MULTILOCK* 040/070 and 070/250 Series Hybrid Connectors NOTE i Application Specification 114-- 8005 02 NOV 09 Rev A 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 application of MULTILOCK 040/070 and 070/250 Series Hybrid Connectors. The 040/070 series I/O (input/output) connectors are available in wire--to--board configurations incorporating mixed 040--series (signal) and 070--series (power). The 070/250 mixed series connectors are a wire--to--wire configuration with 11, 13, and 15 positions. The 040/070 series plug connectors are available 10 through 26 positions and the cap connectors are available in 16 through 76 positions. The contacts are on 2.5 mm [.098 in.] centerlines. Plug connectors are available in either hinge lock or side lock features. The cap assembly is available in a horizontal (right--angle) position with some positions available in a vertical position. When corresponding with Tyco Electronics Representatives, use the terminology provided in this specification to facilitate your inquiry for information. Basic terms and features of the connectors and contacts are provided in Figure 1. Printed Circuit (PC) Board Female Cap Assembly (Typ) Male Plug Housing (Typ) Wire Barrel Contact Tine Insulation Barrel Tab Contact (070 Series Shown) Wire Barrel Double Lock Plate Receptacle Contact (070 Series Shown) Figure 1 TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111 E2009 Tyco Electronics Corporation, Harrisburg, PA PRODUCT INFORMATION 1-- 800-- 522-- 6752 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. This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 20 LOC B MULTILOCK 040/070 and 070/250 Series Hybrid Connectors 114- 8005 2. REFERENCE MATERIALS 2.1. Revision Summary S Updated document to corporate requirements S Deleted obsolete tooling part numbers and related documents 2.2. Customer Assistance Reference Part Number 638211 and Product Code 0417 are representative numbers that identify the MULTILOCK 040/070 and 070/250 Series Hybrid Connectors. These numbers are used in the network of customer service to access tooling and product application information. This service is provided by your local Tyco Electronics Representative or, after purchase, by calling the Product Information number at the bottom of page 1. 2.3. Drawings Customer Drawings for specific products are available from the responsible Tyco Electronics Engineering Department via the service network. The information contained in the Customer Drawings takes priority if there is a conflict with this specification or with any other technical documentation supplied by Tyco Electronics. 2.4. Specifications The following Product Specifications (108--series) provide test and performance results, and Application Specifications (114--series) provide related application information: Specification Number 108--5244 108--5280 108--5216 108--5281 108--5342 108--5352 Specification Title 040 Series, MULTILOCK I/O Connector 040/070 Hybrid I/O Connector for PC Board 070 Series, MULTILOCK I/O Connector 040 Series MULTILOCK I/O Connector MK II 040 II/070 II Hybrid I/O Connector MK II for Wire--to--Board Termination 040 Series MULTILOCK Connector Wire to Wire Type 114--5091 114--5092 114--5094 114--5108 070 Series Receptacle Contact 070 Series Tab Contact 040 Series Receptacle Contact 040 Series Tab Contact 114--5133 114--5134 114--5159 114--5160 114--5162 040 Series Receptacle Contact for CAVUS Wires 070 Series Receptacle Contact for CAVUS Wires 040 II Series Tab and Receptacle Contact 070 II Series Tab and Receptacle Contact 040 Receptacle Contact for CAVUS 2.5. Manuals Manual 402--40 is available upon request and can be used as a guide in soldering. This manual provides information on various flux types and characteristics along with the commercial designation and flux removal procedures. A checklist is included in the manual as a guide for information on soldering problems. 