Application Specification 114-10000 HD-20 Precision Formed Contacts NOTE i 09 FEB 09 Rev T 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 HD-20 Precision Formed Contacts. These contacts are available in three snap-in types: crimp, posted, and solder cup. The crimp snap-in contacts are available with or without an insulation support barrel for strain relief. The contacts accept a wire size range of 28 through 18 AWG and may be terminated to either stranded or solid wire. After termination, these contacts are inserted into the cavities in the BACK of the connector housing and snap into place. Assembled connectors containing these contacts are available and designed to meet requirements of Military Specification MIL-C-24308. 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. Snap-In Crimp Contacts Typical Pin Contact Locator Slot Insulation Typical Socket Contact Wire Barrel Barrel Color Dot on Underside of Wire Barrel Posted Contact Crimp Contact Solder Cup Contact Solder Cup Stabilizer Pin Contact Without Transition Insulation Barrel Flange Figure 1 2. REFERENCE MATERIAL 2.1. Revision Summary Revisions to this application specification include: S Updated document to corporate requirements S Added wire size range 32-28 to tables in Figures 2, 3, and 7 E 2009 Tyco Electronics Corporation, Harrisburg, PA All International Rights Reserved TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. visit our website at www.tycoelectronics.com 1 of 11 LOC B HD-20 Precision Formed Contacts 114-10000 2.2. Customer Assistance Reference Product Base Part Number 66504 and Product Code 5899 are representative numbers of HD-20 Precision Formed Contacts. 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 Tyco Electronics Representative or, after purchase, by calling Product Information at the number at the bottom of page 1. 2.3. Drawings Customer Drawings for each product part number are available from the service network. The information contained in Customer Drawings takes priority if there is a conflict with this specification or with any technical documentation supplied by Tyco Electronics. 2.4. Manuals Manual 402-40 is available from the service network. 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. 2.5. Instructional Material The following list includes available instruction sheets (408-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 provides setup, operation, and maintenance of machines. Document Title Document Number 408-3295 408-7424 408-7799 408-8040 408-8547 408-9404 408-9816 409-5128 409-5842 409-5852 409-10012 Preparing Reel of Contacts for Application Tooling Checking Terminal Crimp Height Gaging Die Closure AMPLIMITE* Solder Pot Contacts (66569-3 and 66570-3) HD Quick-Change Applicators (Side-Feed Type) with Mechanical Feed System CERTI-CRIMP* II Straight Action Hand Tools Insertion/Extraction Tool 91285-1 and Replacement Tip Kits 543382-[ ] Handling of Reeled Products Basic AMP-O-LECTRIC* Model "K" Terminating Machine 565435-5 AMP-O-LECTRIC Model "G" Terminating Machine 354500-[ ] AMPOMATOR* CLS Model III-G Lead-Making Machine 122500-[ ] AMP-O-MATIC* Side-Feed Stripper-Crimper III Machine No. 1320895-[ ] 3. REQUIREMENTS 3.1. Storage A. Reeled Contacts When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically. B. Shelf Life The contacts should remain in the shipping containers until ready for use to prevent deformation to the contacts and/or damage to the housings. The products should be used on a first in, first out basis to avoid storage contamination