dim. Mating Tab Size .300 7.62 .310 7.87 .715 18.15 .020 0.51 .032 0.81 .250 x .020 6.35 x 0.51 Part Number Reeled Loose 2-1601075-221, 2 4-1601075-2 2-1601075-21,2 21, 2-1601137-2 4-1601137-22 2-1601137-21,2 2-1601149-221, 4-1601149-22 2-1601149-21,2 Reverse Reeled--Consult Tyco Electronics drawing for orientation. Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 39 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 MAG-MATE and SIAMEZE Application Tooling 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 Solderless MAG-MATE Terminations: 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 ) airoperated insertion machine with micro-processor control. The MPT-5 machine inserts a MAG-MATE terminal into a customerdesigned cavity in the coil bobbin or similar magnetwire 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 inserting 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. 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 40 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 MAG-MATE and SIAMEZE Application Tooling (Continued) 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 MAG-MATE and SIAMEZE Application Tooling 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 41 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 MAG-MATE and SIAMEZE Application Tooling (Continued) Application Tooling for MAG-MATE Terminals 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. The Module Specifications Electrical--120 VAC, 60 Hz, 5 A, 1 O, or 240 VAC, 50 Hz, 2 A, 1 O 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 startup 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 42 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 MAG-MATE and SIAMEZE Application Tooling (Continued) Application Tooling for MAG-MATE Terminals Rotary Index Table 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 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. MAG-MATE and SIAMEZE Application Tooling 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. 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 TollFree Technical Support Center at 1-800522-6752. Besides its fast production rates, the rotary 43 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 MAG-MATE and SIAMEZE Application Tooling (Continued) 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 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. Specifications Air -- 10 scfm@80 psi minimum Electrical -- 110 VAC, 5 AMP Footprint -- 60"x 52" 44 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 MAG-MATE and SIAMEZE Application Tooling (Continued) LPT-522 Linear Product Terminator (Continued) MAG-MATE and SIAMEZE Application Tooling Rotary Index Insertion Process Optional Continuity Test Station Magnet Wire Termination Machines--Cost Comparison Machine Attribute Applications Horizontal Bench Machine (HBM) Vertical Bench Machine (VBM) LPT-522 Insertion Machine RIT Insertion Machine Single row bobbin Single terminal feed Bottom trim Single/Dual/Axial bobbin Single or dual feed Bottom or top trim Same as VBM plus: -Multiple bobbin capacity Auxiliary stations Serial Processing Same as LPT, plus: -Up to 3 different terminals Parallel 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. 45 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR Splices 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. be combined with standard, pre-stripped solid or stranded lead wires. The resulting termination produces a high tensile strength, air-sealed connection that is as resistant to corrosion as the insulated conductor. 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. 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 The crimping of AMPLIVAR splices is done by semiautomatic crimping machines for high output per hour production rates. Stranded Wire on top Magnet Wire on bottom Section AA 46 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR Splices (Continued) Test Results 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 mm2 to 6.6 mm2) Terminal Base Material -- Brass, phosphor bronze Surface Finish -- plain and tin plated except where noted Temperature Range -- -65C to +150C Rated Current -- according connected wire size Rated Voltage -- according terminated winding 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 +125C followed by 30 minutes at -65C Heat Age -- 96 hours at +150C Thermal Shock -- 25 cycles with each cycle consisting of 30 minutes at +150C followed by 30 minutes at -65C Salt Spray -- 96 hours at +35C with a 5% salt solution spray Humidity -- 96 hours at 90-95% relative humidity and +40C 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 AMPLIVAR Splices Technical Features 47 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR Splices (Continued) General Application Guidelines Suggested Splice Selection Procedure To assist you in obtaining the optimum AMPLIVAR termination, the following guidelines are recommended: Use the following guide to help you to determine the proper splice for your application: 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. 1. Use 9-serration splices, tin plated when terminating aluminum magnet wire or combinations with aluminum magnet wire. 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. 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. 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 22 AWG [0.64 mm] coated magnet wire 18 AWG [0.8-0.9 mm2] stranded lead wire = 185 CMA = 708 CMA = 1608 CMA Total = 2501 CMA Calculate the sum of the magnet wire diameters (Procedure 5): 28 AWG [0.32 mm] coated magnet wire 22 AWG [0.64 mm] coated magnet wire = .0136 [0.35] = .0266 [0.68] Total = .0402 [1.03] Technical Documents Select a terminal for trial calculations. Splice No. 62305-2, page 49 (Procedure 6): 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. CMA range Stock thickness Crimp width 114-2002 114-2003 114-2005 AMPLIVAR 7Serration Pigtail Splices AMPLIVAR 9Serration Pigtail Splices AMPLIVAR Subminiature Thru Splices 114-2006 114-2009 114-2016 AMPLIVAR Subminiature Pigtail Splices AMPLIVAR 5Serration Thru Splices AMPLIVAR Miniature Pigtail Splices = 600-3000 = .016 [0.41] = .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. 48 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR Splices (Continued) 9 Serrations -- Pigtail Type Product Facts (Plus All 7 Serration Facts) AWG/ mm2 24-18.5 0.26-0.80 22-15.5 0.38-1.54 22-15.5 0.38-1.54 18.5-13.5 0.80-2.54 18.5-13.5 0.80-2.54 15.5-12 1.54-3.46 13.5-10 2.54-4.90 12-9 3.46-6.38 10-6.5 4.90-9.45 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 Material Part Number Tin Plated Brass 62303-2* Tin Plated Brass 62304-2* Tin Plated Brass 62305-2* Tin Plated Brass 62306-2* Tin Plated Brass 62307-2* Tin Plated Brass 62308-2* Tin Plated Brass 62309-2* Tin Plated Brass 62310-2* Tin Plated Brass 62311-21* Additional serrations enhance stability of crimp 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]) Dim. L .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .265 6.73 .265 6.73 .265 6.73 .340 8.64 *These splices are recommended for applications using wire size 28 AWG [0.32 mm] or smaller. Special high force application equipment required. AWG/ mm2 22-15.5 0.38-1.54 22-15.5 0.38-1.54 22-15.5 0.38-1.54 22-15.5 0.38-1.54 22-15.5 0.38-1.54 18.5-13.5 0.80-2.54 18.5-13.5 0.80-2.54 18.5-13.5 0.80-2.54 15.5-12 1.54-3.46 15.5-12 1.54-3.46 15.5-12 1.54-3.46 12-10 2.10-6.0 12-10 2.10-6.0 12-9 2.10-6.38 Product Facts Crimp Width .080 2.03 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .140 3.56 .180 4.57 .180 4.57 .220 5.59 1 7 Serrations -- Pigtail Type Wire Range Wire Range Stock Solid Dia. CMA Thickness .020-.039 .016 400-1500 0.55-1.00 0.41 .028-.055 .020 600-3000 0.70-1.40 0.51 .028-.055 .016 600-3000 0.70-1.40 0.41 .039-.071 .020 1500-5000 1.00-1.80 0.51 .039-.071 .016 1500-5000 1.00-1.80 0.41 .055-.083 .020 3000-7000 1.40-2.10 0.51 .071-.098 .025 5000-10,000 1.80-2.50 0.64 .083-.112 .025 7000-13,000 2.10-2.85 0.64 .098-.137 .030 10,000-22,000 2.50-3.47 0.76 AMPLIVAR Splices Splice length is increased on larger CMA splices for improved performance 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 Wire Range Solid Dia. .028-.055 0.70-1.40 .028-.055 0.70-1.40 .028-.055 0.70-1.40 .028-.055 0.70-1.40 .028-.055 0.70-1.40 .039-.071 1.00-1.80 .039-.071 1.00-1.80 .039-.071 1.00-1.80 .055-.083 1.40-2.10 .055-.083 1.40-2.10 .055-.083 1.40-2.10 .085-.110 2.10-2.85 .085-.110 2.10-2.85 .085-.115 2.10-3.47 Wire Range CMA 600-3000 600-3000 600-3000 600-3000 600-3000 1500-5000 1500-5000 1500-5000 3000-7000 3000-7000 3000-7000 7000-12,000 7000-12,000 7000-13,000 Stock Thickness .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .025 0.64 .025 0.64 .025 0.64 Crimp Width .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .140 3.56 .140 3.56 .140 3.56 .250 6.35 .250 6.35 .180 4.57 Dim. L .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 Material Part Number Brass 62000-1* Brass 62157-1* Tin Plated Brass 62000-2* Tin Plated Brass 62157-2* Tin Plated Brass 62200-21 Brass 62040-2* Tin Plated Brass 62040-1* Phosphor Bronze 964156-1 Brass 62001-1* Tin Plated Brass 62001-2* Tin Plated Brass 62201-21 Tin Plated Brass 62295-1* Brass 62295-2* Tin Plated Brass 62002-2* *These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller. Flat bottom. 1 49 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR Splices (Continued) 7 Serrations -- Thru Type Product Facts L Crimp bellmouth provides retention in circular cavity slot in bobbin AWG/ mm2 22-15.5 0.38-1.54 Wire Range Solid Dia. .028-.055 0.70-1.40 Wire Range CMA 600-3000 Stock Thickness .020 0.51 Crimp Width .110 2.79 Dim. L .225 5.72 Material Part Number Tin Plated Brass 1217384-1** *These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller. 5 Serrations -- Thru Type A B Product Facts Wide range of thru splices Serrations centered in splice to achieve optimum electrical and mechanical performance in a thru splice Type A CMA range accepts a wide variety of wire sizes and combinations B AWG/ Wire Range Wire Range Stock mm2 Solid Dia. CMA Thickness 17-12.5 .045-.075 .020 2000-5400 1.00-2.80 1.15-1.85 0.51 10-8 .100-.125 .032 10,000-16,000 5.00-8.00 2.55-3.20 0.80 10-7.5 .100-.150 .030 10,400-22,900 5.00-11.50 2.60-3.80 0.76 22-15.5 .028-.055 .020 600-3000 0.38-1.54 0.70-1.40 0.51 22-15.5 .028-.055 .020 600-3000 0.38-1.54 0.70-1.40 0.51 22-15.5 .028-.055 .020 600-3000 0.38-1.54 0.70-1.40 0.51 22-15.5 .028-.055 .020 600-3000 0.38-1.54 0.70-1.40 0.51 22-15.5 .028-.055 .020 600-3000 0.38-1.54 0.70-1.40 0.51 18.5-13.5 .039-.071 .020 1500-5000 0.80-2.54 1.00-1.80 0.51 18.5-13.5 .039-.071 .020 1500-5000 0.80-2.54 1.00-1.80 0.51 18.5-13.5 .039-.071 .020 1500-5000 0.80-2.54 1.00-1.80 0.51 18.5-13.5 .039-.071 .020 1500-5000 0.80-2.54 1.00-1.80 0.51 18.5-13.5 .039-.071 .020 1500-5000 0.80-2.54 1.00-1.80 0.51 15.5-12 .055-.083 .020 3000-7000 1.54-3.46 1.40-2.10 0.51 15.5-12 .055-.083 .020 3000-7000 1.54-3.46 1.40-2.10 0.51 15.5-12 .055-.083 .020 3000-7000 1.54-3.46 1.40-2.10 0.51 15.5-12 .055-.083 .020 3000-7000 1.54-3.46 1.40-2.10 0.51 12-10 .083-.110 .025 7000-12,000 3.46-6.00 2.10-2.80 0.64 12-9 .083-.112 .025 7000-13,000 3.46-6.38 2.10-2.85 0.64 12-9 .083-.112 .025 7000-13,000 3.46-6.38 2.10-2.85 0.64 12-9 .083-.112 .025 7000-13,000 3.46-6.38 2.10-2.85 0.64 12-9 .083-.112 .025 7000-13,000 3.46-6.38 2.10-2.85 0.64 Crimp Width .110 5.08 .180 4.57 .300 7.62 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .140 3.56 .140 3.56 .140 3.56 .140 3.56 .250 6.35 .180 4.57 .180 4.57 .180 4.57 .180 4.57 Dim. L .235 5.97 .267 6.78 .310 7.87 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 Material Part Number Brass 63564-1 Tin Plated Brass 63561-1 Tin Plated Brass 63562-1 Brass 42076 Brass 42192-1* Tin Plated Brass 42192-2* Brass 42778-1*1 Tin Plated Brass 42778-2*1 Brass 41765 Tin Plated Brass 41899 Brass 42119-1* Brass 42776-1*1 Tin Plated Brass 42776-2*1 Brass 41766 Tin Plated Brass 41900 Brass 42779-11 Tin Plated Brass 42779-21 Tin Plated Brass 61074-11,2 Brass 41770 Tin Plated Brass 41904 Brass 42780-11 Tin Plated Brass 42780-21 * These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller. Increased terminal pitch. Increased U-diameter. 