2.6. Instructional Material The following list includes available instruction sheets (408--and 411--series) that provide assembly procedures for product, operation, maintenance and repair of tooling, as well as setup and operation procedures of applicators; and customer manuals (409--series) that provide setup, operation, and maintenance of machines. Also included are Hand Books (410--series) which are written for operator training and reference material for customers on various product lines and procedures. Document Number 408--3295 408--3326 408--7424 408--8024 408--8039 2 of 20 Document Title Preparing Reel Of Contacts for Application Tooling Disengaging Double Lock Plate on .040/.070 Hybrid MULTILOCK Connector Checking Terminal Crimp Height or Gaging Die Closure Miniature Quick--Change Applicator (End--Feed Type) Heavy Duty Miniature Quick--Change Applicators (End--Feed Type) Tyco Electronics Corporation Rev A MULTILOCK 040/070 and 070/250 Series Hybrid Connectors Document Number 408--8040 408--8053 408--8547 408--9640 408--9816 408--9853 408--9854 408--9855 408--9992 408--9997 114- 8005 Document Title Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type) Conversion Guide for Miniature Quick--Change Applicators CERTI--CRIMP* II Straight Action Hand Tools Crimp Quality Monitor Applicators for Side and End Feed Applications Handling Of Reeled Products PRO--CRIMPER* Hand Tool Assembly 90652--1 with Die Assembly 90652--2 PRO--CRIMPER Hand Tool Assembly 90653--1 with Die Assembly 90653--2 PRO--CRIMPER Hand Tool Assembly 90654--1 with Die Assembly 90654--2 PRO--CRIMPER III Hand Tool Assembly 58521--1 PRO--CRIMPER III Hand Tool Assembly 58528 409--5128 409--5842 409--5852 409--5855 409--5878 409--10012 Basic AMP--O--LECTRIC* Model "K" Terminating Machine AMP--O--LECTRIC Model "G" Terminating Machine 354500--[ ] AMPOMATOR CLS III--G Lead--Making Machine AMP--O--MATIC* Side Feed Stripper--Crimper Model II Machine 854040--3, --4 AMPOMATOR CLS IV+ Lead--Making Machine AMP--O--MATIC Side--Feed Stripper--Crimper III Machine 1320895--[ ] 410--5721 410--5841 Setup and Operation Handbook for the Model II AMPOMATOR CLS Machine Customer Training Guide for AMP--O--LECTRIC Model "G" Terminator 411--5287 411--5288 411--5338 411--5417 411--5480 411--5655 411--5658 Extraction Tool 755430--2 for 070 Series Contacts Extraction Tool 755430--1 for 040 Series Contacts DAHT 755223--1 for 070 Series Contacts SAHT 911738--1, --2 for 040 Series Contacts SAHT 911788 --2 for 070 Series Contacts Double Action Tool 934192--1 Double Action Tool 934195--1 3. REQUIREMENTS 3.1. Storage A. Ultraviolet Light Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housing material. B. Reel Storage When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically. C. Shelf Life The contacts and housings should remain in the shipping containers until ready for use to prevent deformation to those components. The components 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 contacts near any chemicals listed below as they may cause stress corrosion cracking in the contacts. Alkalies Amines NOTE i Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfides Nitrites Sulfur Compounds Tartrates Where the above environmental conditions exist, phosphor--bronze contacts are recommended instead of brass if available. 3.2. Wire Selection and Preparation A. Type The wire size range for MULTILOCK 040/070 and 070/250 Series Hybrid Connectors is 24 to 12 AWG stranded or solid copper wire. Refer to the specific application specifications or instructional material supplied with the products or application tooling. Rev A Tyco Electronics Corporation 3 of 20 MULTILOCK 040/070 and 070/250 Series Hybrid Connectors 114- 8005 B. Preparation The wire must be stripped to the dimensions provided in the specific application specifications or instructional material supplied with the products or application tooling. CAUTION Do not nick, scrape, or cut the wire conductor during the stripping operation. ! NOTE i There are tool designs available to meet various application requirements. The developed crimp configuration is unique for each tool design and is acceptable provided the crimp height is within the functional range. For crimp dimensions of a specific tool, refer to instruction sheet packaged with manual tools and applicator log packaged with power tools. 