640007-3 - Tyco Electronics - Datasheet.Directory

Application Specification

114-2084

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2008 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property of their respective owners.

TOOLING ASSISTANCE CENTER 1-800-722-1111

PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at

www.tycoelectronics.com

Ring and Spade Terminals

21 JUL 08 Rev D

All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and

inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2

Figures and illustrations are for identification only and are not drawn to scale.

1. INTRODUCTION

This specification covers the requirements for the application of Standard Ring and Spade Terminals, Flanged

Spade Terminals, and Insulation Piercing Ring and Spade Terminals. These requirements are applicable to

hand or automatic machine crimping tools.

When corresponding with Tyco Electronics Personnel, use the terminology provided in this specification to

facilitate your inquiries for information. Basic terms and features of this product are provided in Figure 1.

Figure 1

Flanged Spade

Ring

Insulation Piercing Ring

Spade

Insulation Piercing Spade

Insulation Barrel

Wire Barrel

Cutoff Tab

Serrations

0.76 [.030] +

Two Stock

Thicknesses

2. REFERENCE MATERIAL

2.1. Revision Summary

Updated document to corporate requirements

Added new NOTE to Section 5, TOOLING

NOTE

114-2084

Ring and Spade Terminals

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2.2. Customer Assistance

Reference Product Part Numbers 41409 (Insulation Piercing), 60771 (Standard), 60775 (Flanged Spade) and

Product Code 1170 are representative of Ring and Spade Terminals. Use of these numbers will identify the

product line and expedite your inquiries through a service network established to help you obtain product and

tooling information. Such information can be obtained through a local Tyco Electronics Representative or, after

purchase, by calling the Product Information Center at the number at the bottom of page 1.

2.3. Drawings

Customer Drawings for product part numbers are available from the service network. The information

contained in the Customer Drawing takes priority if there is a conflict with this specification or any other

technical documentation supplied by Tyco Electronics.

2.4. Instructional Material

Because of the large amount of dies, hand tools, applicators, and power units used to terminate this product line, it is

not feasible to list all the related tooling documents in this section. Related tooling documents are available through

the service network and are also shipped with the specific application tooling.

Reference generic documents available which pertain to the application of this product are:

Document Number Document Title

408–3295 Preparing Reel of Contacts for Application Tooling

408–7424 Checking Terminal Crimp Height or Gaging Die Closure

408–8053 Conversion Guide for Miniature Quick–Change Applicators

408–8059 General Preventative Maintenance for Applicators

408–9816 Handling of Reeled Products

3. REQUIREMENTS

3.1. Storage

A. Ultraviolet Light

Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the terminal

materials.

B. Reeled Terminals

When using reeled terminals, store coil wound reels horizontally and traverse wound reels vertically.

C. Shelf Life

The terminals should remain in the shipping containers until ready for use to prevent deformation to the

terminals. The terminals should be used on a first in, first out basis to avoid storage contamination that

could adversely affect signal transmissions.

D. Chemical Exposure

Do not store terminals near any chemicals listed below, as they may cause stress corrosion cracking in the

terminals.

Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds

Amines Carbonates Nitrites Sulfur Nitrites Tartrates

Where the above environmental conditions exist, phosphor-bronze terminals are recommended instead of brass if

available.

3.2. Materials

A variety of materials are available in this product line. Contact the Product Information Center at the number

at the bottom of page 1 for specific metals and platings available for your production needs.

3.3. Wire Size and Preparation

The terminals will accept a wide range of stranded wire sizes. Contact the Product Information Center at the

number at the bottom of page 1 for specific wire size ranges available for your production needs.

NOTE

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Tyco Electronics Corporation

A. Standard and Flanged Spade Wire Preparation

Insulation shall be stripped as indicated in Figure 2 and is based on wire barrel length which may be found

on the product customer drawing.

DO NOT nick, scrape, or cut the wire conductors during the stripping operation. Filaments of insulation material

remaining after stripping should be avoided and shall never extend among the bare conductors.