1 2 50 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR Splices (Continued) 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 L AWG/ mm2 20-17 0.50-1.00 Wire Range Solid Dia. .030-.045 0.80-1.15 Wire Range CMA 1000-2000 Stock Thickness .016 0.41 Crimp Width .100 2.54 Dim. L .225 5.72 Material Part Number Tin Plated Brass 62670-2*1 *These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller. Flat bottom. 1 AMPLIVAR Splices 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 AWG/ mm2 27-21 0.10-0.40 25-18 0.16-0.90 24-18.5 0.20-0.75 24-18.5 0.20-0.75 24-18 0.20-0.80 Wire Range Solid Dia. .014-.030 0.35-0.75 .015-.045 0.45-1.10 .020-.039 0.55-1.00 .020-.039 0.55-1.00 .020-.040 0.55-1.00 Wire Range CMA AWG/ mm2 30-26 0.05-0.15 24-19 0.26-0.60 24-19 0.26-0.60 Wire Range Solid Dia. .010-.015 0.30-0.50 .020-.035 0.55-0.90 .020-.035 0.55-0.90 Wire Range CMA 200-850 300-1850 480-1500 480-1500 480-1700 Stock Thickness .012 0.30 .012 0.30 .014 0.36 .014 0.36 .016 0.41 Crimp Width .055 1.40 .070 1.78 .080 2.03 .080 2.03 .070 1.78 Dim. L .195 4.95 .195 4.95 .195 4.95 .195 4.95 .195 4.95 Stock Thickness .010 0.25 .016 0.41 .016 0.41 Crimp Width .042 1.08 .070 1.78 .070 1.78 Dim. L .080 2.03 .100 2.54 .100 2.54 Material Part Number Tin Plated Brass 63431-1 Copper-Nickel 61166-1 Tin Plated Brass 62341-1 Brass 62341-2 Brass 62044-1 Material Part Number Tin Plated Brass 63621-2 Tin Plated Brass 62194-2 Gold Plated Brass 62194-4 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 100-300 400-1300 400-1300 51 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR Terminals 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. 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] Matched with AMP automated application tooling allows high production rates for stripform terminals. 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. 114-2145 114-2146 114-2070 AMPLIVAR .125 Blade Terminals AMPLIVAR FASTIN-FASTON Series 187 Tab Terminals AMPLIVAR FASTON Series 250 Tab Terminals 114-2144 114-2152 AMPLIVAR FASTON Series .250 Straight Receptacle Terminals AMPLIVAR Flag FASTON Series 187 & 250 Receptacle Terminal 114-2080 114-2128 AMPLIVAR Pin Receptacle Terminals [Type A] AMPLIVAR Stator Receptacle with FASTON Mating End 52 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR Terminals (Continued) Ring Tongue Terminals A Wire Size Range 29-22 AWG [0.287-0.643 mm] Type Insulation Dia. Range Hole Dia. Stud Size Stock Thk. Material B .040-.060 1.02-1.52 .197 5 10 .020 0.51 Tin Plated Brass W .342 8.69 Dimensions L E .833 .662 21.16 16.81 C .312 7.92 W .342 8.69 .300 7.62 .342 8.69 .300 7.62 Dimensions L E .833 .662 21.16 16.81 .700 .550 17.78 13.97 .833 .662 21.16 16.81 .695 .545 17.65 13.84 C .312 7.92 .230 5.84 .312 7.92 .230 5.84 Dimensions W L E .420 .872 .662 10.67 22.15 16.81 .290 .500 .355 7.37 12.7 9.02 .420 .702 .492 10.67 17.83 12.5 .290 .500 .355 7.37 12.7 9.02 C .312 7.92 .195 4.95 .312 7.92 .195 4.95 Part Number 63399-1 Wire Size Range 23-19 AWG [0.574-0.912 mm] B Type Insulation Dia. Range Hole Dia. Stud Size Stock Thk. B .100-.140 2.54-3.56 .125-.165 3.18-4.19 .100-.140 2.54-3.56 .125-.165 3.18-4.19 .171 4.34 .171 4.34 .197 5 .197 5 8 .020 0.51 .020 0.51 .020 0.51 .020 0.51 A B A 8 10 10 Material Tin Plated Brass Tin Plated Brass Tin Plated Brass Tin Plated Brass Part Number 60321-2 60323-2 60319-2 60325-2 Wire Size Range 22-18 AWG [0.643-1.024 mm] C Insulation Dia. Range Hole Dia. B .125-.165 3.18-4.19 E -- C -- .265 6.73 .145 3.58 .265 6.73 .171 4.34 E -- Stud Size 1/4 6 1/4 8 Stock Thk. .025 0.64 .025 0.64 .025 0.64 .025 0.64 Material Tin Plated Brass Tin Plated Brass Tin Plated Brass Brass Tin Plated Brass Part Number 63612-1 63649-1 AMPLIVAR Terminals Type 62835-1 63446-1 63446-2 Wire Size Range 20-16 AWG [0.813-1.29 mm] D E Type Insulation Dia. Range Hole Dia. Stud Size A .125-.165 3.18-4.19 .171 4.34 8 H -- -- 8 L -- -- 3/8 M -- -- 3/8 B .243 [6.15] .020 0.51 .020 0.51 .020 0.51 .020 0.51 Material Tin Plated Brass Brass Brass Brass W .300 7.62 .340 8.64 .625 15.88 .645 16.38 Dimensions L E C .695 .545 .230 17.65 13.84 5.84 1.220 .660 .500 30.98 16.76 12.7 .939 .627 .467 23.85 15.93 11.86 .950 .627 .467 24.12 15.93 11.86 W .342 8.69 .342 8.69 .342 8.69 .370 9.4 .365 9.27 Dimensions L E .833 .662 21.16 16.81 .833 .662 21.16 16.81 .833 .662 21.16 16.81 .915 .730 23.24 18.54 .882 .700 22.4 17.78 C .312 7.92 .312 7.92 .312 7.92 .380 9.65 .380 9.65 W .310 7.87 .310 7.87 Dimensions L E .692 .505 17.58 12.83 .692 .505 17.58 12.83 C .312 7.92 .312 7.92 Part Number 060322-2 505071-1 505075-1 505072-1 Wire Size Range 18-14 AWG [1.024-1.628 mm] Type F Stock Thk. D 1High Insulation Dia. Range Hole Dia. .100-.140 2.54-3.56 .100-.140 2.54-3.56 .100-.140 2.54-3.56 .080-.120 2.03-3.05 .080-.120 2.03-3.05 .171 4.34 .171 4.34 .197 5 .173 4.39 .185 4.7 Stud Size 8 8 10 8 8 Stock Thk. .020 0.51 .020 0.51 .020 0.51 .028 0.71 .028 0.71 Material Brass Tin Plated Brass Brass Lu-Bronze1 Lu-Bronze1 Part Number 060320-1 060320-2 060318-1 485079-1 485044-1 conductivity copper-tin-zinc alloy. Wire Range 17-13.5 AWG [1.151-1.78 mm] Type Insulation Dia. Range Hole Dia. Stud Size -- -- 8 -- -- 8 F G Stock Thk. .020 0.51 .020 0.51 Material Brass Tin Plated Brass Part Number 63147-1 63147-2* *Available on request .243 [6.15] Wire Size Range 14-12 AWG [1.628-2.05 mm] or (2) 15 AWG [1.45 mm] Type Insulation Dia. Range Hole Dia. Stud Size Stock Thk. Material G -- -- 8 .025 0.64 Brass W .342 8.69 Dimensions L E C .945 .750 .570 24.00 19.05 14.48 Part Number 062755-1 53 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR Terminals (Continued) Stud Retaining Terminals H Wire Size Range 13-11 AWG [1.83-2.3 mm] Type Insulation Dia. Range Hole Dia. Stud Size Stock Thk. Material A .085-.150 2.16-3.81 .180 4.57 .180 4.57 .197 5.00 8 .025 0.64 .025 0.64 .025 0.64 Brass -- 45 C -- J 8 10 Tin Plated Brass Tin Plated Brass Dimensions L E .833 .662 21.16 16.81 .665 .495 16.89 12.57 .665 .495 16.89 12.57 C .312 7.92 .312 7.92 .312 7.92 W .340 8.64 Dimensions L E .955 .660 24.26 16.76 C .500 12.7 505044-1 W Dimensions L E C Part Number W .342 8.69 .342 8.69 .342 8.69 Part Number 061710-1 350571-1 640212-1 Wire Range (1) 18 AWG [1.024 mm] and (1) 20.5 AWG [0.768 mm] 45 Type Insulation Dia. Range Hole Dia. Stud Size Stock Thk. Material J -- -- 8 .020 0.51 Brass Part Number Wire Range (2) 17 AWG [1.51 mm] or (2) 15 AWG [1.45 mm] K Type Insulation Dia. Range B .150-.190 or (2) .115 3.18-4.83 or (2) 2.92 .150-.190 or (2) .115 3.18-4.83 or (2) 2.92 Hole Dia. Stud Size Stock Thk. Material .171 4.34 8 .025 0.64 Tin Plated Brass .342 8.69 .827 .656 21.01 16.66 .312 7.92 60752-2 .197 5.00 10 .025 0.64 Tin Plated Brass .342 8.69 .827 .656 21.01 16.66 .312 7.92 61151-1 W .340 8.64 Dimensions L E 1.220 .660 30.99 16.76 C .500 12.7 W .240 6.1 .240 6.1 Dimensions L E .620 .500 15.75 12.7 .620 .500 15.75 12.7 C .165 4.19 .165 4.19 W .342 8.69 Dimensions L E .827 .656 21.00 16.66 C .312 7.92 L .376 [9.55] Wire Range 16-13.5 AWG [1.29-1.78 mm] .388 [9.85] Type Insulation Dia. Range Hole Dia. Stud Size Stock Thk. Material K -- -- 10 .020 0.51 Brass Material Part Number 505079-1 M Wire Range 14.5 AWG [1.539 mm] Type Insulation Dia. Range Hole Dia. Stud Size Stock Thk. -- -- 2 -- -- 2 .025 0.64 .025 0.64 N Tin Plated Brass Brass Part Number 505036-1 505036-3 Wire Range (2) 13 AWG [1.83 mm] Alternator Eyelet Terminal N Type Insulation Dia. Range Hole Dia. Stud Size Stock Thk. Material B .150-.190 3.81-4.83 .171 4.34 8 .025 0.64 Tin Plated Brass Part Number 63864-1 54 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR Terminals (Continued) A 125 Series Blade B Stock Thickness A = .013 [0.33] B = .020 [0.51] .330 [8.38] .125 [3.18] .810 [20.57] .020 [.508] Mates with Power Blade Receptacle terminals 61603-1, 61604-1, 770642-1 and 1217039-1 Type AWG 27-20.5 Housings A Contact Tyco Electronics Engineering for housing options available 24-18 18.5-13.5 27-20.5 B 24-18 18.5-13.5 .940 [23.88] .370 [9.40] .020 [.508] Magnet Wire Range mm2 Solid Dia. .015-.030 0.10-0.45 0.35-0.75 .020-.040 0.2-0.8 0.50-1.00 .040-.070 0.75-2.5 0.50-1.80 .015-.030 0.10-0.45 0.35-0.75 .020-.040 0.2-0.8 0.50-1.00 .040-.070 0.75-2.5 0.50-1.80 Material Material Thickness 200-850 Tin Plated Brass 400-1600 Tin Plated Brass 1500-5000 Tin Plated Brass 200-850 Tin Plated Brass 400-1600 Tin Plated Brass 1500-5000 Tin Plated Brass .013 0.33 .013 0.33 .016 0.41 .013 0.33 .020 0.51 .020 0.51 CMA A Part Number 63871-1 63889-1 63870 1217072-1 1217029-1 1217073-1 AMPLIVAR Terminals 187 Series FASTON Tabs1 .125 [3.18] B Board Thickness A = .062-.072 [1.57-1.83] Stock Thickness A = .020 [0.51] B = .032 [0.81] Type B Wire Range AWG mm2 Dim. L Material 27-23 0.1-0.2 Tin Plated Brass 24-21 0.2-0.4 Tin Plated Brass 22-16 0.3-1.4 Tin Plated Brass 15-13 1.6-2.6 Tin Plated Brass 15-12 1.6-3.0 Tin Plated Brass .935 23.75 .935 23.75 1.015 25.78 .935 23.75 1.015 25.78 A 2 Part Number 63484-12 61440-3 62447-1 61442-3 62445-1 Varnish resist coating. These part numbers are available upon special request, contact Tyco Electronics Engineering for details. 250 Series FASTON Tabs1 Stock Thickness .032 [0.81] Wire Range AWG mm2 14-12 2.0-3.0 Material Part Number Quick-Change Applicator3 Tin Plated Brass 62922-12 466510-1 Varnish resist coating. 3 Quick-Change Applicator for AMP-O-LECTRIC Machine 565435-5. For AMPOMATOR Machine and other machines not listed, contact Tyco Electronics. 2 1Mates with FASTON receptacles. See AMP Catalog 82004. 55 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR Terminals (Continued) 250 Series FASTON Tabs1 (Continued) Stock Thickness .032 [0.81] 1 Mates with FASTON receptacles. See AMP Catalog 82004. Wire Range AWG mm2 Material 28-23.5 0.08-0.2 Tin Plated Brass 25-19.5 0.16-0.6 Tin Plated Brass 23-19 0.2-0.6 Tin Plated Brass Dimensions L E .580 .342 14.73 8.69 .650 .450 16.51 11.43 .225 .583 5.72 14.81 W .250 6.35 .250 6.35 .250 6.35 T Part Number 45 63136-1 30 63140-1 15 63165-1 Part Number Applicator No. 250 Series FASTON Receptacles1 .280 [7.11] .690 [17.53] Stock Thickness .016 [0.41] 1 .290 [7.37] Mates with FASTON tabs. See AMP Catalog 82004. Magnet Wire Range CMA mm2 Dia. Insulation Diameter Mating Tab Thk. Material Material Thickness 24-19 0.51-0.98 .050-.080 1.30-2.00 .020 0.51 Brass Tin Plated Brass .016 0.41 63623-11 63623-21 567451-22 23-19 or (2) 24 or (2) 26 20-16 or (2) 23 or (2) 20 0.60-0.98 or (2) 0.57 or (2) 0.45 0.85-1.37 or (2) 0.63 or (2) 0.88 .050-.100 1.30-2.55 .025 0.64 Brass .016 0.41 62069-1 567343-22 .032 [0.81] Brass Tin Plated Brass .016 0.41 60384-1 60384-2 466010-12 20-16 0.85-1.37 .020 0.51 Brass .016 0.41 62080-1 466010-12 18-14 or (2) 17 1.02-1.71 .100-.140 or (2) .060 Max. 2.55-3.55 .100-.140 2.55-3.55 .120-.170 or (2) .060 Max. 3.05-4.30 .120-.170 3.05-4.30 .120-.170 3.05-4.30 .032 [0.81] Tin Plated Brass .016 0.41 60385-2 466816-12 63622-11 466816-12 1217835-11 466816-12 18-14 or (2) 19 18-14 or (2) 19 1 2 1.02-1.71 1.02-1.71 .020 0.51 .020 0.51 Brass Brass .016 0.41 .016 0.41 Low insertion force Quick-Change Applicator for AMP-O-LECTRIC Machine 565435-5. 