3.3. Crimped Contact Requirements Refer to Paragraphs 2.4 and 2.6 for related documentation which provide specific parameters for crimp requirements. Locate the contact to be crimped in the appropriate tooling according to the instructions packaged with that tooling. Detailed instructions covering the placement of contacts in the tooling and the use of such tooling is packaged with each tool. Terminate the contact according to the directions shipped with the appropriate tooling. See Section 5, TOOLING. CAUTION ! Wire insulation shall NOT be cut or broken during the crimping operation, nor shall the insulation be crimped into the contact wire barrel. Reasonable care should be taken by tooling operators to provide undamaged wire terminations. A typical contact as it should appear after crimping is shown in Figure 2. A. Crimp Height The crimp applied to the wire portion of the contact is the most compressed area and is most critical in ensuring optimum electrical and mechanical performance of the crimped contact. The crimp height must be within the dimensions provided. B. Crimp Length For optimum crimp effectiveness, the crimp must be within the area shown in Figure 2. 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. See Figure 15. C. Bellmouths Front and rear bellmouths shall be evident and conform to the dimensions provided in the supplied documentation. D. Cutoff Tab The cutoff tab shall be cut to the dimensions provided in the supplied documentation. E. Burrs The cutoff burr shall not exceed the dimensions provided in the supplied documentation. F. Wire Barrel Flash The wire barrel flash shall not exceed the dimensions provided in the supplied documentation. G. Conductor Location The conductor may extend beyond the wire barrel to the maximum dimensions provided in the supplied documentation. H. Wire Barrel Seam The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam. 4 of 20 Tyco Electronics Corporation Rev A MULTILOCK 040/070 and 070/250 Series Hybrid Connectors 114- 8005 End of Wire to be Flush to Required Dimension from End of Wire Barrel No Missing or Nicked Wire Strands Both Conductor and Insulation Must Be Visible No Wire Strands in Wire Barrel Seam No Insulation In Seam Crimp Length Front Bellmouth Rear Bellmouth X See View A Wire Barrel Crimp Width Wire Barrel Crimp Height X Max. Wire Barrel Flash Max. Burr View A Section X- X NOTE: Receptacle Contact Shown, Requirements the Same for Tab Contact Cutoff Tab Figure 2 I. Twist and Roll There shall be no twist, roll, deformation or other damage to the mating portion of the crimped contact that will prevent proper mating. See Figure 3. 15_ (Max) Wire Barrel Figure 3 J. Straightness The force applied during crimping may cause some bending between the crimped wire barrel and the mating portion of the contact. Such deformation is acceptable within the limits as shown in Figure 4. Rev A Tyco Electronics Corporation 5 of 20 MULTILOCK 040/070 and 070/250 Series Hybrid Connectors 114- 8005 1. Up and Down The crimped contact, including cutoff tab and burr, shall not be bent above or below the datum line more than the amount shown in Figure 4. 2. Side to Side The side--to--side bending of the contact may not exceed the limits provided in Figure 4. Periodic inspections must be made to ensure crimped contact formation is consistent as shown. NOTE i NOTE: Angles are drawn for clarification only and are not to scale. 5_ Max Datum Line 5_ Max 5_ Max NOTE: Receptacle Contact Shown, Requirements the Same for Tab Contact Datum Line 5_ Max Figure 4 3.4. Strain Relief The MULTILOCK product family is designed so all wire crimped contacts float inside the circuit cavity. This float helps the contact to find their centers during connector mating. In order to maintain proper contact float and avoid excessive tension on wire crimps, the wire harness should not be taped, or otherwise secured within 30 mm [1.181 in.] of the connector assembly body. The individual wire leads between the connector and the point of bundling must be able to move freely. Refer to Application Specification 114--5763, Figure 15. NOTE i If the installation is to be subject to bending forces, strain relief should be provided on the wire bundle approximately 25.4 mm [1.00 in.] from the back of the housing. When bending or forming wires, hold the wire bundle at least 30 mm [1.181 in.] beyond the back of the housing before bending in any direction. CAUTION Do not bend unsupported wires as this may cause strain on the contacts inside the housing. ! 