that could adversely affect signal transmissions. C. Chemical Exposure Do not store contacts near any chemicals listed below, as they may cause stress corrosion cracking in the components. Alkalies Amines Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Sulfur Compounds Tartrates 3.2. Wire Size and Preparation The contacts will accept a wire size range of 28 to 18 AWG and may be terminated to either stranded or solid wire. Figure 2 lists insulation stripping lengths as determined by the contact wire size range used. Also listed are acceptable wire insulation outside diameters for the contacts, and color codes used to easily identify loose-piece contacts. 2 of 11 Tyco Electronics Corporation Rev T HD-20 Precision Formed Contacts CAUTION 114-10000 DO NOT nick, scrape, or cut the wire conductor during the stripping operation. ! Outer Jacket Strip Length Cable A" + 1.27 [.050] Discrete Wire Ferrule Strip Length Braid OUTER JACKET STRIP LENGTH CONTACT POSITIONS A" LENGTH 9 33.02 [1.300] 15 25 37 43.18 [1.700] 50 40.64 [1.600] DISCRETE WIRE CONTACT WIRE SIZE RANGE (AWG) COLOR CODE ((ON WIRE BARREL OF LOOSE PIECE CONTACTS ONLY) 32-28 --- 0.76-1.02 [.030-.040] BLUE 1.73 [.068] Max BLACK 1.27-1.52 [.050-.060] BLUE 0.76-1.02 [.030-.040] 26-22 YELLOW 1.27 [.050] Max 24 20 24-20 RED INSULATION DIAMETER ACCEPTED STRIP LENGTH 0.25 [.010] " DECIMAL INCHES FRACTIONAL INCHES 2.39 .094 3/32 2.77 .109 7/64 2.39 .094 3/32 1.73 [.068] Max 2.77 .109 7/64 1.27-1.52 [.050-.060] 2.39 .094 3/32 1.73 [.068] Max 2.77 .109 7/64 3.96 .156 9/64 MILLIMETERS OPEN BARREL CONTACTS (With or Without Insulation Support) 28-24 22-18 GREEN SOLDER-CUP CONTACTS 18 and Smaller None None Specified Figure 2 3.3. Crimped Contact Requirements Contact 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 and instructional materials. 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. Contact Crimp Barrel Configurations The contact wire barrel shall be crimped to an F-crimp configuration as shown in Section X-X of Figure 3. The insulation barrel (when present) shall be crimped to an O-crimp configuration. Refer to the table in Figure 3 for crimp dimensions. Rev T Tyco Electronics Corporation 3 of 11 HD-20 Precision Formed Contacts 114-10000 B. Contact Crimp Features Figure 3 shows a typical contact as it should appear after crimping. Although a pin contact with insulation barrel is shown, the requirements apply equally to socket contacts and to contacts not having an insulation barrel. 1. Crimp Location For optimum crimp effectiveness, the crimp must be within the area shown and must meet the crimp requirements provided in Figure 3. Effective crimp length shall be no less than the dimension given in Figure 3 and is 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. 2. Conductor Extension The conductor may extend beyond the wire barrel to the maximum shown. 3. Wire Barrel Seam The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam. 4. Conductor/Insulation The conductor and insulation must both be visible in the area between the insulation barrel and the wire barrel. 5. Bellmouth Front and rear bellmouths shall be formed and adhere to the dimensions given. 6. Cutoff Tab The cutoff tab shall be cut to the dimensions shown. 7. Burrs The cutoff burr shall not exceed the dimensions shown. 