56 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR Terminals (Continued) 187 Series FASTON Flag Receptacles Stock Thickness .045 [1.14] .016 [0.41] .240 [6.10] .232 [5.89] Magnet Wire Range CMA mm2 Dia. 1 0.56-0.79 24-20 AWG 0.51-0.81 1500-2350 0.99-1.22 2000-4050 1.14-1.63 2000-4050 1.14-1.63 Insulation Diameter Mating Tab Thk. Material Material Thickness .020-.040 0.51-1.02 .020-.040 0.51-1.02 .020-.040 0.51-1.02 .020-.040 0.51-1.02 .020-.040 0.51-1.02 .020 0.51 .032 0.81 .020 0.51 .020 0.51 .032 0.81 Tin Plated Brass .016 0.41 .016 0.41 .016 0.41 .016 0.41 .016 0.41 Tin Plated Brass Tin Plated Brass Tin Plated Brass Tin Plated Brass Part Number Applicator No. 63942-1 566411-11 1217624-1 566411-11 63941-1 566410-11 63940-1 680353-32 1217417-1 680353-32 Standard Applicator for "G" Splice Terminator No. 356462-2. Quick-Change Applicator for "G" Splice Terminator No. 356462-1. AMPLIVAR Terminals 2 500-960 .4.35 [11.05] 250 Series FASTON Flag Receptacles Stock Thickness .018 [0.45] .070 [1.78] .305 [7.75] .600 [15.24] .300 [7.62] 1 Pin Receptacles Magnet Wire Range CMA mm2 Dia. Insulation Diameter Mating Tab Thk. Material Material Thickness Part Number Applicator No. 16-12 .120-.170 3.05-4.32 .032 0.81 Tin Plated Phos Bronze .018 0.45 63944-1 680421-31 1.29-2.13 Quick-Change Applicator for "G" Splice Terminator No. 356462-1. A B Stock Thickness .016 [0.41] Type A B Wire Range AWG mm2 29-22 21-16 0.07-0.3 0.4-1.4 Insulation Dia. Range Material .040-.060 1.02-1.52 Tin Plated Brass -- Tin Plated Phos. Bronze Dimensions W Max. L .084 .590 2.13 14.99 .235 .660 5.97 16.76 C .195 4.95 .250 6.35 Part Number 63506-1 60177-2 57 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR Terminals (Continued) 250 Series Stator Receptacles -- 7 Serrations .070 [1.78] .860 [21.84] .305 [7.75] .300 [7.62] AWG 27-22 21-15 22-15.5 Magnet Wire Range mm2 Solid Dia. CMA .014-.026 200-700 0.10-0.3 0.35-0.66 .028-.060 800-3600 0.4-1.6 0.71-1.52 .053-.086 2800-7400 0.3-1.5 1.35-2.18 Mating Tab Thickness Stock Thickness Crimp Width .032 0.81 .032 0.81 .032 0.81 .018 0.44 .018 0.44 .018 0.44 .070 1.77 .110 2.79 .155 3.94 Material Part Number Tin Plated Brass 63480-1 Tin Plated Brass 62381-1 Tin Plated Brass 63964-1 Stator Terminal -- Receptacle .250 x .032 [6.35 x 0.81] Stator Terminal with Receptacle .250 x .032 [6.35 x 0.81] Plastic Cavity For design and material selection Tyco Electronics Engineering has to be contacted before decision. The terminal is separated from the strip and placed automatically into the cavity. The magnet wire is positioned via posts into the AMPLIVAR crimp barrel and fixed inside clamping barrel. Production only according to Tyco Electronics Specifications (Contact Tyco Electronics Engineering for details). Wire Clamping Barrel AMPLIVAR 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. 58 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Cluster Blocks 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 R 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 Cluster Blocks 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. Pin Receptacle Terminal (Crimped to Wire) Typical Assembly 59 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Cluster Blocks .090 [2.29] Pin Size (Lead Wire) Housings K W K .530 Dia. [13.46] H .229 [5.82] H L .090 .001 [2.29 0.03] Pin Dia. 3 Plcs. .459 [11.66] W A B Pin Location A and B .108 [2.74] L W .108 [2.74] .683 Dia. [17.35] H .324 [8.23] L K .108 [2.74] .108 [2.74] .090 .001 [2.29 0.03] Pin Dia. 4 Plcs. .324 [8.23] C .324 [8.23] Pin Header Pin Type Center Position Circle Dia. .530 Forward 13.46 .530 A Forward 13.46 .530 Forward 13.46 .530 Back 13.46 B .530 Back 13.46 .683 C -- 17.35 Pin Location C Dim. L 1.245 31.60 1.240 31.50 1.220 31.00 1.225 31.10 1.200 30.50 1.490 37.85 Dim. W .710 18.05 .710 18.05 .695 17.65 .810 20.55 .695 17.65 .900 22.85 Dim. H .355 9.00 .320 8.15 .260 6.60 .320 8.15 .310 7.85 .355 9.00 Dim. K .850 21.60 .840 21.35 .820 20.85 .840 21.35 .805 20.40 .845 21.45 Material PBT Polyester 15% Glass Reinforced PBT Polyester 15% Glass Reinforced PBT Polyester 15% Glass Reinforced PBT Polyester 15% Glass Reinforced PBT Polyester Non-Reinforced PBT Polyester 15% Glass Reinforced Pin Receptacles A A B -- -- -- 360033-1 281006-0 1217262-1 .115 [2.92] .115 [2.92] CMA 521078-1 .180 [4.57] .180 [4.57] Wire Range Solid Dia. .025-.065 0.65-1.65 .040-.050 1.00-1.30 .040-.050 1.00-1.30 360050-1 .313 [7.95] .313 [7.95] AWG/ mm2 22-14 0.3-2.0 18-16 0.8-1.4 18-16 0.8-1.4 1217263-1 .670 [17.02] .670 [17.02] Type Part Number Crimp Width .100 2.54 .110 2.79 .110 2.79 B Insulation Diameter .080-.150 2.00-3.80 .060-.100 1.50-2.55 .090-.170 2.30-4.30 Crimp Width .130 3.30 .140 3.56 .180 4.57 Stock Thickness .016 0.41 .016 0.41 .016 0.41 Material Part Number Tin Plated Phos Bronze 1217264-1 Tin Plated Phos Bronze 62131-3 Tin Plated Phos Bronze 63448-1 60 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Cluster Blocks .125 [3.18] Pin Size (Lead Wire and Direct Connect) Housings W K W K H .530 Dia. [13.46] H L .229 [5.82] L .125 .001 [3.18 0.03] Pin Dia. 3 Plcs. .459 [11.66] A B Pin Location A and D W W Cluster Blocks .687 Dia. [17.45] K H H .125 .001 [3.18 0.03] Pin Dia. 3 Plcs. .297 [7.55] K L L .595 [15.12] Pin Location B C .815 Dia. [20.70] Type A B .353 [8.96] .706 [17.92] Pin Location C .125 .001 [3.18 0.03] Pin Dia. 3 Plcs. C D Center Pin Header Pin Position Circle Dia. .530 Forward 13.46 .530 Forward 13.46 .687 Forward 17.45 .687 Forward 17.45 .815 Forward 20.70 .530 Back 13.46 .530 Back 13.46 .687 Back 17.45 D Dim. L 1.755 44.60 1.755 44.60 1.730 43.95 1.595 40.50 1.975 50.15 1.860 47.25 1.755 44.60 1.850 47.00 Dim. W .765 19.45 .765 19.45 .895 22.75 .895 22.75 1.015 25.80 .765 19.45 .765 19.45 .895 22.75 Dim. H .525 13.35 .470 11.95 .615 15.60 .380 9.65 .590 15.00 .525 13.35 .470 11.95 .615 15.60 Dim. K 1.230 31.25 1.230 31.25 1.080 27.45 1.080 27.45 1.050 26.65 1.225 31.10 1.225 31.10 1.225 31.10 Material PBT Polyester 15% Glass Reinforced PBT Polyester 15% Glass Reinforced PBT Polyester 15% Glass Reinforced PBT Polyester 15% Glass Reinforced PBT Polyester Non-Reinforced PBT Polyester 15% Glass Reinforced PBT Polyester 15% Glass Reinforced PBT Polyester 15% Glass Reinforced Part Number 1217181-1 360052-1 1217186-1 520995-1 1217261-1 1217200-1 360051-1 1217187-1 61 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Cluster Blocks .125 [3.18] Pin Size (Lead Wire and Direct Connect) (Continued) Pin Receptacles .805 [20.45] .805 [20.45] .400 [10.16] .400 [10.16] .240 [6.10] .240 [6.10] .160 [4.06] .160 [4.06] A B Lead Wire Lead Wire .870 [22.1] .870 [22.1] .400 [10.16] .400 [10.16] .240 [6.1] .240 [6.1] .160 [4.06] .160 [4.06] Type A B AWG/ mm2 18-16 0.8-1.4 18-16 0.8-1.4 14-10 2.0-6.0 18-16 0.8-1.4 14-10 2.0-6.0 -- -- -- C -- -- -- -- -- -- -- D -- -- -- Wire Range Solid Dia. .040-.050 1.00-1.30 .040-.050 1.00-1.30 .065-.100 1.60-2.60 .040-.050 1.00-1.30 .065-.100 1.60-2.60 .020-.040 0.50-1.00 .020-.040 0.50-1.00 .040-.065 1.00-1.65 .040-.065 1.00-1.65 .065-.090 1.65-2.30 .065-.090 1.65-2.30 .065-.090 1.65-2.30 .020-.040 0.50-1.00 .020-.040 0.50-1.00 .040-.065 1.00-1.65 .040-.065 1.00-1.65 .065-.090 1.65-2.30 .065-.090 1.65-2.30 C D AMPLIVAR Direct Connect AMPLIVAR Direct Connect CMA -- -- -- -- -- 400-1600 400-1600 1500-4200 1500-4200 4000-8500 4000-8500 4000-8500 400-1600 400-1600 1500-4200 1500-4200 4000-8500 4000-8500 Crimp Width .110 2.79 .110 2.79 .140 3.56 .110 2.79 .140 3.56 .090 2.27 .090 2.27 .110 2.79 .110 2.79 .140 3.56 .140 3.56 .160 4.06 .090 2.27 .090 2.27 .110 2.79 .110 2.79 .140 3.56 .140 3.56 Insulation Diameter .090-.130 2.30-3.30 .090-.130 2.30-3.30 .130-.170 3.30-4.30 .090-.130 2.30-3.30 .130-.170 3.30-4.30 .060-.100 1.50-2.55 .060-.100 1.50-2.55 .075-.125 1.90-3.20 .075-.125 1.90-3.20 .090-.170 2.30-4.30 .090-.170 2.30-4.30 .090-.170 2.30-4.30 .060-.100 1.50-2.55 .060-.100 1.50-2.55 .075-.125 1.90-3.20 .075-.125 1.90-3.20 .090-.170 2.30-4.30 .110-.150 2.80-3.80 Crimp Width .155 3.94 .155 3.94 .180 4.57 .155 3.94 .170 4.32 .140 3.56 .140 3.56 .155 3.94 .155 3.94 .170 4.32 .170 4.32 .170 4.32 .140 3.56 .140 3.56 .155 3.94 .155 3.94 .170 4.32 .170 4.32 Stock Thickness .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 Part Number Material Tin Plated Phos Bronze 62244-3 Phos Bronze 62244-5 Tin Plated Phos Bronze 62243-3 Tin Plated Phos Bronze 1217176-1 Tin Plated Phos Bronze 1217175-1 Tin Plated Phos Bronze 63908-1 Tin Plated Phos Bronze 63453-1 Tin Plated Phos Bronze 63907-1 Tin Plated Phos Bronze 63454-1 Tin Plated Phos Bronze 63906-1 Tin Plated Phos Bronze 63455-1 Tin Plated Phos Bronze 1217122-1 Tin Plated Phos Bronze 1217670-1 Tin Plated Phos Bronze 1217172-1 Tin Plated Phos Bronze 1217671-1 Tin Plated Phos Bronze 1217174-1 Tin Plated Phos Bronze 1217672-1 Tin Plated Phos Bronze 1217173-1 62 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR and Cluster Blocks Application Tooling 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 without major shut-height adjustments Specifications APT III A 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 autoadjust 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. AMPLIVAR and Cluster Blocks Application Tooling 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] 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 with vertical base (679984-1) for direct connect terminals APT II E 63 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR and Cluster Blocks Application Tooling (Continued) 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 Precision Adjust Crimp Quality Monitor Manual Automatic Not included Included Programmable Crimp-Height Sequencing Not included Included Model APT IIE** APT IIIA Base Part Number* Direct Connect Contact "-1338906- " "-1338907- " "-679453- " "-679457- " Pigtail-type Splice *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 AMPLIVAR Pigtail-Type Splice Suffix and Prefix Dash Numbers (Aluminum base 679984-1 not included) Pigtail-type Splice Base Number 42775 42776 42777 42778 42779 62000 62001 62001 62201 62002 62040 62157 62200 62295 62303 62304 62305 62306 62306 62307 62308 62308 62309 62309 62310 62310 280002 280004 964156 Crimp Width 120/240 VAC IIE Machine 120/240 VAC IIIA Machine "-1338906-" "-679453-" .110 [2.79] 1-( )-1 3-( )-7 .110 [2.79] 1-( )-2 3-( )-8 .140 [3.56] .110 [2.79] .140 [3.56] .180 [4.57] .140 [3.56] .180 [4.57] .110 [2.79] ( )-8 1-( )-2 ( )-7 ( )-6 ( )-8 ( )-3 1-( )-1 3-( 3-( 3-( 3-( 3-( 2-( 3-( .110 [2.79] 1-( )-2 3-( )-8 .250 [6.35] .080 [2.03] ( )-1 1-( )-3 2-( )-7 3-( )-9 )-4 )-8 )-3 )-2 )-4 )-9 )-7 .110 [2.79] 1-( )-2 3-( )-8 .140 [3.56] 1-( )-0 3-( )-6 .110 [2.79] 1-( )-1 3-( )-7 .140 [3.56] .180 [4.57] .220 [5.59] .180 [4.57] .220 [5.59] .180 [4.57] .110 [2.79] .110 [2.79] .110 [2.79] ( )-9 ( )-6 5-( )-4 ( )-5 ( )-2 ( )-4 1-( )-1 1-( )-2 1-( )-1 3-( 3-( 5-( 3-( 2-( 3-( 3-( 3-( 3-( )-5 )-2 )-3 )-1 )-8 )-0 )-7 )-8 )-7 AMPLIVAR Direct Connect Contact Suffix and Prefix Dash Numbers (Aluminum base 679984-1 included) Extraction Tool Part No. 274186-1 Direct Connect Contact Base Number 63453 63454 63455 63548 63549 63906 63907 63908 1217122 1217172 1217173 1217174 1217670 1217671 1217672 Crimp Width .090 [2.286] .110 [2.79] .140 [3.56] .090 [2.286] .110 [2.79] .140 [3.56] .110 [2.79] .090 [2.286] .160 [4.064] .090 [2.286] .140 [3.56] .110 [2.79] .090 [2.286] .110 [2.79] .140 [3.56] 120/240 VAC IIE Machine 120/240 VAC IIIA Machine "-1338907-" "-679457-" ( )-3 ( )-2 ( )-1 ( )-5 ( )-4 ( )-1 ( )-2 ( )-3 1-( )-1 ( )-3 ( )-1 ( )-2 ( )-3 ( )-2 ( )-1 ( )-8 ( )-7 ( )-6 1-( )-0 ( )-9 ( )-6 ( )-7 ( )-8 1-( )-2 ( )-8 ( )-6 ( )-7 ( )-8 ( )-7 ( )-6 64 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR and Cluster Blocks Application Tooling (Continued) 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 highlyreliable 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. 