3.5. Placement of Crimped Contact in Housing The contact must be inserted in the back of the plug housing and snapped into place. When fully inserted, the contact will engage the internal housing latch and prevent backing out during mating of the connector. After inserting contact into housing, pull back lightly on the wire to ensure contact is fully seated. See Figure 5. 6 of 20 Tyco Electronics Corporation Rev A MULTILOCK 040/070 and 070/250 Series Hybrid Connectors 114- 8005 Primary Lock Contact Fully Inserted and Locked in Housing Double Lock Plate NOTE: Secondary lock shown pre-- staged before final engagement Figure 5 3.6. Mating and Unmating The design of the MULTILOCK Hybrid Connectors prevents mis--mating of connectors. The plug and cap housing features an internal lock system to ensure positive retention. See Figure 6. A. Mating Make sure all contacts are locked in position, and the double lock plate is fully engaged in the locked position. If the double lock plate is in the pre--staged position, it must be changed to the final locked position. For plugs with hinge locks, rotate lock towards crimped wires, and press closed until it latches. Insert the plug into the female cap assembly until you hear a click. This will ensure the plug connector has bottomed. Pull back slightly on the plug connector to ensure the connectors can not be unmated. B. Unmating Grasp the female cap assembly by the ends. Release the hinge lock on the back of the plug connector, by depressing the lever. Pull straight out from the female cap assembly. CAUTION Do NOT pull the plug assembly out from the female cap assembly by the wires. This could damage the connectors. ! Internal Locking Feature Lever Male Plug Assembly Female Cap Assembly PC Board Figure 6 Rev A Tyco Electronics Corporation 7 of 20 MULTILOCK 040/070 and 070/250 Series Hybrid Connectors 114- 8005 3.7. PC Board A. Material and Thickness 1. Board material will be glass epoxy (FR--4, G--10). 2. The female cap assembly connector can be installed on 1.57 mm [.062 in.] thick pc boards. Board thickness may vary depending upon the application; however, contact tine length through the pc board becomes important for wave soldering operations. A recommended minimum of 1.02 mm [.040 in.] of the contact solder tine should protrude through the pc board. Contact the Product Information Center or the Tooling Assistance Center number listed at the bottom of page 1 for suitability of other board materials, thicknesses, specialized board designs or applications. B. Tolerance Maximum allowable bow of the pc board shall be 0.03 mm [.001 in.] over the length of the female cap assembly. C. PC Board Layout The mounting and contact holes in the pc board must be precisely located to ensure proper placement and optimum performance of the connector. See Figure 7. The connectors may be placed on the pc board manually or by machine. NOTE i Figure 7 represents a typical pc board layout for this product. For dimensions and hole pattern layout for specific product, obtain the appropriate customer drawing through your Tyco Electronics Representative or refer to the telephone numbers at the bottom of page 1. Figure 7 3.8. PC Board Contact Tine Holes These connectors may be used with or without plated through holes. If plated, the drilled hole size, plating types and plating thickness are dependent on customer application requirements. The finished hole size must be as stated in Figure 8 to provide unrestricted insertion and ensure adequate application of the solder to the connector solder tines. 8 of 20 Tyco Electronics Corporation Rev A MULTILOCK 040/070 and 070/250 Series Hybrid Connectors Board Thickness 1.57 [.062] 114- 8005 Pad Diameter (As Required) See Specific Product Customer Drawing for Dia of Finished Hole After Plating Tin/Lead Plated (As Required) Drilled Hole Diameter (As Required) Copper Plating (As Required) (Maximum Hardness of Copper to be 150 Knoop) Figure 8 3.9. PC Board Female Cap Assembly Placement The female cap assembly should be handled only by the housing body to prevent deformation, contamination, or other damage to the contact tines or boardlocks. NOTE i Determine the number one contact tine hole, then orient the connector so the number one solder tine is aligned with the hole. Start all solder tines into the pc board. When the boardlocks (if applicable), start to engage the pc board, press on the connector until it fully seats on the pc board. After the connector is snapped into the pc board, the boardlocks (if applicable) are soldered with the connector solder tines during the soldering process. 