8. Flash The wire barrel flash shall not exceed the dimensions shown in Section X-X. Wire Conductors and Insulation Must Both be Visible in this Area 0.13-0.51 [.005-.020] Conductor Location Wire Barrel Seam Closed with No Conductor Strands Showing Section X-X Rear Bellmouth 0.30+0.13 [.012+.005] Contact with Insulation Barrel Crimp Width 0.33+0.13 [.013+.005] Contact Without Insulation Barrel at Tangent (See Table) 1.27 [.050] Effective Crimp Length X 0.25 [.010] Max Front Bellmouth X 0.25 [.010] Max No Damage or Distortion to 0.25 [.010] Max Crimp Height Contact or Retention Feature Wire Barrel Flash (See Table) Rear Cutoff Tab with 0.08 [.003] Max Burr Figure 3 (cont'd) 4 of 11 Tyco Electronics Corporation Rev T HD-20 Precision Formed Contacts 114-10000 HAND TOOL WIRE CRIMP DIMENSIONS WIRE SIZE RANGE (AWG) 32-28 WIRE INSUL DIA ACCEPTED 00.76-1.02 76 1 02 [.030-.040] [ ] SIZE OF WIRE BARREL CRIMP INSULATION BARREL CRIMP WIRE APPLIED HEIGHT RANGE 32 0.58-0.46 [.023-.018] 30 0.61-0.46 [.024-.018] 28 0.63-0.51 [.025-.020] WIDTH WIDTH (Ref) HEIGHT (Ref) 0.84 [.033] 1 35 1 57 1.35-1.57 [[.053-.062]] 0 64 1 93 0.64-1.93 [.025-.076] [ ] 1.40 [.055] --- --- 1.40 [.055] 1.27 [.050] 1.40 [.055] 0.76 [.030] 1.40 [.055] 0.76 [.030] --- --- 1.40 [.055] 1.27 [.050] --- --- 28 1.73 [.068] Max 26 0.47-0.57 [.0185-.0225] 24 28 28-24 1.27-1.52 [.050-.060] 26 24 28 0.76-1.02 [.030-.040] 0.67-0.77 0 67-0 77 [.0265-.0305] [ 0265- 0305] 1.07 1 07 [[.042] 042] 26 24 26 26-22 1.02-1.27 [.040-.050] 24 22 0.71-0.81 0 71-0 81 [.028-.032] [ 028- 032] 1.07 [.042] 0.81-0.91 [.032-.036] 24 1.73 [.068] Max 22 20 24-20 24 1.27-1.52 [.050-.060] 0 70-0 80 [.0275-.0315] 0.70-0.80 [ 0275- 0315] 1 40 [[.055] 1.40 055] 22 20 22 22-18 1.73 [.068] Max 20 18 0 84-0 94 [.033-.037] 0.84-0.94 [ 033- 037] 1.57 [.062] 1.07-1.17 [.042-.046] Figure 3 (cont'd) Rev T Tyco Electronics Corporation 5 of 11 HD-20 Precision Formed Contacts 114-10000 AUTOMATIC MACHINE WIRE CRIMP DIMENSIONS WIRE SIZE RANGE (AWG) 32-28 WIRE INSUL SIZE OF DIA WIRE ACCEPTED APPLIED 0 76 1 02 0.76-1.02 [.030-.040] [ ] 1.73 [.068] Max 28-24 1.27-1.52 [.050-.060] 0.76-1.02 [.030-.040] 26-22 1.02-1.27 [.040-.050] 1.73 [.068] Max 24-20 1.27-1.52 [.050-.060] 22-18 1.73 [.068] Max INSULATION BARREL WIRE BARREL CRIMP HEIGHT RANGE TENSILE STRENGTH N [LB] Min 32 0.58-0.46 [.023-.018] 8.01 [1.8] 30 0.61-0.46 [.024-.018] 10.01 [2.2] 28 0.63-0.51 [.025-.020] 11.12 [2.8] 28 0.66-0.76 [.026-.030] 12.01 [2.7] 26 0.71-0.81 [.028-.032] 20.02 [4.5] 24 0.76-0.86 [.030-.034] 35.91 [8.0] 28 0.64-0.69 [.025-.027] 12.01 [2.7] 26 0.71-0.76 [.028-.030] 20.02 [4.5] 24 0.79-0.84 [.031-.033] 35.91 [8.0] 28 0.64-0.69 [.025-.027] 12.01 [2.7] 26 0.74-0.79 [.029-.031] 20.02 [4.5] 24 0.79-0.84 [.031-.033] 35.91 [8.0] 26 0.71-0.81 [.028-.032] 20.02 [4.5] 24 0.76-0.86 [.030-.034] 35.91 [8.0] 22 0.86-0.97 [.034-.038] 53.38 [12.0] 24 0.76-0.86 [.030-.034] 35.91 [8.0] 22 0.76-0.86 [.030-.034] 53.38 [12.0] 20 0.76-0.86 [.030-.034] 88.96 [20.0] 24 0.76-0.86 [.030-.034] 35.91 [8.0] 22 0.76-0.86 [.030-.034] 53.38 [12.0] 20 0.76-0.86 [.030-.034] 88.96 [20.0] 22 0.84-0.94 [.033-.037] 53.38 [12.0] 20 0.89-0.99 [.035-.039] 18 1.07-1.17 [.042-.046] 88 96 [20 88.96 [20.0] 0] CRIMP WIDTH 0.84 [.033] 1.07 [.042] 1.07 [.042] WIDTH HEIGHT (Ref) (Ref) 1 35 1 57 1.35-1.57 [.053-.062] [ ] 0 64 1 93 0.64-1.93 [.025-.076] [ ] --- --- 1.35-1.57 [.053-.062] 1.14-1.93 [.045-.076] 1.35-1.57 [.053-.062] 0.64-1.93 [.025-.076] 1.35-1.57 [.053-.062] 0.64-1.93 [.025-.076] --- --- 1.35-1.57 [.053-.062] 1.14-1.93 [.045-.076] --- --- 1 40 [.055] 1.40 [ 055] 1.57 [.062] Figure 3 (end) 6 of 11 Tyco Electronics Corporation Rev T HD-20 Precision Formed Contacts 114-10000 3.4. Crimped Contact Straightness A. Twist or Roll The crimped wire and insulation barrels must be aligned with the un-crimped portion of the contact to within the limit shown in Figure 4. Front of Contact _ (Max) (Pin or Socket) 15 Wire Barrel Figure 4 B. Straightness Test questionable contacts using a straightness gage manufactured to the specifications of Figure 5. To be considered acceptable for use, a contact must fully enter the gage without binding. 