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. (Shown with optional Crimp Quality Monitor.) Model "K" Specifications 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. 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 AMPLIVAR and Cluster Blocks Application Tooling Crimp Quality Monitor 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. 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. 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. 65 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR and Cluster Blocks Application Tooling (Continued) Model G Splice Terminating Machine, P/N 356462-2 & Applicator 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. Standard G Splice Applicator Available for the AMP-O-LECTRIC Model G splice terminator only. 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. 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 smallfootprint 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 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. 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. 66 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR and Cluster Blocks Application Tooling (Continued) 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 different 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 AMPLIVAR and Cluster Blocks Application Tooling 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. 67 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 AMPLIVAR and Cluster Blocks Application Tooling (Continued) 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-tofollow, 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. 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 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. 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 [0.125mm25mm2] 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. 68 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 MTM Crimpband Splices 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, tinplated brass, and coppernickel alloy material Make parallel or pigtail connections on same machine 100% of Crimpband material is used in scrap free terminations Cut Formed 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 Applications Motors windings and connections Coil connections Transformer windings and connections Lighting ballasts Power supplies Mod I Tyco Electronics features the AMP MTM Crimpband system that is comprised of two key features: the semiautomatic 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 Mod III 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. Crimpband Crimped When aluminum magnet wire is used, MTM Crimpband splices must be tin plated. 69 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 MTM Crimpband Splices (Continued) MTM Crimpband Interconnection System 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. How the System Operates Feed (Magnet Wire Connector Material) Machine feeds strip until the strip hits the wire stop. Shear (Blank Length) The strip is cut by the cutter block former bar insert tooling. W Bend (Crimp Formed) The former bar drives the cut strip over the anvil, bending the cut strip into an upside down "U". In Pigtail and Parallel (Thru) splices magnet wires must be placed on top of the lead wire. The anvil retracts as the driver takes the formed strip down into the clincher. Connector Specification Code Splice No. Example: L See Figure 1 and/or Legend below W Dim. T Dim. Connector Material Finish Width Thickness 6R 20 T 092 Blank Length W Magnet Wires on top L D A Crimp (Crimp Formed) B.L. Dim. Tooling Size 092 Serrations Section A-A Wire (Placement) Machine Basis Burrs T A 6R 20 T Material Code Lead Wire B B Legend L Leased Machine Basis P G* Purchase General * Customer has their own Tooling Tooling Size Code 032 032/036 036 045 051 061 061/076 076 076/092 092 092/125 125 125/160 125/165 165 Blank Length B/L (Nom.) .167 .228 .224 .246 .267 .292 .324 .339 .361 .379 .413 .446 .485 .506 .546 Note: For B/L above, .546 consult Tyco Electronics for tooling size code. Connector Width Code 4R 5 Serrations 6R 7 Serrations 8R 9 Serrations 10R 11 Serrations Material Thickness Code 12 14 16 20 25 Material Code B A TB T.002 Dim. .012 .014 .016 .020 .025 W .138 .154 .194 .234 D Serration Depth .005 .005 .007 .007 .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 Material/Finish CDA 260 Brass CDA 725 Copper/ Nickel Alloy Pre-Tin over CDA 260 Brass 70 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 MTM Crimpband Splices (Continued) 11 Serrations T W AWG/ Wire Range mm2 Solid Dia. .059-.087 1412-1112 1.80-4.00 1.50-2.21 .059-.087 1412-1112 1.80-4.00 1.50-2.21 .071-.097 1312-1012 2.54-4.50 1.70-2.46 .071-.097 1312-1012 2.54-4.50 1.70-2.46 CMA Range 3500-7500 3500-7500 4500-9500 4500-9500 Stock Mat'l Thk. (T) Width (W) Material .025 .234 Brass 0.64 5.94 .025 .234 Tin Plated 0.64 5.94 Brass .025 .234 Brass 0.64 5.94 .025 .234 Tin Plated 0.64 5.94 Brass Toolset Part Number Descriptive X-ref P125/ 16510R25B L125/ 16510R25TB P165/ 20010R25B P165/ 20010R25TB 125/165 1601842-1 125/165 1601705-1 165/200 1601847-1 165/200 1601848-1 Toolset Part Number 032/036 1601794-1 Descriptive X-ref P032/ 0368R16TB 061 1601607-1 L0618R16TB 061 1601608-1 L0618R20B 9 Serrations T W CMA Range 400-1100 900-2600 900-2600 900-2600 1600-4000 1600-4000 1800-4600 1800-4600 2600-6100 2600-6100 2600-6100 2600-6100 3000-6750 3000-6750 3000-6750 3000-6750 3500-7500 3500-7500 4000-8500 7000-13000 Stock Mat'l Thk. (T) Width (W) .016 .194 0.41 4.93 .018 .194 0.46 4.93 .018 .194 0.46 4.93 .018 .194 0.46 4.93 .016 .194 0.41 4.93 .020 .194 0.51 4.93 .020 .194 0.51 4.93 .020 .194 0.51 4.93 .020 .194 0.51 4.93 .020 .194 0.51 4.93 .025 .194 0.64 4.93 .025 .194 0.64 4.93 .016 .194 0.41 4.93 .016 .194 0.41 4.93 .020 .194 0.51 4.93 .025 .194 0.64 4.93 .025 .194 0.64 4.93 .025 .194 0.64 4.93 .025 .194 0.64 4.93 .025 .194 0.64 4.93 Material Tin Plated Brass Tin Plated Brass Brass Tin Plated Brass Tin Plated Brass Tin Plated Brass 061 1601814-1 P0618R20TB 076 1601824-1 P0768R16TB 076 1601857-1 PO768R20TB Brass 076/092 1601823-1 Tin Plated Brass 076/092 1601639-1 Brass 092/125 1601678-1 Tin Plated Brass 092/125 1601835-1 P076/ 0928R20B L076/ 0928R20TB P092/ 1258R20B L092/ 1258R20TB L092/ 1258R25B P092/ 1258R25TB Brass 125 1601717-1 L1258R16B Tin Plated Brass 125 1601718-1 L1258R16TB Brass 125 1601846-1 P1258R20B Brass 125 1601719-1 L1258R25B Brass 125/165 1601706-1 Tin Plated Brass Tin Plated Brass Tin Plated Brass 125/165 1601707-1 165 1601750-1 L1658R25TB 200/202 1601761-1 L200/ 2028R25TB Brass 092/125 1601833-1 Tin Plated Brass 092/125 1601677-1 Crimpband AWG/ Wire Range mm2 Solid Dia. 24-20 .020-.033 0.20-0.50 0.51-0.84 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 16-12 .051-.078 1.30-3.46 1.29-1.98 16-12 .051-.078 1.30-3.46 1.29-1.98 16-12 .051-.078 1.30-3.46 1.29-1.98 16-12 .051-.078 1.30-3.46 1.29-1.98 .055-.082 1512-12 1.54-3.46 1.40-2.10 .055-.082 1512-12 1.54-3.46 1.40-2.10 .055-.082 1512-12 1.54-3.46 1.40-2.10 .055-.082 1512-12 1.54-3.46 1.40-2.10 .059-.087 1412-1112 1.80-4.00 1.50-2.21 .059-.087 1412-1112 1.80-4.00 1.50-2.21 14-11 .063-.092 2.00-4.20 1.60-2.34 .084-.114 1112-9 4.00-6.50 2.13-2.90 L125/ 1658R25B L125/ 1658R25TB These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 71 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 MTM Crimpband Splices (Continued) 7 Serrations T W AWG/ Wire Range mm2 Solid Dia. .013-.028 2712-21 0.09-0.40 0.33-0.71 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 22-19 .024-.036 0.38-0.60 0.70-0.91 22-19 .024-.036 0.38-0.60 0.70-0.91 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 .042-.068 1712-1312 0.95-2.54 1.07-1.80 .047-.072 1612-13 1.10-2.60 1.19-1.83 16-12 .051-.078 1.30-3.46 1.29-1.98 16-12 .051-.078 1.30-3.46 1.29-1.98 .055-.082 1512-12 1.54-3.46 1.40-2.10 .055-.082 1512-12 1.54-3.46 1.40-2.10 .055-.082 1512-12 1.54-3.46 1.40-2.10 1 CMA Range 170-800 400-1100 400-1100 400-1100 400-1100 600-1300 600-1300 900-2600 900-2600 1600-4000 1600-4000 1600-4000 1800-4600 2200-5200 2600-6100 2600-6100 3000-6750 3000-6750 3000-6750 Stock Mat'l Thk. (T) Width (W) .012 .154 0.30 3.91 .012 .154 0.30 3.91 .012 .154 0.30 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .020 .154 0.51 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .020 .154 0.51 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .020 .154 0.51 3.91 .012 .154 0.30 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 Part Number Material Toolset Brass 032 Brass 032/036 1601539-1 Cu Ni 032/036 1601538-1 Descriptive X-ref 1601800-1 P0326R12BUF1 Brass 032/036 1601540-1 Tin Plated Brass 032/036 1601793-1 L032/ 0366R12B L032/ 0366R12AUF1 L032/ 0366R16B P032/ 0366R16TB Brass 045 1601559-1 L0456R16B Brass 045 1601560-1 L0456R20B Brass 061 1601604-1 L0616R16B Tin Plated Brass 061 1601606-1 L0616R16TB Brass 076 1601644-1 L0766R16B Tin Plated Brass 076 1601646-1 L0766R16TB Brass 076 1601647-1 L0766R20B Brass 076/092 1601637-1 L076/ 0926R16BX L0926R16TB Tin Plated Brass Tin Plated Brass 092 1601683-1 092/125 1601675-1 Brass 092/125 1601832-1 L092/ 1256R16TB P092/ 1256R20B Brass 125 1601844-1 P1256R12B Brass 125 1601845-1 P1256R16B Tin Plated Brass 125 1601716-1 L1256R16TB UF 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. 72 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 RTM Crimpband Splices 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 nonelectrical 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 Applications Formed Crimped Mod I Tyco Electronics features the AMP RTM Crimpband system that is comprised of two key features: the semiautomatic 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 Mod III 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. Crimpband Stranded and solid wire-towire 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 73 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 RTM Crimpband Splices (Continued) RTM Crimpband Interconnection System 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. How the System Operates Feed (Ribbon Connector Material) Machine feeds strip until the strip hits the wire stop. Shear (Blank Length) The strip is cut by the cutter block former bar insert tooling. W Bend (Crimp Formed) The former bar drives the cut strip over the anvil, bending the cut strip into an upside down "U". Ridges T Section A-A A Wire (Placement) Pigtail and Parallel (Thru) splice terminations are made on the same machine. A Crimp (Crimp Formed) The anvil retracts as the driver takes the formed strip down into the clincher. W B.L. Dim. Tooling Size 092 L Splice No. Example: L See Figure 1 and/or Legend below W Dim. T Dim. Connector Material Material Width Thickness F 20 TCRS 092 Lead Wires Connector Specification Code Machine Basis Blank Length F 20 TCRS Legend Machine Basis L P Leased Purchase Tooling Size Code 032 032/036 036 045 051 061 061/076 076 076/092 092 092/125 125 125/160 125/165 165 Blank Length B/L (Nom.) .167 .228 .224 .246 .267 .292 .324 .339 .361 .379 .413 .446 .485 .506 .546 Connector Width Code B C D E F G H L M N P W Dim. .076 .138 .154 .185 .216 .234 .247 .086 .330 .500 .114 Note: For B/L