3.10. Methods of Attaching Female Cap Assembly to PC Board (See Figure 9) These connectors have been designed to be used with 3 mm dia x 6 mm long [.118 in. dia x .236 in. long] pan head class 2 self--tapping screws as specified in JIS B1115 and JIS B1122 or equivalent. Maximum tightening torque is provided on the specific product customer drawings. In addition to boardlocks available from Tyco Electronics, these connectors will also accept other types of commercially available mating hardware. The connector may be affixed to the pc board by using commercially available hardware such as screws, lock washers, nuts, rivets, or similar devices. Tyco Electronics applied boardlocks have shoulders that pass through the pc board at the same time the connector solder tines are inserted through the pc board. The boardlocks lock into position when the connector is seated on the pc board. The initial insertion and extraction forces are 41.15N [9.25 lb] maximum for insertion, and 6.68N [1.50 lb] minimum for extraction per connector with two boardlocks. NOTE: Boardlocks are NOT designed to be a strain relief for the connector. And for maximum torque requirements on screws, refer to the specific product customer drawings. Self-- Tapping Screw PC Board Boardlock Rev A Figure 9 Tyco Electronics Corporation 9 of 20 MULTILOCK 040/070 and 070/250 Series Hybrid Connectors 114- 8005 3.11. Soldering A. Flux Selection Contact solder tines must be fluxed prior to soldering with a mildly active, rosin base flux. Selection of the flux will depend on the type of pc board and other components mounted on the board. Additionally, the flux must be compatible with the wave solder line, manufacturing, health, and safety requirements. Call the Product Information phone number at the bottom of page 1 for consideration of other types of flux. Some fluxes that are compatible with these connectors are provided in Figure 10. FLUX TYPE ACTIVITY RESIDUE Type RMA (Mildly Activated) Mild Noncorrosive COMMERCIAL DESIGNATION KESTER 186 ALPHA 611 Figure 10 B. Cleaning After soldering, removal of fluxes, residues, and activators is necessary. Consult with the supplier of the solder and flux for recommended cleaning solvents. The following is a listing of common cleaning solvents that will not affect the connectors for the time and temperature specified. See Figure 11. DANGER NOTE i Consideration must be given to toxicity and other safety requirements recommended by the solvent manufacturer. Refer to the manufacturer's Material Safety Data Sheet (MSDS) for characteristics and handling of cleaners. Trichloroethylene and Methylene Chloride can be used with no harmful affect to the connectors; however Tyco Electronics does not recommend them because of the harmful occupational and environmental effects. Both are carcinogenic (cancer--causing) and Trichloroethylene is harmful to the earth's ozone layer. If you have a particular solvent that is not listed, contact the Tooling Assistance Center or Product Information number at the bottom of page 1. CLEANER NAME TYPE TIME (Minutes) TEMPERATURES (Maximum) CELSIUS FAHRENHEIT ALPHA 2110 Aqueous 1 132 270 BIOACT EC--7 Solvent 5 100 212 Butyl CARBITOL Solvent 1 Isopropyl Alcohol Solvent 5 100 212 KESTER 5778 Aqueous 5 100 212 KESTER 5779 Aqueous 5 100 212 LONCOTERGE 520 Aqueous 5 100 212 LONCOTERGE 530 Aqueous 5 100 212 Terpene Solvent Solvent 5 100 212 C. Drying Room Ambient Figure 11 When drying cleaned assemblies and printed circuit boards, make certain that temperature limitations are not exceeded: --55_ to 105_C [--67_ to 221_F] for standard temperature products. Excessive temperatures and dwell time may cause housing degradation. D. Soldering Guidelines MULTILOCK Hybrid Connectors can be soldered using wave, vapor phase (VPR), double sided non--focused infrared reflow processes (IR) or equivalent soldering techniques. The temperatures