1.07 + 0.03 1.77 + 0.03 [.042 + .001] DIA [.0695 + .0010] DIA -A- 2.16 + 0.01 [.0850 + .0005] DIA 0.10 [.004] A 2.16 + 0.01 [.0850 + .0005] DIA -B- 0.10 [.004] EEEEEEEEEEE EEEEEEEEEEE EEEEEEEEEEE EEEEEEEEEEE EEEEEEEEEEE Socket 6.35 7.11 [.250] [.280] 7.37 End B 12.7 + 0.51 [.500 + .020] DIA Pin End [.590] 29.97 + 0.51 [1.180 + .020] NOTES: Material . . . . . . . . Tool Steel, AISI Type 01 or 02 Hardness . . . . . . . . . . . Rockwell B99 Maximum Finish . . . . . . . . . . . . . . . . . . . . . . Black Oxide Figure 5 3.5. Solder Cup Contacts Observe the guidelines and procedures described in Instruction Sheet 408-7799 when solder cup contacts are required. Solder, clean, and dry all wire leads to contacts according to the following: A. Flux Selection Wire lead and contact wire barrel interior shall be fluxed prior to soldering using a mildly active rosin. Flux must be compatible with manufacturing, safety, and health guidelines. B. Cleaning After cleaning, removal of fluxes, residues, and activators is mandatory. Cleaning procedures and solvents depend on the type of flux used. See Figure 6. Rev T Tyco Electronics Corporation 7 of 11 HD-20 Precision Formed Contacts DANGER 114-10000 Consideration must be given to toxicity and other safety and health requirements as recommended in the Material Safety Data Sheet supplied by the solder cleaning solvent manufacturer. CLEANER TIME NAME (Mi (Minutes) ) TYPE TEMPERATURES (Maximum) CELSIUS FAHRENHEIT Alpha 2110H Aqueous 1 132 270 Bioact EC-7z Solvent 5 100 212 Butyl CarbitolD Solvent 1 Isopropyl Alcohol Solvent 5 100 212 Kester 5778s Aqueous 5 100 212 Kester 5779s Aqueous 5 100 212 Loncoterge 520D Aqueous 5 100 212 Loncoterge 530D Aqueous 5 100 212 Terpene Solvent Solvent 5 100 212 H Product of Fry's Metals, Inc. z Product of Petroferm, Inc. D Product of Union Carbide Corp. Room Ambient s Product of Litton Systems, Inc. Figure 6 C. Drying When drying cleaned assemblies, DO NOT exceed recommended temperature limitations. Excessive temperatures may cause degradation of the connector used as a stabilizer during the soldering process. D. Soldering Guideline Manual 402-40 is available upon request and can be used as a guide in soldering. This manual gives various flux types and characteristics, commercial designation, and flux removal procedures. A checklist is included in the manual to aid in obtaining information pertaining to soldering problems. 3.6. Posted Contacts Pin and socket contacts having 0.64 mm [.025 in.] square technology posted aft ends are available to fit HD-20 connectors. Posts 3.18 mm [.125 in.], 4.78 mm [.188 in.], 10.80 mm [.425 in.], and 16.54 mm [.651 in.] in length are offered, allowing a variety of mating or grounding options. When inserting posted contacts into housings, be careful to hold the contact by the transition flange. See Figure 1. 3.7. Repair/Replace Use Insertion/Extraction Tool 91285-1 (Instruction Sheet 408-9404) to remove individual contacts from housings for replacement or for relocation to another housing cavity. Damaged or worn contacts may be replaced provided there is sufficient slack, after restripping the wire, to insert the new contact. CAUTION DO NOT re-use damaged or worn contacts. Instead, replace them with new contacts and discard the old ones. ! 