above, .546 consult factory for tooling size code N No. of Ridges 3 6 7 8 9 10 10 3 14 20 5 Material Thickness Code 12 16 18 20 22 24 25 Material Code B A TB TCRS SS ST T.002 Dim. .012 .016 .018 .020 .022 .024 .025 Material/Finish 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 CDA 260 Brass CDA 725 Copper/ Nickel Alloy Pre-Tin over CDA 260 Brass 1010 Cold Rolled Steel, Tin Plated 301 or 302 Stainless Steel Stainless Steel, Tin Plated 74 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 RTM Crimpband Splices (Continued) 20 Ridges T W AWG/ Wire Range CMA Stock Mat'l Material mm2 Solid Dia. Range Thk. (T) Width (W) 1 .084-.114 7000-13000 .020 .500 Tin Plated 11 2-9 4.00-6.50 2.13-2.90 0.51 12.70 Brass Toolset 200/202 Part Number Descriptive X-ref 1601771-1 L200/202N20TB 14 Ridges T W AWG/ Wire Range CMA mm2 Solid Dia. Range 22-19 .024-.036 600-1300 0.38-0.60 0.61-0.91 22-19 .024-.036 600-1300 0.38-0.60 0.61-0.91 Stock Mat'l Thk. (T) Width (W) .012 .330 0.30 8.38 .012 .330 0.30 8.38 Material Toolset Part Number Descriptive X-ref Cu Ni 045 1601577-1 L045M12A Brass 045 1601578-1 L045M12B These part numbers are available upon special request; contact Tyco Electronics Engineering for details. Crimpband 10 Ridges T W AWG/ Wire Range mm2 Solid Dia. 22-19 .024-.036 0.38-0.60 0.61-0.91 1 .028-.039 21-18 2 0.40-0.75 0.71-0.99 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .084-.114 1112-9 4.00-6.50 2.13-2.90 .084-.114 1112-9 4.00-6.50 2.13-2.90 CMA Range Stock Mat'l Thk. (T) Width (W) .012 .234 600-1300 0.30 5.94 .016 .234 800-1500 0.41 5.94 .012 .234 900-2600 0.30 5.94 .020 .234 900-2600 0.51 5.94 .234 7000-13000 .020 0.51 5.94 .025 .234 7000-13000 0.64 5.94 Material Toolset Part Number Descriptive X-ref Brass 045 1601575-1 L045G12B Cu Ni 051 1601593-1 L051G16A Brass 061 1601632-1 L061G12B Brass 061 1601633-1 L061G20B Brass 200/202 1601853-1 Brass 200/202 1601769-1 P200/ 202G20B L200/ 202G25BX These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 75 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 RTM Crimpband Splices (Continued) 9 Ridges T W AWG/ Wire Range CMA mm2 Solid Dia. Range 22-19 .024-.036 600-1300 0.38-0.60 0.61-0.91 .030-.051 2012-16 900-2600 0.45-1.30 0.76-1.29 Stock Mat'l Thk. (T) Width (W) .012 .216 0.30 5.49 .012 .216 0.30 5.49 Material Toolset Part Number Descriptive X-ref Stainless Steel Stainless Steel 045 1601807-1 P045F12SS 061 1601520-1 G061F12SS Toolset Part Number 032/036 1601553-1 Descriptive X-ref L032/ 036E12A 8 Ridges T W AWG/ Wire Range CMA Stock Mat'l mm2 Solid Dia. Range Thk. (T) Width (W) Material 24-20 .020-.033 .012 .185 400-1100 Cu Ni 0.20-0.50 0.51-0.84 0.30 4.70 18-14 .040-.063 1600-4000 .018 .185 Tin Plated 0.80-2.00 1.02-1.60 0.46 4.70 CRS .084-.114 7000-13000 .024 .185 1112-9 Brass 4.00-6.50 2.13-2.90 0.61 4.70 076 1601669-1 L076E18TCRS L200/ 202E24B 200/202 1601768-1 Toolset Part Number 032/036 1601550-1 032/036 1601551-1 032/036 1601797-1 032/036 1601798-1 Descriptive X-ref L032/ 036D12B L032/ 036D16A P032/ 036D16B P032/ 036D16TB 045 1601572-1 L045D12B 045 1601573-1 L045D16A 7 Ridges T W AWG/ Wire Range mm2 Solid Dia. 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 22-19 .024-.036 0.38-0.60 0.61-0.91 22-19 .024-.036 0.38-0.60 0.61-0.91 CMA Range 400-1100 400-1100 400-1100 400-1100 600-1300 600-1300 Stock Mat'l Material Thk. (T) Width (W) .012 .154 Brass 0.30 3.91 .016 .154 Cu Ni 0.41 3.91 .016 .154 Brass 0.41 3.91 .016 .154 Tin Plated 0.41 3.91 Brass .012 .154 Brass 0.30 3.91 .016 .154 Cu Ni 0.41 3.91 76 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 RTM Crimpband Splices (Continued) 7 Ridges (Continued) T W CMA Range 600-1300 800-1500 800-1500 800-1500 800-1500 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 1100-3200 1200-3700 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 Stock Mat'l Part Toolset Thk. (T) Width (W) Material Number .016 .154 Brass 045 1601507-1 0.41 3.91 .012 .154 Brass 051 1601587-1 0.30 3.91 .016 .154 Brass 051 1601588-1 0.41 3.91 .020 .154 Nickel Plated 051 1601591-1 0.51 3.91 Steel .020 .154 Tin Plated 051 1601811-1 0.51 3.91 CRS .012 .154 Cu Ni 061 1601818-1 0.30 3.91 .012 .154 Brass 061 1601620-1 0.30 3.91 .012 .154 Tin Plated 061 1601514-1 0.30 3.91 Brass .016 .154 Cu Ni 061 1601819-1 0.41 3.91 .016 .154 Brass 061 1601820-1 0.41 3.91 .016 .154 Tin Plated 061 1601623-1 0.41 3.91 Brass .018 .154 Brass 061 1601625-1 0.46 3.91 .018 .154 Tin Plated 061 1601628-1 0.46 3.91 Brass .020 .154 Cu Ni 061 1601629-1 0.51 3.91 .020 .154 Brass 061 1601630-1 0.51 3.91 .020 .154 Tin Plated 061 1601631-1 0.51 3.91 Brass .016 .154 Brass 061/076 1601601-1 0.41 3.91 .016 .154 Brass 061/092 1601603-1 0.41 3.91 .012 .154 Cu Ni 076 1601828-1 0.30 3.91 .012 .154 Brass 076 1601655-1 0.30 3.91 .016 .154 Cu Ni 076 1601656-1 0.41 3.91 .016 .154 Brass 076 1601829-1 0.41 3.91 .016 .154 Tin Plated 076 1601658-1 0.41 3.91 Brass .018 .154 Cu Ni 076 1601660-1 0.46 3.91 .018 .154 Brass 076 1601661-1 0.46 3.91 .018 .154 Tin Plated 076 1601664-1 0.46 3.91 Brass .020 .154 Brass 076 1601665-1 0.51 3.91 .020 .154 076 1601667-1 0.51 3.91 .024 .154 Brass 076 1601668-1 0.61 3.91 Descriptive X-ref G045D16B L051D12B L051D16B L051D20NPS P051D20TCRS P061D12A L061D12B G061D12TB P061D16A P061D16B L061D16TB L061D18B L061D18TB L061D20A Crimpband AWG/ Wire Range mm2 Solid Dia. 22-19 .024-.036 0.38-0.60 0.61-0.91 1 .028-.039 21-18 2 0.40-0.75 0.71-0.99 .028-.039 21-1812 0.40-0.75 0.71-0.99 .028-.039 21-1812 0.40-0.75 0.71-0.99 .028-.039 21-1812 0.40-0.75 0.71-0.99 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 20-15 .033-.057 0.60-1.60 0.84-1.45 .035-.061 1912-1412 0.60-1.80 0.89-1.54 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 L061D20B L061D20TBX L061/076D16B L061/092D16B P076D12A L076D12B L076D16A P076D16B L076D16TB L076D18AX L076D18B L076D18TB L076D20B L076D20TCRS L076D24B These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 77 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 RTM Crimpband Splices (Continued) 7 Ridges (Continued) T W AWG/ Wire Range mm2 Solid Dia. 1 17 2-13 .042-.068 0.95-2.54 1.07-1.80 .047-.072 1612-13 1.10-2.60 1.19-1.83 .047-.072 1612-13 1.10-2.60 1.19-1.83 .047-.072 1612-13 1.10-2.60 1.19-1.83 .047-.072 1612-13 1.10-2.60 1.19-1.83 .047-.072 1612-13 1.10-2.60 1.19-1.83 .047-.072 1612-13 1.10-2.60 1.19-1.83 .047-.072 1612-13 1.10-2.60 1.19-1.83 16-12 .051-.078 1.30-3.46 1.29-1.98 16-12 .051-.078 1.30-3.46 1.29-1.98 16-12 .051-.078 1.30-3.46 1.29-1.98 .055-.082 1512-12 1.54-3.46 1.40-2.10 .055-.082 1512-12 1.54-3.46 1.40-2.10 .055-.082 1512-12 1.54-3.46 1.40-2.10 .055-.082 1512-12 1.54-3.46 1.40-2.10 .055-.082 1512-12 1.54-3.46 1.40-2.10 .055-.082 1512-12 1.54-3.46 1.40-2.10 .055-.082 1512-12 1.54-3.46 1.40-2.10 .059-.087 1412-1112 1.80-4.00 1.50-2.21 .059-.087 1412-1112 1.80-4.00 1.50-2.21 .059-.087 1412-1112 1.80-4.00 1.50-2.21 .059-.087 1412-1112 1.80-4.00 1.50-2.21 14-11 .063-.092 2.00-4.20 1.60-2.34 14-11 .063-.092 2.00-4.20 1.60-2.34 .071-.097 1312-1012 2.54-4.50 1.70-2.46 .084-.114 1112-9 4.00-6.50 2.13-2.90 .084-.114 1112-9 4.00-6.50 2.13-2.90 .084-.114 1112-9 4.00-6.50 2.13-2.90 .084-.114 1112-9 4.00-6.50 2.13-2.90 CMA Range 1800-4600 2200-5200 2200-5200 2200-5200 2200-5200 2200-5200 2200-5200 2200-5200 2600-6100 2600-6100 2600-6100 3000-6750 3000-6750 3000-6750 3000-6750 3000-6750 3000-6750 3000-6750 3500-7500 3500-7500 3500-7500 3500-7500 4000-8500 4000-8500 4500-9500 7000-13000 7000-13000 7000-13000 7000-13000 Stock Mat'l Thk. (T) Width (W) .016 .154 0.41 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .018 .154 0.46 3.91 .018 .154 0.46 3.91 .018 .154 0.46 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .016 .154 0.41 3.91 .018 .154 0.46 3.91 .018 .154 0.46 3.91 .018 .154 0.46 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .018 .154 0.46 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .016 .154 0.41 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 Material Toolset Part Number Descriptive X-ref L076/ 092D16BX Brass 076/092 1601642-1 Cu Ni 092 1601689-1 L092D16ASP Brass 092 1601691-1 L092D16B Tin Plated Brass 092 1601693-1 L092D16TB Cu Ni 092 1601694-1 L092D18A Brass 092 1601695-1 L092D18B Tin Plated Brass 092 1601841-1 P092D18TB Brass 092 1601528-1 G092D20B Cu Ni 092/125 1601680-1 Brass 092/125 1601681-1 Tin Plated CRS 092/125 1601682-1 L092/ 125D20A L092/ 125D20B 092/ 125D20TCRS Brass 125 1601529-1 G125D16B Cu Ni 125 1601531-1 G125D18A Brass 125 1601726-1 L125D18B Tin Plated Brass 125 1601729-1 L125D18TBX Brass 125 1601730-1 L125D20B Tin Plated Brass 125 1601731-1 L125D20TB 125 1601733-1 L125D20TCRS Tin Plated Brass 125/165 1601709-1 Brass 125/165 1601711-1 Tin Plated Brass 125/165 1601712-1 L125/ 165D18TB L125/ 165D20A L125/ 165D20B L125/ 165D20TB Cu Ni 125/165 1601710-1 Cu Ni 165 1601754-1 L165D20A Brass 165 1601755-1 L165D20B Brass 165/200 1601532-1 Brass 200/202 1601764-1 Cu Ni 200/202 1601765-1 Brass 200/202 1601852-1 Tin Plated Brass 200/202 1601766-1 G165/ 200D20B L200/ 202D16B L200/ 202D20A P200/ 202D20B L200/ 202D20TB These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 78 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 RTM Crimpband Splices (Continued) 6 Ridges T W CMA Range 400-1100 400-1100 600-1300 600-1300 600-1300 800-1500 800-1500 800-1500 800-1500 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 1100-3200 1100-3200 1100-3200 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1800-4600 2200-5200 2200-5200 3000-6750 3000-6750 3000-6750 Stock Mat'l Thk. (T) Width (W) .012 .138 0.30 3.51 .016 .138 0.41 3.51 .012 .138 0.30 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .012 .138 0.30 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .018 .138 0.46 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .018 .138 0.46 3.51 .018 .138 0.46 3.51 .020 .138 0.51 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .018 .138 0.46 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .018 .138 0.46 3.51 .018 .138 0.46 3.51 .018 .138 0.46 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .018 .138 0.46 3.51 .018 .138 0.46 3.51 Material Toolset Part Number Tin Plated Brass 032/036 1601548-1 Brass 032/036 1601549-1 Descriptive X-ref L032/ 036C12TB L032/ 036C16B Brass 045 1601566-1 L045C12B Cu Ni 045 1601569-1 L045C16A Brass 045 1601571-1 L045C16B Brass 051 1601808-1 P051C12B Cu Ni 051 1601809-1 P051C16A Brass 051 1601810-1 P051C16B Brass 051 1601586-1 L051C18B Cu Ni 061 1601614-1 L061C16A Brass 061 1601511-1 G061C16B Tin Plated Brass 061 1601617-1 L061C16TB Cu Ni 061 1601618-1 L061C18AX Brass 061 1601619-1 L061C18B Brass 061 1601513-1 G061C20B Brass 061/076 1601597-1 Tin Plated Brass 061/076 1601599-1 Brass 061/076 1601600-1 L061/ 076C16B L061/ 076C16TB L061/ 076C18B Cu Ni 076 1601650-1 L076C16A Brass 076 1601651-1 L076C16B Cu Ni 076 1601652-1 L076C18A Brass 076 1601827-1 P076C18B 076 1601654-1 L076C18TCRS Brass 076/092 1601640-1 L076/ 092C16B Cu Ni 092 1601837-1 P092C16AX Brass 092 1601687-1 L092C16B Tin Plated Brass 125 1601721-1 L125C16TB Cu Ni 125 1601722-1 L125C18A Brass 125 1601723-1 L125C18B Crimpband AWG/ Wire Range mm2 Solid Dia. 