and exposure time shall be within the ranges specified in Figure 12. We recommend using SN60 or SN62 solder for these connectors. NOTE Manual 402--40 provides some guidelines for establishing soldering practices. Refer to Paragraph 2.5, Manuals. i 10 of 20 Tyco Electronics Corporation Rev A MULTILOCK 040/070 and 070/250 Series Hybrid Connectors SOLDERING PROCESS 114- 8005 TEMPERATURE TIME (At M Max T Temperature) t ) CELSIUS FAHRENHEIT 260s 215 500s 419 5 Seconds VAPOR PHASE SOLDERING INFRARED REFLOW SOLDERING 230 446 5 Minutes WAVE SOLDERING s Wave Temperature 3.12. Checking Installed Connector 5 Minutes Figure 12 MULTILOCK Hybrid Connectors must be seated on the pc board to the dimensions shown in Figure 13. Connector Connector Must be Flush Against PC Board to 0.08 [.003] Max Solder Must be Evenly Distributed and Not Cracked Solder Tine PC Board Figure 13 3.13. Connector Spacing Care must be used to avoid interference between adjacent connectors and/or other components. The information provided in Figure 14 is to ensure proper mating. NOTE i The information provided is for manual placement of connectors. If robotic equipment is used, other space allowances will be required for the grippers. Dimension Variable Based on Customers Requirements Female Cap Assembly PC Board Figure 14 3.14. Repair/Replacement Use an extraction tool to remove individual contacts from male plug connectors for replacement or for relocation to another housing cavity. Extraction Tool 755430--[ ] (Instruction Sheets 411--5287 or 411--5288) is used to extract contacts from male plug connectors. Damaged or worn contacts may be replaced provided there is sufficient slack, after restripping the wire, to insert the new contact into the connector. Damaged pc board connectors may be removed from the pc board by standard de--soldering methods. Rev A Tyco Electronics Corporation 11 of 20 MULTILOCK 040/070 and 070/250 Series Hybrid Connectors 114- 8005 4. QUALIFICATIONS MULTILOCK 040/070 and 070/250 Series Hybrid Connectors are not required to be agency evaluated. 5. TOOLING This section provides a selection of tools for various application requirements. They include hand tools for manual application of loose piece form contacts, and semi--automatic and automatic machines for power assist application of strip form contacts. Modified designs and additional tooling concepts may be available to meet other application requirements. For additional information, contact one of the service groups at the bottom of page 1. A listing of tooling recommendations covering the full wire size range is provided in Figure 15. NOTE i Tyco Electronics Tool Engineers have designed machines for a variety of application requirements. For assistance in setting up prototype and production line equipment, contact Tyco Electronics Tool Engineering through your local Tyco Electronics Representative or call the Tooling Assistance Center number at the bottom of page 1. S Applicators Applicators are designed for the full wire size range of strip--fed, precision formed contacts, and provide for high volume, heavy duty production requirements. The applicators can be used in bench or floor model power units. NOTE i 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. S 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. NOTE i The Model "K" AMP--O--LECTRIC Terminating Machine PN 565435--5 (409--5128) has been superseded by the Model "G" Terminating Machine PN 354500--1 (409--5842) for new applications. For existing applications, the Model "K" is still recommended because of the large number of installed machines. S Hand Crimping Tools Hand crimping tools that accommodate the full wire size range are designed for prototype and low--volume applications such as repair of damaged contacts. S Extraction Tools Extraction tools are designed to release the contacts inside the plug connector without damaging the housing or contacts. Refer to Paragraph 3.14. S PC Board Support A pc board support must be used to prevent bowing of the pc board during insertion of the connector. It should have a flat surface with holes or a channel large enough to receive the contact tines during installation. Typical PRO CRIMPER Hand Tool Typical DAHT SAHT 911738--1, - 2 SAHT 911788--2, 