B. Insulation Piercing Wire Preparation

Wire shall be trimmed cleanly and squarely. Due to the insulation piercing technique employed in crimping

the terminal, it is not necessary to strip the insulation from the wire. See Figure 2.

Wire Insulation

Strip Length

Note:

Not to Scale

Conductors

Wire Insulation

Insulation and Conductors

Trimmed Squarely

Standard Ring and Spade or Flanged Spade Terminals Insulation Piercing Ring and Spade Terminals

TERMINAL STYLE WIRE BARREL LENGTH WIRE STRIP LENGTH

2.36-2.74 [.093-.108] 3.18 [.125]

STANDARD RING AND SPADE

2.77-3.58 [.109-.141] 3.96 [.156]

STANDARD RING AND SPADE

TERMINALS

3.61-4.42 [.142-.174] 4.78 [.188]

FLANGED

SPADE TERMINALS

4.44-5.26 [.175-.207] 5.56 [.219]

SPADE TERMINALS

5.28-6.10 [.208-.240] 6.35 [.250]

6.12-6.93 [.241-.273] 7.14 [.281]

INSULATION PIERCING TERMINALS --- ---

Figure 2

3.4. Crimped Terminal Requirements

The terminal shall be located in desired tooling and crimped according to the instructions packaged with that

tooling. See Section 5, TOOLING, of this document for details on tooling options.

The applied crimp dimension (within the functional range of the product) is dependent on the termination tooling being

used. Refer to the documentation (applicator logs and instruction sheets) supplied with the termination tooling for the

applied crimp height.

Wire insulation shall NOT be fully cut or broken during the crimping operation, nor shall the insulation be crimped into

the terminal wire barrel. Reasonable care should be taken by tooling operators to provide undamaged wire

terminations.

A. Wire Barrel Crimp

The crimp applied to the wire portion of the terminal is the most compressed area and is most critical in

ensuring optimum electrical and mechanical performance of the crimped terminal. The terminal wire barrel

crimp height must be within the dimension provided on the application tooling documentation.

CAUTION

NOTE

CAUTION

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B. Effective Crimp Length

For optimum crimp effectiveness, the crimp must be within the area shown in Figure 3 and must meet the

crimp dimensions provided in the application tooling documentation. Effective crimp length shall be defined

as that portion of the wire barrel, excluding bellmouth(s), fully formed by the crimping tool. Instructions for

adjusting, repairing, and inspecting tools are packaged with the tools.

C. Bellmouths

Front and rear bellmouth shall be as shown and conform to the dimensions given in Figure 3.

D. Cutoff Tabs

The cutoff tab shall be cut to the dimensions shown in Figure 3.

Figure 3

0.13 [.005]

Max.

Rear Cutoff Tab

0.51 [.020] Max.

0.13 [.005]

Max Wire

Barrel Flash

Section X-X

Wire Barrel

Crimp Width

Wire Barrel

Crimp Height

Front Cutoff Tab

0.51 [.020] Max.

Wire Insulation and

Conductors Must Both

Be Visible In This Area

No Insulation

in Seam

Wire Barrel Closed at Seam with

No Strands Protruding or Showing

Flush to 0.76 [.030]

Crimp Location

Front Bellmouth

0.0-0.51

[.000-.020]

Rear Bellmouth

14-26 AWG is

0.25-0.64 [.010-.025]

or 14-8 AWG is

0.38-0.89 [.015-.035]

See View A"

View A"

NOTE:

Ring Terminal Shown, Other Terminals Have Same Dimensions

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E. Burrs

The cutoff burr shall not exceed the dimensions shown in Figure 3.

F. Wire Barrel Flash

The wire barrel flash shall not exceed the dimensions shown in Figure 3, Section X–X.

G. Insulation Barrel Crimp

The insulation barrel shall grip the insulation firmly without fully cutting into it. Care must be taken to

prevent cutting, nicking, or scraping of the insulation. Insulation crimp shall comply to width dimensions

provided in the application tooling documentation.

H. Wire Location

The wire conductor and insulation must be visible in the transition area between the wire and insulation

barrels as shown in Figure 3.