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 22-19 .024-.036 0.38-0.60 0.61-0.91 22-19 .024-.036 0.38-0.60 0.61-0.91 22-19 .024-.036 0.38-0.60 0.61-0.91 .028-.039 21-1812 0.40-0.75 0.71-0.99 .028-.039 21-1812 0.40-0.75 0.71-0.99 .028-.039 21-1812 0.40-0.75 0.71-0.99 .028-.039 21-1812 0.40-0.75 0.71-0.99 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 20-15 .033-.057 0.60-1.60 0.84-1.45 20-15 .033-.057 0.60-1.60 0.84-1.45 20-15 .033-.057 0.60-1.60 0.84-1.45 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 .042-.068 1712-13 0.95-2.54 1.07-1.80 .047-.072 1612-13 1.10-2.60 1.19-1.83 .047-.072 1612-13 1.10-2.60 1.19-1.83 .055-.082 1512-12 1.54-3.46 1.40-2.10 .055-.082 1512-12 1.54-3.46 1.40-2.10 .055-.082 1512-12 1.54-3.46 1.40-2.10 These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 79 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 RTM Crimpband Splices (Continued) 3 Ridges T W AWG/ Wire Range mm2 Solid Dia. 1 .013-.028 27 2-21 0.09-0.40 0.33-0.71 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 22-19 .024-.036 0.38-0.60 0.61-0.91 22-19 .024-.036 0.38-0.60 0.61-0.91 22-19 .024-.036 0.38-0.60 0.61-0.91 22-19 .024-.036 0.38-0.60 0.61-0.91 .028-.039 21-1812 0.40-0.75 0.71-0.99 .028-.039 21-1812 0.40-0.75 0.71-0.99 .028-.039 21-1812 0.40-0.75 0.71-0.99 .028-.039 21-1812 0.40-0.75 0.71-0.99 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 .030-.051 2012-16 0.45-1.30 0.76-1.29 20-15 .033-.057 0.60-1.60 0.84-1.45 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 CMA Range Stock Mat'l Thk. (T) Width (W) .012 .076 170-800 0.30 1.93 .012 .076 400-1100 0.30 1.93 .012 .076 400-1100 0.30 1.93 .016 .076 400-1100 0.41 1.93 .016 .076 400-1100 0.41 1.93 .018 .076 400-1100 0.46 1.93 .016 .076 600-1300 0.41 1.93 .016 .076 600-1300 0.41 1.93 .016 .076 600-1300 0.41 1.93 .016 .076 600-1300 0.41 1.93 .016 .076 800-1500 0.41 1.93 .016 .076 800-1500 0.41 1.93 .016 .076 800-1500 0.41 1.93 .020 .076 800-1500 0.51 1.93 .016 .076 900-2600 0.41 1.93 .016 .076 900-2600 0.41 1.93 .016 .076 900-2600 0.41 1.93 .016 .076 900-2600 0.41 1.93 .016 .076 1100-3200 0.41 1.93 .016 .076 1600-4000 0.41 1.93 .020 .076 1600-4000 0.51 1.93 Material Toolset Part Number Descriptive X-ref Brass 032 1601555-1 L032B12B Cu Ni 032/036 1601542-1 Brass 032/036 1601795-1 Brass 032/036 1601545-1 Tin Plated Brass 032/036 1601546-1 Brass 032/036 1601547-1 L032/ 036B12A P032/ 036B12B L032/ 036B16B L032/ 036B16TB L032/ 036B18B Cu Ni 045 1601503-1 G045B16A Brass 045 1601562-1 L045B16B 045 1601504-1 G045B16TB 045 1601564-1 L045B16TBSP Cu Ni 051 1601580-1 L051B16A Brass 051 1601582-1 L051B16B Tin Plated Brass 045 1601583-1 L051B16TB Tin Plated Brass Tin Plated Brass Brass 051 1601584-1 L051B20B Tin Plated Brass 061 1601612-1 L061B16TB Cu Ni 061 1601610-1 L061B16A Brass 061 1601611-1 L061B16B Brass 061 1601635-1 L061L16B Tin Plated Brass 061/076 1601596-1 L061/ 076B16TBX Brass 076 1601825-1 P076B16B Brass 076 1601649-1 L076B20B These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 80 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Crimpband Application Tooling 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 Mod I 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. Crimpband 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. Mod III Tooling and Equipment Selector Volume To Be Crimped CMA in2/mm2 .003-.016 140-800 0.07 - 0.40 .008-.024 400-1200 0.20 - 0.60 .012-.032 600-1600 0.30 - 0.81 .018-.052 900-2600 0.45 - 1.31 .032-.080 1600-4000 0.81 - 2.02 .044-.104 2200-5200 1.11 - 2.63 .060-.135 3000-6750 1.52 - 3.42 .080-.170 4000-8500 2.02 - 4.31 .010-.219 5000-11000 2.53 - 5.57 .120-.259 6000-13000 3.04 - 6.58 Recommended Equipment Toolset Size Machine 032 Mod I 032/036 Mod I 045 Mod I 061 Mod I 076 Mod I 092 Mod I 125 Mod I 165 Mod III 200 Mod III 200/202 Mod III 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. 81 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems 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 -- individually 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 insulation 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 performance in a low-cost reliable termination Applications Transformers Coil windings Motors Regulators 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 insulation displacement crimp configuration and an integral 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 highdensity hole pattern of the sleeve. The crimp shears the film insulation and the conductor extrudes into the perforated sleeve, producing a hermetic seal. These terminations 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 provides a robust interface which optimizes the mechanical properties (tensile strength, vibration, resistance, flex life) of the electrical crimp. The insulation 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 regarding size, number and total CMA of conductors being terminated are observed. Cross Section of Insulation Piercing Crimp 82 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 COPALUM Terminals and Splices (For Solid and Stranded Aluminum or Copper Wire) (Continued) General Application Guidelines To assist you in obtaining the optimum COPALUM insulation piercing crimp termination for solid copper, solid aluminum and stranded copper in the same wire barrel, the following guidelines regarding size, number and total CMA of conductors 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 insulation removal. 2. Four rectangular wires (where T 1/4W) or 2 rectangular wires (where T 1/4W) may be crimped without insulation 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 Test Results of Insulation Piercing Crimp Terminations Current Cycling -- 100 cycles @ 35 amperes, AC; each cycle consisting of 15 min. "on current" and 15 min. "off current" 5. To use a butt splice when the lead wire CMA is the combined magnet wire CMA. connector. In instances where 7 or more equal round conductors or a combination of solid aluminum and stranded copper is used, and the total CMA is at least 50% of the maximum CMA of the next larger size connector, this larger size connector may be used. 6. In a solid (or combination of solids) aluminum and stranded copper application, the maximum amount of CMA fill for the copper conductor should not exceed 40% of the total CMA being crimped. 8. For applications using wire combinations not covered by guidelines above, consult Tyco Electronics Engineering. 7. Due to the closed barrel, it may not be possible for a particular CMA loading to fit in the normally recommended Warning: Not approved for reconnection of residential aluminum branch circuit wiring. (Refer to Catalog 82205.) 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. Typical Millivolt Drop (Current Cycling/Thermal Shock) Performance 3.5 MAX. INDIVIDUAL CONNECTOR READINGS AVG. INDIVIDUAL CONNECTOR READINGS 3.0 MIN. INDIVIDUAL CONNECTOR READINGS 2.5 2.0 INITIAL 301430114 AFTER CURRENT CYCLING AFTER 5 CYCLES SHOCK AFTER 10 CYCLES SHOCK AFTER 15 CYCLES SHOCK Technical Documents Test Reports -- Product Specification -- 110-13506 -- Copper lead wire to aluminum magnet wire in a COPALUM parallel splice 502-1084 -- COPALUM butt splice performance in several copper lead wire to copper magnet wire combinations 108-13013 Application Specification -- 114-02121 COPALUM VOLTAGE DROP IN MILLIVOLTS Thermal Shock -- 0.5 hr. @ +150C and 0.17 hr. in ice water per cycle; 5 amperes, DC sum of the magnet wire CMA, and the total number of conductors (lead and magnet) must be less than six. AFTER 20 CYCLES SHOCK AFTER 25 CYCLES SHOCK 502-1085 -- Performance comparison: COPALUM butt splice vs. brazing process 83 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 COPALUM Terminals and Splices (For Solid and Stranded Aluminum or Copper Wire) (Continued) 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 [mm2] Circular Mils Aluminum Copper 16-14 18-16 [1.25] [0.8] 2050-5180 1290-3260 12-10 14-12 [5.0] [3.0] 5180-13100 3260-8230 L Dim. L Max. Part Numbers Heads for Pneumatic Tools 626 Tooling 68068 Hand Tool .701 17.81 68140-1 189447-1 68100 52001 .799 20.29 68141-1 189444-1 68100 68101 52004 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 [mm2] Circular Mils Aluminum 8 [8.0] 13100-20800 6 [14] 20800-33100 4 [21] 33100-52600 2 [35] 52600-83700 1/0 [50] 83700-119500 2/0 [70] 119500-150500 3/0 [85] 150500-190000 4/0 [105] 190000-231000 Copper 12-10 [5.0] 5180-13100 8 [8.0] 13100-20800 6 [14] 20800-33100 4 [21] 33100-52600 2 [35] 52600-83700 1/0 [50] 83700-119500 2/0 [70] 119500-150500 3/0 [85] 150500-190000 Splice L Part Numbers Dim. L Max. Heads for Pneumatic Tools 626 Tooling 69015 68068 Tooling for Power Unit 69120 Head Die Insert Splice 1.195 30.35 662546-1 68081 68101-1 68192-1 69099 68084 51826 1.340 34.04 -- 68082 68102-1 69099 68085 51941 1.630 41.4 -- 68038 -- 69099 68086 51942 1.995 50.67 -- -- -- 69099 68130 52007 1.985 50.42 -- -- -- 69099 68131 52010 1.985 50.42 -- -- -- 69099 68132 52013 1.985 50.42 -- -- -- 69099 68133 52016 1.985 50.42 -- -- -- 69082 68129 52019 84 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 COPALUM Terminals and Splices (For Solid and Stranded Aluminum or Copper Wire) (Continued) 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 Wire Size [mm2] Circular Mils 16-14 [1.25] 2050-5180 12-10 [5.0] 5180-13100 8 [8.0] 13100-20800 6 [14] 20800-33100 4 [21] 33100-52600 2 [35] 52600-83700 1/0 [50] 83700-119500 2/0 [70] 11950-150500 3/0 [85] 150500-190000 4/0 [105] 190000-231000 Dim. L Max. L Part Numbers Hand Tool 69015 Heads for Pneumatic Tools 626 Tooling 68068 Tooling for Power Unit 69120 Head Die Insert Splice .283 7.19 68140-1 -- 189447-1 68100 -- -- 52791 .375 9.53 68141-1 -- 189444-1 68100 68101 -- -- 52792 .437 11.1 -- 68081 662546-1 68101-1 68192-1 69099 68084 52745 .450 11.43 -- 68082 -- 68102 69099 68085 52746 .562 14.27 -- 68038 -- -- 69099 68086 52747 .781 19.84 -- -- -- -- 69099 68130 52748 .734 18.64 -- -- -- -- 69099 68131 52749 .734 18.64 -- -- -- -- 69099 68132 52750 .749 19.02 -- -- -- -- 69099 68133 52751 .765 19.43 -- -- -- -- 69082 68129 52752 COPALUM Important: When two or more wires are used in a parallel splice, the combined cross-section area must be within the CMA range listed. 85 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 COPALUM Terminals and Splices (For Solid and Stranded Aluminum or Copper Wire) (Continued) 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 C E L W C Min. Hand Tool .531 13.49 1.107 28.12 .839 21.31 .564 14.33 68140-1 189447-1 68100 .375 9.53 .375 9.53 .375 9.53 .375 9.53 .593 15.06 .593 15.06 .835 21.21 .835 21.21 .835 21.21 .835 21.21 1.173 29.79 1.173 29.79 .645 16.38 .645 16.38 .645 16.38 .645 16.38 .874 22.20 .874 22.20 .302 7.67 .302 7.67 .302 7.67 .302 7.67 .531 13.49 .531 13.49 -1 68141-1 189444-1 1 68141-1 189444-1 1 68141-1 189444-1 -1 68141-1 189444-1 1 68141-1 189444-1 -1 68141-1 189444-1 68100 68101 68100 68101 68100 68101 68100 68101 68100 68101 68100 68101 Tongue Thickness Max. Stud Size W 16-14 [1.25] 2050-5180 .033 0.84 1/4 M6 .042 1.07 6 M3.5 8 M4 10 -- 1/4 M6 1/4 M6 5/16 M8 12-10 [5.0] 5180-13100 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 Wire Size Tongue [mm2] Thickness Circular Mils Max. 8 [8.0] 13100-20800 6 [14] 20800-33100 .048 1.22 .051 1.30 Stud Size 10 -- 1/4 M6 5/16 M8 10MM -- 10 -- 1/4 M6 5/16 M8 3/8 -- 10MM -- Part Numbers Heads for Pneumatic Tools 626 Tooling 68068 Dimensions L E Max. Max. Wire Size [mm2] Circular Mils Terminal 52587-1 51979-1 51979-1 51979-2 51979-3 52590-1 52590-2 R E L W W .500 12.70 .500 12.70 .625 15.88 .625 15.88 .500 12.70 .500 12.70 .679 17.25 .679 17.25 .679 17.25 Dimensions L E Max. Max. R Max. 1.384 35.15 1.384 35.15 1.446 36.73 1.446 36.73 1.415 35.94 1.415 35.94 1.504 38.20 1.504 38.20 1.504 38.20 .560 14.22 .560 14.22 .560 14.22 .560 14.22 .580 14.73 .580 14.73 .580 14.73 .580 14.73 .580 14.73 1.131 28.73 1.131 28.73 1.131 28.73 1.131 28.73 1.162 29.51 1.162 29.51 1.162 29.51 1.162 29.51 1.162 29.51 Part Numbers Heads for Heads & Die Inserts Pneumatic Tools for Power Unit 69120 626 