91580--1 Extraction Tool 755430--1, - 2 Figure 15 (cont'd) 12 of 20 Tyco Electronics Corporation Rev A MULTILOCK 040/070 and 070/250 Series Hybrid Connectors AMPOMATOR CLS III--G Machine 22500--[ ] 114- 8005 Typical Applicator PC Board Support (Customer Supplied) Channel (Ref) Holes (Ref) Figure 15 (cont'd) Rev A Tyco Electronics Corporation 13 of 20 MULTILOCK 040/070 and 070/250 Series Hybrid Connectors 114- 8005 AMP--O--MATIC Stripper Crimper II 854040--[ ] and Stripper Crimper III 1320895--[ ] AMPOMATOR CLS IV+ Lead--Making Machine 356500--[ ], 1213400--[ ] AMP--O--LECTRIC Model "G" Terminating Machine 354500--[ ] AMP--O--LECTRIC Model "K" Terminating Machine 565435--5, U--2 Assy 722460--1 Figure 15 (cont'd) 14 of 20 Tyco Electronics Corporation Rev A MULTILOCK 040/070 and 070/250 Series Hybrid Connectors CONTACT TYPE SERIES SIZE WIRE SIZE, AWG INSUL DIA RANGE APPLICATOR (DOCUMENT) 114- 8005 POWER UNIT (DOCUMENT) HAND TOOL (DOCUMENT) EXTRACTION TOOL (DOCUMENT) 58528--11 58528 (408--9997) 755430--11 755430 (411--5288) 122500--2 (409--5852) 122500--3 (409--5852) 567381 1 567381--1 (408--8040) 356500--1 (409--5878) 356500--2 (409--5878) 1213400--1 (409--5878) 1213400--2 (409--5878) 24 20 24--20 1.4 2.1 1.4--2.1 [.055--.083] 567381--22 567381 (408--8040) 567381--3 (408--8040) 354500--1 (409--5842) 565435--5 (409--5128) 354500--[ ] (409--5842) 122500--2 (409--5852) 567732 1 567732--1 (408--8040) 122500--3 (409--5852) 356500--2 (409--5878) 1213400--2 (409--5878) RECEPT 040 567949--1 567949-1 (409--5855) 22--20 22--20 1.0 1.4 1.0--1.4 [.039--.055] 854040--3 (409--5855) 1320895--1, --3 (409--10012) 9--482414--0 ------ 911924--2 ------ 911738--11 911738 (411--5417) 122500--2 (409--5852) 122500--3 (409--5852) 567442--11 567442 (408--8040) 22--18 22 18 356500--1 (409--5878) 356500--2 (409--5878) 1213400--1 (409--5878) 1.1--1.8 [[.043--.071] 043 071] 1213400--2 (409--5878) 567442--22 567442 (408--8040) 354500--1 (409--5842) 567442--3 (408--8040) 354500--[ ] (409--5842) 90652 1 90652--1 (408--9853) or 934192--1 (411--5655) 755430 1 755430--1 ((411--5288)) 565435--5 (409--5128) Figure 15 (cont'd) Rev A Tyco Electronics Corporation 15 of 20 MULTILOCK 040/070 and 070/250 Series Hybrid Connectors CONTACT TYPE SERIES SIZE WIRE SIZE, AWG INSUL DIA RANGE APPLICATOR (DOCUMENT) 114- 8005 POWER UNIT (DOCUMENT) HAND TOOL (DOCUMENT) EXTRACTION TOOL (DOCUMENT) 122500--2 (409--5852) 122500--3 (409--5852) 567454--1 567454--1 (408--8040) 356500--1 (409--5878) 356500--2 (409--5878) 1213400--1 (409--5878) 1213400--2 (409--5878) 567454--2 567454-2 (408--8040) 567454--3 (408--8040) 24--22 11.4--1.9 4 19 [.055--.075] 567929--11 567929 (409--5855) 354500--1 (409--5842) 565435--5 (409--5128) 354500--[ ] (409--5842) 854040--3 (409--5855) 1320895--1, --3 (409--10012) 122500--2 (409--5852) RECEPT 58528--11 58528 (408--9997) or 91580--1 (408--8547) or 755221--1 122500--3 (409--5852) 070 680386--1 680386--1 (408--8040) 755430--2 (411--5287) 356500--1 (409--5878) 356500--2 (409--5878) 1213400--1 (409--5878) 1213400--2 (409--5878) 680386--2 680386-2 (408--8040) 354500--1 (409--5842) 565435--5 (409--5128) 680386--3 (408--8040) 354500--[ ] (409--5842) ------ 22--20 1.0--1.4 [.039--.055] 913281--2 22 18 22--18 1.1--1.8 [.043--.071] 567488--2 567488-2 (408--8040) 20 16 20--16 1.2--1.9 [.047--.075] 567491--2 567491--2 (408--8040) 354500--1 (409--5842) 565435--5 (409--5128) 354500--1 (409--5842) 565435--5 (409--5128) 90653--1 (408--9854) 934195--1 934195-1 (411--5658) ------ Figure 15 (cont'd) 16 of 20 Tyco Electronics Corporation Rev A MULTILOCK 040/070 and 070/250 Series Hybrid Connectors CONTACT TYPE SERIES SIZE WIRE SIZE, AWG INSUL DIA RANGE APPLICATOR (DOCUMENT) 114- 8005 POWER UNIT (DOCUMENT) HAND TOOL (DOCUMENT) EXTRACTION TOOL (DOCUMENT) 122500--2 (409--5852) 122500--3 (409--5852) 1.8--2.5 [.071--.098] 567441--1 567441-1 (408--8040) 356500--1 (409--5878) 356500--2 (409--5878) 1213400--1 (409--5878) 90654--1 90654-1 (408--9855) 1213400--2 (409--5878) 567441--2 567441--2 (408--8040) 354500--1 (409--5842) 565435--5 (409--5128) 122500--2 (409--5852) 122500--3 (409--5852) 567375--1 567375--1 (408--8040) 070 356500--1 (409--5878) 356500--2 (409--5878) 755430--2 (411--5287) 1213400--1 (409--5878) 20--16 1213400--2 (409--5878) 567375--2 