I. Conductor Extension

The conductor may extend beyond the wire barrel to the maximum shown. No strands may extrude over

the height of the conductor crimp. See Figure 3.

J. Wire Barrel Seam

The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam. See

Figure 3.

K. Twist and Roll

Twist or roll of the crimped terminal shall not exceed the limits specified in Figure 4.

Figure 4

Wire Barrel

Max.10

Max.

L. Straightness

The force applied during crimping may cause some bending between the crimped wire barrel and the

mating portion of the terminal. Such deformation is acceptable within the limits provided in Figure 5.

1. The up and down bend of the crimped terminal, including cutoff tab and burr, shall not be bent above

or below the datum line more than the amount shown.

2. The side–to–side bend of the terminal may not exceed the limits provided.

Damaged terminals may not be used. If a damaged terminal is evident, it must be removed from the wire and replaced

with a new one.

Periodic inspections must be made to ensure crimped terminal formation is consistent as shown.

CAUTION

NOTE

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Figure 5

Max

Datum Line

Max

4. QUALIFICATION

Contact Tyco Electronics Product Engineering for agency approval information.

5. TOOLING

Because of the large amount of product variations and application tooling available, it is not feasible to list all the

tooling on this document. Contact Tyco Electronics using the phone numbers listed at the bottom of page 1 for specific

dies, hand tools, applicators, and power units to fit your production needs and requirements.

Lubrication is required when terminating any steel or stainless steel terminals.

This section provides information on tools for various application requirements.

Crimping Die Assemblies

Crimping Die Assemblies for crimping the terminals are available for the full wire size range. They are

designed for easy installation and removal in hand crimping tool frame assemblies or applicators.

Hand Tools

Hand crimping tools are designed for prototype, low–volume applications, and repair.

Applicators

Applicators are designed for the full wire size range of terminals, and provide for high volume, heavy

duty production requirements. The applicators can be used in bench or floor model power units.

Each applicator is shipped with a metal identification tag attached. DO NOT remove this tag or disregard the

information on it. Also, a packet of associated paperwork is included in each applicator shipment. This information

should be read before using the applicator; then it should be stored in a clean, dry area near the applicator for future

reference. Some changes may have to be made to the applicators to run in all related power units. Contact the Tooling

Assistance Center number at the bottom of page 1 for specific changes.

Power Units

A power unit is an automatic or semi–automatic device used to assist in the application of a product.

Power unit includes the power source used to supply the force or power to an applicator.

Tool Engineers have designed machines for a variety of application requirements. For assistance in setting up

prototype and production line equipment, contact Tool Engineering through your local Tyco Electronics Representative

or call the Tooling Assistance Center number at the bottom of page 1.

NOTE

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Tyco Electronics Corporation

6. VISUAL AID

Figure 6 shows a typical application of Ring and Spade Terminals. This illustration should be used by

production personnel to ensure a correctly applied product. Applications which DO NOT appear correct should

be inspected using the information in the preceding pages of this specification and in the instructional material

shipped with the product or tooling.

FIGURE 6. VISUAL AID

WIRE BARREL SEAM MUST BE

CLOSED WITH NO PROTRUDING

WIRE STRANDS

WIRE AND INSULATION

MUST BE VISIBLE IN THIS

AREA

INSULATION MUST NOT BE

CUT, TORN, OR SCRAPED

BY INSULATION BARREL

CONTACT BODY MUST BE

STRAIGHT AND ALIGNED

WITH CRIMPED BARRELS

FRONT AND REAR

BELLMOUTHS

MUST BE VISIBLE

NO EXCESSIVE WIRE

BARREL FLASH

CONTACT CUTOFF TAB MUST

BE STRAIGHT AND ALIGNED

WITH CRIMPED BARRELS

WIRE MUST BE VISIBLE AT

END OF WIRE BARREL

NO INSULATION

IN INSULATION

BARREL SEAM

PIERCING LANCES

MUST PROTRUDE

THROUGH INSULATION

TO CONDUCTORS