Tooling 69015 68068 Head Die Insert 68101-1 68081 69099 68084 662546-1 68192-1 68101-1 68081 69099 68084 662546-1 68192-1 68101-1 68081 69099 68084 662546-1 68192-1 68101-1 68081 69099 68084 662546-1 68192-1 Terminal 150720-1 1 50720-1 150720-2 184076-1 -- 68082 68102 69099 68085 150719-1 -- 68082 68102 69099 68085 1 50719-1 -- 68082 68102 69099 68085 150719-2 -- 68082 68102 69099 68085 150719-3 -- 68082 68102 69099 68085 184079-1 86 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems 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 Wire Size [mm2] Circular Mils 4 [21] 33100-52600 2 [35] 52600-83700 2/0 [70] 119500-150500 3/0 [85] 150500-190000 4/0 [105] 190000-231000 .060 1.52 .060 1.52 .073 1.85 .083 2.11 .094 2.39 .105 2.67 L W Stud Size W 10 -- 1/4 M6 5/16 M8 3/8 -- 1/2 -- 10MM -- 1/4 M6 5/16 M8 3/8 -- 1/2 -- 10MM -- 1/4 M6 5/16 M8 3/8 -- 1/2 -- 10MM -- 5/16 M8 3/8 -- 1/2 -- 10MM -- 7/16 -- 1/2 -- 10MM -- 1/2 -- 10MM -- .531 13.49 .531 13.49 .531 13.49 .675 17.15 .675 17.15 .675 17.15 .675 17.15 .675 17.15 .675 17.15 .807 20.50 .807 20.50 .675 17.15 .675 17.15 .675 17.15 .807 20.50 .807 20.50 .926 23.52 .926 23.52 .926 23.52 .926 23.52 1.020 25.91 1.020 25.91 1.020 25.91 1.087 27.61 1.087 27.61 Dimensions L E Max. Max. R Max. 1.630 41.40 1.630 41.40 1.630 41.40 1.702 43.23 1.702 43.23 1.702 43.23 1.859 47.22 1.859 47.22 1.859 47.22 1.925 48.90 1.925 48.90 1.859 47.22 1.859 47.22 1.859 47.22 1.925 48.90 1.925 48.90 1.930 49.02 1.930 49.02 1.930 49.02 1.930 49.02 2.112 53.64 2.112 53.64 2.112 53.64 2.178 55.32 2.178 55.32 .625 15.88 .625 15.8 .62 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 1.362 34.59 1.362 34.59 1.362 34.59 1.362 34.59 1.362 34.59 1.362 34.59 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.560 39.62 1.560 39.62 1.560 39.62 1.560 39.62 1.645 41.66 1.645 41.66 1.645 41.66 1.676 42.57 1.676 42.57 Part Numbers Heads & Die Inserts for Power Unit 69120 Head Die Insert Terminal 69099 68086 150717-1 69099 68086 150717-1 69099 68086 150717-2 69099 68086 150717-3 69099 68086 150717-5 69099 68086 184082-1 69099 68130 151982-1 69099 68130 151982-1 69099 68130 151982-2 69099 68130 151982-3 69099 68130 184084-1 69099 68131 151986-1 69099 68131 151986-1 69099 68131 151986-2 69099 68131 151986-3 69099 68131 184087-1 69099 68132 1 51989-1 69099 68132 151989-2 69099 68132 151989-3 69099 68132 184090-1 69099 68133 1 51992-2 69099 68133 1 51992-3 69099 68133 184092-1 69082 68129 69082 68129 COPALUM 1/0 [50] 83700-119500 Tongue Thickness Max. R E 151995-2 184094-1 87 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 COPALUM Application Tooling 626 Pneumatic Tool System 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. Power Unit Style Hand Actuated Foot Actuated Power Unit Part Number 189721-1* 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 356302-1 w/o Ratchet Control 189767-1 Crimp Heads AWG 16-14 12-10 8 Part Number 189447-1 189444-1 602546-1 Bench Mount Assembly Part Number 856402-1* Fully adjustable stand allows operator free use of both hands -- recommended for maximum productivity. 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 88 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 COPALUM Application Tooling (Continued) DYNA-CRIMP ElectricHydraulic Power Units, 69120-1, -2, plus Heads 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 footactuation switch, and hose/coupling assemblies up to 28 ft [8.5 m] in length. 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. Accessories for DYNA-CRIMP Power Units 69120-1 (115 V) or 69120-2 (230 V) Accessory Part No. Description 59907-7 1-59907-5 2-59907-1 2-59908-1 2-59907-8 68284-1 59909-3 59909-7 1-59909-5 2-59909-1 59220 59220-2 7 ft. [2.13m] Handle Control Assembly -- Hose and Cord* 15 ft. [4.57m] Handle Control Assembly -- Hose and Cord* 21 ft. [6.4m] Handle Control Assembly -- Hose and Cord* 21 ft. [6.4 m] Handle Control Assembly -- Cord w/o Hose* 28 ft [8.53m] Handle Control Assembly -- Hose and Cord* 15 ft. [4.57m] Foot Switch Assembly (requires hose assembly) 3 ft [0.91m] Hose Assembly** 7 ft. [2.13m] Hose Assembly** 15 ft. [4.57m] Hose Assembly** 21 ft. [6.4m] Hose Assembly** 3-Way Multi-Directional Valve (for use with foot switch only) 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 Designed for medium production, these semi-automatic 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 terminating a variety of AMP products. COPALUM Pneumatic Power Units, 68068, 69015 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. 89 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Power Splice 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. Applications Hermetic/Compressor motors Squirrel Cage DC motors Capacitor Start motors Gear & Traction motors Power supplies Liner, Torroid & RF transformers Circuit breakers & welders 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. 90 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Technical Information Tensile Strength of Magnet Wire1 Wire Size 1 C. F. C. -80 -70 -60 -50 -45 -40 -35 -30 -25 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -09 -08 -07 -06 -05 -04 -03 -02 -01 0 1 2 4 5 6 7 8 -112.0 -94.0 -76.0 -58.0 -49.1 -40.0 -31.0 -22.0 -13.0 -04.0 -02.2 -00.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 8.4 30.2 32.0 33.8 35.6 39.2 41.0 42.8 44.6 46.4 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 42 43 44 45 46 F. 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 107.6 109.4 111.2 113.0 114.8 C. F. 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 80 81 82 83 84 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 176.0 177.8 179.6 181.4 183.2 C. 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 110 120 130 140 150 160 170 180 190 200 220 240 260 280 300 400 600 700 800 900 1000 F. 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 230.0 248.0 266.0 284.0 302.0 320.0 338.0 356.0 374.0 392.0 428.0 464.0 500.0 536.0 572.0 752.0 1112.0 1292.0 1472.0 1652.0 1832.0 C = 5/9 (F. - 32) F = 9/5C. + 32 Technical Information 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Nominal Nominal Dia. Dia. Copper Aluminum (lbs.) (lbs.) 438 142 340 113 269 89 213 71 189 56 134 44 106 35 84 28 66 22 53 17 42 14 33 11 6 8 21 7 16 5 13 4 10 3 8 2.7 6 2.1 5 1.7 4 1.3 3 1.1 2 .86 2 .68 1 .55 1 .43 1 .34 .81 .27 .65 .21 .65 .21 .42 .13 .32 .10 .25 .083 .20 .067 .16 .054 .12 .041 .10 .034 .08 .027 .06 .022 .05 .017 .04 .013 .03 .010 .02 .009 .02 .007 .01 .005 Magnet 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. 93 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Technical Information (Continued) Circular Mil Area (CMA) and Diameter for Magnet Wires (AWG Wire Size Range 52-251/2) AWG Bare Wire 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 35 34 33 32 31 301/2 30 291/2 29 281/2 28 271/2 27 261/2 26 251/2 Bare Wire Dia. in. mm .0008 .020 .0009 .023 .0010 .025 .0011 .028 .0012 .031 .0014 .035 .0016 .040 .0018 .045 .0020 .050 .0022 .056 .0025 0.06 .0028 0.07 .0031 0.08 .0035 0.09 .0040 0.10 .0045 0.11 .0050 0.13 .0056 0.14 .0056 0.14 .0063 0.16 .0071 0.18 .0080 0.20 .0089 0.23 .0095 0.24 .0100 0.25 .0107 0.27 .0113 0.29 .0120 0.30 .0126 0.32 .0134 0.34 .0142 0.36 .0151 0.38 .0159 0.40 .0169 0.43 CMA Bare 0.6 0.8 1.0 1.2 1.5 2.0 2.5 3.1 4.0 4.8 6.3 7.8 9.6 12.0 16.0 20.0 25.0 31.0 31.0 40.0 50.0 64.0 79.0 90.0 100.0 115.0 128.0 144.0 159.0 180.0 202.0 225.0 258.0 289.0 Single Film Coated Dia. in. mm .0010 .025 .0011 .028 .0012 .031 .0013 .033 .0014 .035 .0016 .040 .0017 .043 .0019 .048 .0022 .056 .0025 .063 .0028 0.07 .0031 0.08 .0035 0.09 .0039 0.10 .0045 0.11 .0050 0.13 .0056 0.14 .0062 0.16 .0062 0.16 .0069 0.18 .0077 0.20 .0084 0.21 .0092 0.23 .0099 0.25 .0106 0.27 .0114 0.29 .0120 0.30 .0126 0.32 .0136 0.35 .0144 0.37 .0152 0.39 .0160 0.41 .0170 0.43 .0180 0.46 CMA Single Film Coated 1.0 1.2 1.5 1.7 2.0 2.5 2.9 3.6 4.8 6.2 8.0 10.0 12.0 15.0 20.0 25.0 31.0 38.0 38.0 48.0 59.0 71.0 85.0 98.0 112.0 130.0 144.0 159.0 185.0 207.0 231.0 256.0 289.0 324.0 Heavy Film Coated Dia. in. mm .0011 .028 .0012 .031 .0013 .033 .0014 .035 .0015 .038 .0018 .045 .0019 .048 .0021 .053 .0025 .063 .0027 .069 .0030 0.08 .0034 0.09 .0038 0.10 .0043 0.11 .0049 0.12 .0055 0.14 .0060 0.15 .0067 0.17 .0067 0.17 .0075 0.19 .0085 0.22 .0095 0.24 .0105 0.27 .0111 0.28 .0116 0.29 .0123 0.31 .0130 0.33 .0137 0.35 .0144 0.37 .0153 0.39 .0161 0.41 .0170 0.43 .0179 0.45 .0190 0.48 CMA Heavy Film Coated 1.2 1.5 1.7 2.0 2.2 3.1 3.6 4.4 6.2 7.3 9.0 12.0 14.0 18.0 24.0 30.0 36.0 45.0 45.0 56.0 72.0 90.0 110.0 123.0 135.0 151.0 169.0 187.0 207.0 234.0 259.0 289.0 320.0 361.0 94 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Technical Information (Continued) Circular Mil Area (CMA) and Diameter for Magnet Wires (AWG Wire Size Range 25-8) AWG Bare Wire 25 241/2 24 231/2 23 221/2 22 211/2 21 201/2 20 191/2 19 181/2 18 171/2 17 161/2 16 151/2 15 141/2 14 131/2 13 121/2 12 111/2 11 101/2 10 9 8 Bare Wire Dia. in. mm .0179 0.45 .0190 0.48 .0201 0.51 .0214 0.54 .0226 0.57 .0240 0.61 .0253 0.64 .0269 0.68 .0285 0.72 .0303 0.77 .0320 0.81 .0340 0.86 .0359 0.91 .0381 0.97 .0403 1.02 .0428 1.09 .0453 1.15 .0481 1.22 .0508 1.29 .0540 1.37 .0571 1.45 .0606 1.54 .0641 1.63 .0681 1.73 .0720 1.83 .0764 1.94 .0808 2.05 .0858 2.18 .0907 2.30 .0963 2.35 .1019 2.59 .1144 2.91 .1285 3.26 CMA Bare 320 361 404 458 511 576 640 724 812 918 1,024 1,156 1,289 1,452 1,624 1,832 2,052 2,314 2,581 2,916 3,260 3,672 4,109 4,638 5,184 5,837 6,529 7,362 8,226 9,274 10,384 13,087 16,512 Single Film Coated Dia. in. mm .0190 0.48 .0200 0.51 .0213 0.54 .0226 0.57 .0238 0.60 .0252 0.64 .0266 0.68 .0282 0.72 .0298 0.76 .0315 0.80 .0334 0.85 .0353 0.90 .0373 0.95 .0395 1.00 .0418 1.06 .0443 1.13 .0468 1.19 .0496 1.26 .0524 1.33 .0560 1.42 .0587 1.49 .0622 1.58 .0658 1.67 .0698 1.77 .0738 1.87 .0783 1.99 .0827 2.10 .0877 2.23 .0927 2.35 .0983 2.50 .1040 2.64 .1166 2.96 .1307 3.32 CMA Single Film Coated 361 400 455 511 566 635 708 795 888 992 1,116 1,246 1,391 1,560 1,747 1,962 2,190 2,460 2,746 3,136 3,446 3,869 4,330 4,872 5,446 6,131 6,839 7,691 8,593 9,663 10,820 13,600 17,080 Heavy Film Coated Dia. in. mm .0200 0.51 .0212 0.54 .0223 0.57 .0236 0.60 .0249 0.63 .0263 0.67 .0277 0.70 .0293 0.74 .0310 0.79 .0328 0.83 .0346 0.88 .0365 0.93 .0386 0.98 .0409 1.04 .0431 1.09 .0456 1.16 .0482 1.22 .0510 1.30 .0583 1.37 .0570 1.45 .0602 1.53 .0639 1.62 .0675 1.71 .0711 1.81 .0749 1.90 .0793 2.01 .0838 2.13 .0888 2.26 .0938 2.38 .0994 2.52 .1050 2.67 .1177 2.99 .1318 3.35 CMA Heavy Film Coated 400 449 497 557 620 692 767 858 961 1,076 1,197 1,340 1,490 1,673 1,858 2,079 2,323 2,601 2,894 3,249 3,624 4,082 4,556 5,055 5,670 6,188 7,090 7,885 8,892 9,880 11,151 13,971 17,530 Technical Information 95 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Technical Information (Continued) Circular Mil Area (CMA) and Diameter for Lead Wires (AWG Wire Size Range 30-8) Wire Size 30 30 28 28 28 27 27 26 26 26 26 26 26 26 26 26 AN 25 25 25 24 24 24 24 24 24 24 24 24 24 AN 23 23 23 -- 22 22 22 22 22 22 22 AN 20 20 20 20 20 AN 18 -- 18 18 18 18 Strands No. Dia. (Mils) 7 1 7 19 1 7 1 6 10 16 8 1 26 7 3 12 10 8 1 10 8 16 4 1 26 13 7 56 19 10 8 1 21 6 8 16 10 1 7 19 10 1 26 7 19 19 16 1 7 65 7 4.0 10.0 5.0 3.1 12.6 5.6 14.2 6.3 5.0 4.0 5.6 15.9 3.1 6.3 10.0 5.0 5.6 6.3 17.9 6.3 7.1 5.0 10.0 20.1 4.0 5.6 8.0 2.8 5.0 7.1 8.0 22.6 5.0 10.0 8.9 6.3 8.0 25.3 10.0 6.3 10.0 10.0 6.3 12.6 7.9 9.2 10.0 40.3 15.2 5.0 15.3 Wire Area in Circ. Mils 112 100 175 181 159 219 202 238 250 256 251 253 250 278 300 300 314 318 320 397 403 400 400 404 416 408 448 439 475 504 512 511 525 600 634 635 640 640 