567375-2 (408--8040) 2.0--2.6 [.079--.102] RECEPT 567375--3 (408--8040) 567838--1 (409--5855) 567854--1 (409--5855) 567855--1 (409--5855) 567908--11 567908 (409--5855) 354500--1 (409--5842) 565435--5 (409--5128) 354500--[ ] (409--5842) 854040 4 (409--5855) 854040--4 (409 5855) or 1320895--2,, --4 (409 10012) (409--10012) 58521--1 (408--9992) (408 9992) or 755223--1 (411--5338) or 911788--2 (411--5480) 854040--3 (409--5855) 1320895--1, --3 (409--10012) 2--541611--2 2--541611--6 9--541611--2 250 22--20 15 22 1.5--2.2 [.059--.087] ------ 9--541611--6 ------ 722788--1 (408--8024) 722788--2 (408--8024) 722460--1 1--755816--1 (408--8024) ------ ------ Figure 15 (cont'd) Rev A Tyco Electronics Corporation 17 of 20 MULTILOCK 040/070 and 070/250 Series Hybrid Connectors CONTACT TYPE SERIES SIZE WIRE SIZE, AWG INSUL DIA RANGE APPLICATOR (DOCUMENT) 114- 8005 POWER UNIT (DOCUMENT) HAND TOOL (DOCUMENT) EXTRACTION TOOL (DOCUMENT) --------- ------- -- 122500--2 (409--5852) 122500--3 (409--5852) 20--14 2.2--3.4 2.2 3.4 [.087--.134] 466250--11 466250 (408--8039) 356500--1 (409--5878) 356500--2 (409--5878) 1213400--1 (409--5878) 1213400--2 (409--5878) 466250--22 466250 (408--8039) RECEPT 354500--1 (409--5842) 565435--5 (409--5128) 122500--2 (409--5852) 250 122500--3 (409--5852) 680086--11 680086 (408--8039) 14--12 356500--1 (409--5878) 356500--2 (409--5878) 1213400--1 (409--5878) 2.9--3.8 [[.114--.150] 114 150] 1213400--2 (409--5878) 680086 2 680086--2 (408--8039) 354500--1 (409--5842) 680086--3 (408--8039) 354500--[ ] (409--5842) 567478--22 567478 (408--8040) 354500--1 (409--5842) 565435--5 (409--5128) 565435--5 (409--5128) 122500--2 (409--5852) 24--22 TAB 1.4 1.9 1.4--1.9 [.055--.075] 070 122500--3 (409--5852) 567478--11 567478 (408--8040) 356500--1 (409--5878) 58528--11 58528 (408--9997) 755430--2 (411--5287) 356500--2 (409--5878) 1213400--1 (409--5878) 1213400--2 (409--5878) 22--20 1.19--2.49 [.047--.098] ------ ------ 90653--1 (408--9854) 22--18 1.1--2.2 [.043--.087] ------ ------ 934195--1 [411--5658] Figure 15 (cont'd) 18 of 20 Tyco Electronics Corporation Rev A MULTILOCK 040/070 and 070/250 Series Hybrid Connectors CONTACT TYPE SERIES SIZE WIRE SIZE, AWG 114- 8005 INSUL DIA RANGE APPLICATOR (DOCUMENT) POWER UNIT (DOCUMENT) HAND TOOL (DOCUMENT) 2.0--2.6 [.079--.102] 567908--1 (409--5855) 854040--3 (409--5855) ------ 1.68--2.59 [.066--.102] ------ ------ 58521--1 (408--9992) 1.75--2.59 [.069--.102] ------ ------ 90654--1 (408--9855) EXTRACTION TOOL (DOCUMENT) 122500--2 (409--5852) 122500--2 (409--5852) 122500--3 (409--5852) 070 20--16 22.0--2.6 0--2 6 [[.078--.102]] 567375 1 567375--1 (408--8040) 356500--2 (409--5878) 1213400--1 (409--5878) 1213400--2 (409--5878) 567375--22 567375 (408--8040) 567375--3 (408--8040) TAB 755430 2 755430--2 (411--5287) (411 5287) 356500--1 (409--5878) 755224--1 (411--5338) (411 5338) 354500--1 (409--5842) 565435--5 (409--5128) 354500--[ ] (409--5842) 22--20 1.5--2.2 1.5 2.2 [.059--.087] 680050--22 680050 (408--8039) 354500--1 (409--5842) 20--14 2.1--3.4 2.1 3.4 [.083--.134] 567457--22 567457 (408--8039) 354500--1 (409--5842) 565435--5 (409--5128) 565435--5 (409--5128) 122500--2 (409--5852) 122500--3 (409--5852) 356500--1 (409--5878) 567462--11 567462 (408--8039) (408-8039) 250 14--12 2 9--3 8 2.9--3.8 [[.114--.150]] 356500--2 (409--5878) ------ ------ 1213400--1 (409--5878) 1213400--2 (409--5878) 567462 2 567462--2 (408--8039) 567462--3 (408--8039) 354500--1 (409--5842) 565435--5 (409--5128) 354500--1 (409--5842) Figure 15 (end) Rev A Tyco Electronics Corporation 19 of 20 MULTILOCK 040/070 and 070/250 Series Hybrid Connectors 114- 8005 6. VISUAL AID Figure 16 shows a typical application of MULTILOCK 040/070 and 070/250 Series Hybrid Connector. 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. FEMALE CAP ASSEMBLY MUST BE SEATED ON PC BOARD WIRE CONDUCTORS AND INSULATION BOTH VISIBLE IN THIS AREA CONDUCTOR ENDS MUST BE VISIBLE NO CONDUCTOR WIRES SHOWING IN WIRE BARREL SEAM HOUSINGS OR CONTACTS MUST NOT BE BENT OR CRACKED HARDWARE MUST BE SECURELY TIGHTENED CONTACTS MUST BE LOCKED IN PLACE SOLDER FILLET MUST BE FORMED EVENLY AROUND TINES AND BOARDLOCK FEMALE CAP AND MALE PLUG ASSEMBLY MUST BE LATCHED TOGETHER FIGURE 16. 20 of 20 VISUAL AID Tyco Electronics Corporation Rev A