700 754 1,000 1,024 1,032 1,111 1,186 1,608 1,600 1,624 1,617 1,625 1,639 Wire Size -- -- 18 AN 18 AN 16 16 16 16 16 -- 16 14 AN 14 14 14 14 -- 14 14 14 -- 12 12 AN 12 12 12 12 12 12 12 10 -- 10 10 10 10 10 -- 10 9 9 9 8 8 8 8 8 8 8 8 AN Strands No. 41 7 19 19 7 1 65 19 105 26 7 19 37 7 19 1 41 105 168 84 7 19 19 259 19 7 37 1 165 84 7 37 414 37 1 7 19 41 105 7 1 525 7 133 37 1 7 19 49 133 Dia. (Mils) 6.3 16.0 10.0 11.3 19.2 50.8 6.3 11.7 5.0 10.0 20.0 14.2 10.5 24.2 14.7 64.4 10.0 6.3 5.0 71 25.3 17.9 17.9 5.0 18.5 30.5 13.3 80.8 6.3 8.9 36.0 16.0 5.0 16.7 101.9 38.5 23.4 15.9 10.0 43.0 114.4 5.0 45.0 11.1 21.1 128.5 48.6 29.5 18.4 11.3 Wire Area in Circ. Mils 1,627 1,792 1,900 2,426 2,580 2,581 2,580 2,601 2,625 2,600 2,800 3,831 4,079 4,099 4,106 4,109 4,100 4,167 4,200 4,234 4,481 6,088 6,088 6,475 6,503 6,512 6,545 6,529 6,549 6,654 9,072 9,472 10,350 10,319 10,384 10,376 10,404 10,365 10,500 12,943 13,087 13,125 14,175 16,386 16,472 16,512 16,533 16,534 16,589 16,982 96 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Terminal Stud Hole Size The chart shows sizes and dimensions of various studs and the corresponding terminal stud hole sizes used with AMP devices. Use to Select Proper Size Terminal Stud Size U.S. Cust. Metric Stud Dia. Minimum Terminal Hole Diameter #0 .060 .064 #1 .073 .077 .086 .090 #3 .099 .103 #4 .112 .116 #2 M2 #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 .375 .385 7/16" .437 .448 1/2" M12 .500 Stud Size U.S. Cust. Metric Terminal stud hole sizes may easily be checked by fitting sample terminal to black circle. Stud Dia. Minimum Terminal Hole Diameter .625 .651 .750 .776 .875 .901 1" 1.000 1.026 1-1/8" 1.125 1.151 1-1/4" 1.250 1.276 5/8" M16 3/4" 7/8" M22 Technical Information 3/8" For example, with stud #5 (.125 [3.18] Diameter), use AMP device listed for #5 stud (.129 [3.28] Hole Diameter). .510 97 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Part Number Index 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. Part No. 41765 41766 41770 41899 41900 41904 42076 42119 42192 42776 42778 42779 42780 50717 50719 50720 51826 51941 51942 51979 51982 51986 51989 51992 51995 52001 52004 52007 52010 52013 52016 52019 52587 52590 52745 52746 52747 52748 52749 52750 52751 52752 52791 52792 60177 60318 60319 60320 60321 60322 60323 60325 60384 60385 60752 61074 61151 61166 61440 61442 61603 61604 Page 50 50 50 50 50 50 50 50 50 50 50 50 50 87 86 86 84 84 84 86 87 87 87 87 87 84 84 84 84 84 84 84 86 86 85 85 85 85 85 85 85 85 85 85 57 53 53 53 53 53 53 53 56 56 54 50 54 51 55 55 55 55 Part No. 61710 62000 62001 62002 62040 62044 62069 62080 62131 62157 62194 62200 62201 62243 62244 62295 62303 62304 62305 62306 62307 62308 62309 62310 62311 62341 62381 62420 62429 62430 62431 62438 62439 62445 62447 62458 62459 62511 62512 62513 62514 62524 62526 62527 62600 62606 62608 62609 62610 62651 62652 62653 62655 62656 62657 62658 62661 62663 62665 62666 62670 62678 Page 54 49 49 49 49 51 56 56 60 49 51 49 49 62 62 49 49 49 49 49 49 49 49 49 49 51 58 5 5 11 5 11 11 55 55 9 9 17 17 17 17 5 5 5 20 26 10 10 10 20 20 20 20 20 20 20 17 17 9 9 51 17 Part No. 62743 62755 62766 62780 62781 62816 62833 62835 62841 62842 62874 62888 62895 62896 62897 62898 62903 62904 62912 62922 62923 62928 62934 62935 62938 62939 62958 62992 63005 63018 63026 63027 63036 63039 63041 63044 63055 63062 63063 63064 63087 63107 63108 63109 63110 63128 63132 63133 63136 63140 63145 63147 63155 63159 63160 63161 63165 63177 63178 63199 63200 63203 Page 18 53 8 26 26 27 5 53 5 5 11 18 7 7 7 7 8 17 5 55 21 10 11 5 11 20 10 9 8 18 20 20 10 10 27 5 20 16 16 21 8 18 18 18 15 20 20 20 56 56 16 53 21 20 11 27 56 15 15 27 20 20 98 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Part Number Index (Continued) Page 20 14 14 12 7 9 9 9 12 10 18 18 18 21 17 15 14 14 17 14 20 15 14 20 15 15 21 18 19 7 21 15 7 53 20 7 9 21 19 19 18 51 15 15 14 14 53 18 60 62 62 62 7 21 21 17 12 21 21 18 58 55 Part No. 63486 63489 63494 63495 63499 63505 63506 63510 63511 63529 63530 63531 63532 63533 63544 63551 63561 63562 63564 63565 63569 63570 63571 63574 63584 63585 63590 63591 63598 63599 63601 63607 63612 63613 63614 63618 63621 63622 63623 63631 63632 63636 63641 63643 63645 63649 63658 63659 63660 63661 63662 63663 63664 63665 63666 63667 63668 63669 63670 63675 63690 63702 Page 16 13 17 21 20 18 57 17 17 15 15 8 8 8 18 5 50 50 50 11 14 14 20 7 17 17 5 5 21 19 20 20 53 26 20 20 51 56 56 7 6 5 9 19 11 53 5 10 10 10 5 17 17 17 19 19 17 17 17 27 9 11 Part No. 63708 63710 63711 63712 63713 63714 63716 63717 63718 63719 63720 63722 63725 63734 63735 63736 63737 63738 63740 63741 63742 63743 63744 63746 63754 63760 63762 63773 63775 63776 63777 63778 63782 63786 63788 63789 63795 63806 63807 63808 63810 63816 63818 63819 63827 63828 63829 63844 63845 63852 63855 63856 63864 63870 63871 63879 63880 63881 63882 63883 63888 63889 Page 19 23 23 23 23 23 23 23 23 23 23 14 5 23 23 23 23 23 23 23 23 23 23 16 5 18 19 12 7 17 16 27 18 5 14 5 26 12 12 12 12 21 11 11 16 27 17 26 26 17 5 10 54 55 55 14 14 21 21 21 24 55 Part No. 63898 63899 63903 63906 63907 63908 63909 63910 63920 63926 63927 63940 63941 63942 63944 63955 63956 63964 63965 63972 63973 63974 63975 63983 63995 63996 63999 184076 184079 184082 184084 184087 184090 184092 184094 281006 350571 360033 360050 360051 360052 466010 466510 466816 485044 485079 505036 505044 505071 505072 505075 505079 520995 521078 566410 566411 567343 567451 640212 680353 680421 770642 Page 20 13 24 62 62 62 12 12 20 12 12 57 57 57 57 27 27 58 12 13 13 13 6 19 19 19 27 86 86 87 87 87 87 87 87 60 54 60 60 61 61 56 55 56 53 53 54 54 53 53 53 54 61 60 57 57 56 56 54 57 57 55 Part Number Index Part No. 63207 63208 63209 63216 63218 63235 63236 63237 63247 63253 63254 63255 63256 63263 63273 63276 63277 63278 63293 63308 63309 63319 63326 63328 63330 63331 63336 63340 63353 63364 63371 63376 63397 63399 63403 63410 63420 63425 63427 63428 63429 63431 63433 63434 63443 63444 63446 63447 63448 63453 63454 63455 63458 63459 63460 63461 63463 63464 63465 63478 63480 63484 99 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Part Number Index (Continued) Part No. 964156 1217000 1217004 1217011 1217013 1217026 1217029 1217031 1217032 1217039 1217042 1217051 1217052 1217065 1217067 1217068 1217069 1217072 1217073 1217075 1217084 1217090 1217122 1217128 1217132 1217146 1217152 1217172 1217173 1217174 1217175 1217176 1217178 1217181 1217186 1217187 1217189 1217190 1217191 1217192 1217196 1217200 1217209 1217210 1217211 1217214 1217221 1217231 1217234 1217243 1217261 1217262 1217263 1217264 1217302 1217324 1217339 1217355 1217356 1217357 1217358 1217368 Page 49 27 18 5 11 5 55 20 12 55 19 12 12 17 6 6 6 55 55 19 5 19 62 17 7 10 20 62 62 62 62 62 17 61 61 61 5 5 5 5 11 61 8 13 13 7 6 27 5 17 61 60 60 60 10 7 19 6 6 6 6 5 Part No. 1217384 1217405 1217406 1217417 1217426 1217427 1217428 1217429 1217430 1217457 1217458 1217459 1217460 1217470 1217491 1217492 1217493 1217497 1217516 1217529 1217533 1217538 1217579 1217588 1217592 1217593 1217595 1217596 1217613 1217624 1217641 1217642 1217666 1217670 1217671 1217672 1217688 1217689 1217690 1217691 1217709 1217714 1217736 1217745 1217746 1217757 1217783 1217804 1217824 1217830 1217835 1217853 1217856 1217857 1217858 1217860 1217870 1217875 1601000 1601002 1601003 1601004 Page 50 11 7 57 6 6 6 6 16 9 9 11 11 7 19 19 18 23 23 27 6 9 6 21 18 13 12 13 8 57 11 11 23 62 62 62 6 6 6 6 24 23 5 13 13 5 16 27 5 27 56 8 20 18 8 20 20 7 32 38 38 37 Part No. 1601005 1601006 1601008 1601009 1601011 1601013 1601018 1601020 1601021 1601028 1601033 1601035 1601037 1601039 1601040 1601041 1601044 1601045 1601046 1601049 1601051 1601052 1601056 1601058 1601059 1601061 1601063 1601064 1601065 1601066 1601068 1601072 1601073 1601074 1601075 1601077 1601085 1601095 1601097 1601099 1601104 1601110 1601112 1601115 1601116 1601117 1601118 1601120 1601121 1601125 1601128 1601130 1601131 1601133 1601136 1601137 1601138 1601139 1601140 1601142 1601147 1601149 Page 36 37 35 35 37 37 37 37 37 38 37 37 35 36 37 35 38 36 32 37 35 38 32 37 36 38 35 36 35 35 37 37 36 32 39 39 36 35 36 35 35 35 36 38 36 32 38 35 35 32 35 39 39 36 32 39 35 38 34 37 35 39 Part No. 1601151 1601155 1601159 1601161 1601421 1601423 1601424 1601425 1601427 1601431 1601432 1601433 1601434 1601435 1601436 1601437 1601438 1601440 1601447 1601462 1601463 1601470 1601503 1601504 1601507 1601511 1601513 1601514 1601520 1601528 1601529 1601531 1601532 1601538 1601539 1601540 1601542 1601545 1601546 1601547 1601548 1601549 1601550 1601551 1601553 1601555 1601559 1601560 1601562 1601564 1601566 1601569 1601571 1601572 1601573 1601575 1601577 1601578 1601580 1601582 1601583 1601584 Page 36 35 38 38 29, 32, 34, 39 29, 37, 38 29, 35, 39 29, 35-39 29, 37 29, 35, 36 30, 39 30, 32, 34 30, 37 30, 38 30, 32 30 30, 35, 38 30, 32, 34 30, 32, 35-39 30, 32 30, 32 30, 39 80 80 77 79 79 77 76 78 78 78 78 72 72 72 80 80 80 80 79 79 76 76 76 80 72 72 80 80 79 79 79 76 76 75 75 75 80 80 80 80 100 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Part Number Index (Continued) Part No. 1601586 1601587 1601588 1601591 1601593 1601596 1601597 1601599 1601600 1601601 1601603 1601604 1601606 1601607 1601608 1601610 1601611 1601612 1601614 1601617 1601618 1601619 1601620 1601623 1601625 1601628 1601629 1601630 1601631 1601632 1601633 1601635 1601637 1601639 Page 79 77 77 77 75 80 79 79 79 77 77 72 72 71 71 80 80 80 79 79 79 79 77 77 77 77 77 77 77 75 75 80 72 71 Part No. 1601640 1601642 1601644 1601646 1601647 1601649 1601650 1601651 1601652 1601654 1601655 1601656 1601658 1601660 1601661 1601664 1601665 1601667 1601668 1601669 1601675 1601677 1601678 1601680 1601681 1601682 1601683 1601687 1601689 1601691 1601693 1601694 1601695 1601705 Page 79 78 72 72 72 80 79 79 79 79 77 77 77 77 77 77 77 77 77 76 72 71 71 78 78 78 72 79 78 78 78 78 78 71 Part No. 1601706 1601707 1601709 1601710 1601711 1601712 1601716 1601717 1601718 1601719 1601721 1601722 1601723 1601726 1601729 1601730 1601731 1601733 1601750 1601754 1601755 1601761 1601764 1601765 1601766 1601768 1601769 1601771 1601793 1601794 1601795 1601797 1601798 1601800 Page 71 71 78 78 78 78 72 71 71 71 79 79 79 78 78 78 78 78 71 78 78 71 78 78 78 76 75 75 72 71 80 76 76 72 Part No. 1601807 1601808 1601809 1601810 1601811 1601814 1601818 1601819 1601820 1601823 1601824 1601825 1601827 1601828 1601829 1601832 1601833 1601835 1601837 1601841 1601842 1601844 1601845 1601846 1601847 1601848 1601852 1601853 1601857 1601953 111-000-001 Page 76 79 79 79 77 71 77 77 77 71 71 80 79 77 77 72 71 71 79 78 71 72 72 71 71 71 78 75 71 91 91 Part Number Index 101 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Engineering Notes 102 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Power Splice (Continued) .425 [10.80] .375 [9.53] .408 [10.36] Type A 1 Magnet Wire Range CMA 15,000-30,000 Lead Wire Range CMA 4200-10,900 Part Number Reeled 1601953-11 Total combined CMA not to exceed 38000. Magnet Wire Insulation Piercing Serrations Inner saddle for lead wire (CMA 4,200-10,900) Magnet wires smaller than #18 AWG (1.0 mm) are placed here Outer saddle accepts up to 6 Magnet Wires (CMA 15,000-30,000) #20 AWG minimum .430 .010 [10.92 0.25] R .060 [1.52] .118 [3.00] Power Splice .430 Max. [10.92] Cut-off .408 [10.36] Direction of Feed .385 [9.78] .296 [7.52] R .024 [0.61] Part Number 111-000-001 91 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Application Tooling 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 92 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: TE Connectivity: 1601005-3