4. QUALIFICATION No qualifications or approvals are required for HD-20 Precision Formed Contacts. 5. TOOLING HD-20 Precision Formed Contacts can be terminated to wire using hand, semi-automatic, or automatic crimping tools. Recommended tooling, and instructional material, is provided in Figure 7. All hand tools and applicators include integral dies. The automatic machines that hold applicators are also listed in the table along with related documentation. NOTE The Model K" AMP-O-LECTRIC Terminating Machine 565435-5 has been superseded by the Model G" Terminating Machine 354500-1 for new applications. For existing applications, the Model K" is still recommended because of the i 8 of 11 large number of installed machines. Tyco Electronics Corporation Rev T HD-20 Precision Formed Contacts 114-10000 g APPLICATOR WIRE SIZE RANGE WIRE INSULATION HAND TOOL (AWG) DIAMETER ACCEPTED (408-8547) (408-8040) 32-28 0 76-1 02 [[.030-.040] 0.76-1.02 030- 040] --- 680659-2 1 73 [[.068] 1.73 068] Max MACHINE MACHINE DOCUMENT 354500-1 409-5842 565435-5 409-5128 466506-2 565435-5 409-5128 466903-1 1320895-1 409-10012 354500-1 409-5842 565435-5 409-5128 1320895-1 409-10012 122500-2, -3 409-5852 356500-1, -2 409-5878 354500-1 409-5842 565435-5 409-5128 1320895-1 409-10012 122500-2, -3 409-5852 356500-1, -2 409-5878 662700-[ ] 409-5884 1213400-1, -2 409-5878 354500-1 409-5842 565435-5 409-5128 122500-2, -3 409-5852 356500-1, -2 409-5878 354500-1 409-5842 565435-5 409-5128 1320895-1 409-10012 122500-2, -3 409-5852 356500-1, -2 409-5878 354500-1 409-5842 565435-5 409-5128 1320895-1 409-10012 122500-2, -3 409-5852 356500-1, -2 409-5878 662700-[ ] 409-5884 1213400-1, -2 409-5878 354500-1 409-5842 565435-5 409-5128 91548-1 466758-2 1 27 1 52 1.27-1.52 [[.050-.060] 050 060] AUTOMATIC 91549-1 466963-1 28-24 466423-1 91503-1 0.76-1.02 [.030-.040] or 91549-1 466423-2 466901-1 26-24 567036-1 1.02-1.27 [.040-.050] 91525-1 22 567036-2 466505-1 1.73 [.068] Max 91548-1 466505-2 466902-1 24-20 466422-1 1 27 1 52 1.27-1.52 [[.050-.060] 050 060] 91503-1 466422-2 466900-1 22-20 567033-1 1 73 [[.068] 1.73 068] Max or 91513-1 567033-2 18 g In order to use the same applicator in the AMPOMATOR CLS IV Lead-Making Machine and the AMP-O-LECTRIC Terminating Machine, the feed cam and wire stripper must be changed. See the Customer Manuals supplied with these machines. Figure 7 (cont'd) Rev T Tyco Electronics Corporation 9 of 11 HD-20 Precision Formed Contacts 114-10000 AMP-O-LECTRIC Model G" AMP-O-MATIC Side Feed Terminating Machine Stripper-Crimper Model III 354500-[ ] (409-5842) Machine 1320895-[ ] (409-10012) Basic AMP-O-LECTRIC Model K" AMPOMATOR CLS IV+ Lead-Making Machine (409-5878) AMPOMATOR CLS Model III-G Lead-Making Machine Terminating Machine 565435-5 (409-5128) 122500-[ ] (409-5852) Typical Hand Tool (408-8547) Insertion/Extraction Tool HD Quick Change Applicators 91285-1 and Replacement Tip (408-8040) Kits 543382-[ ] (408-9404) Figure 7 (end) 10 of 11 Tyco Electronics Corporation Rev T HD-20 Precision Formed Contacts 114-10000 6. VISUAL AID Figure 8 shows a typical application of HD-20 Precision Formed Contacts. 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. NOTE: CRIMPED CONTACT WITH INSULATION BARREL SHOWN; SAME REQUIREMENTS ALSO APPLY TO CONTACTS WITHOUT INSULATION BARREL WIRE BARREL SEAM CLOSED WITH NO CONDUCTOR STRANDS SHOWING WIRE CONDUCTORS AND CONDUCTOR ENDS MUST BE INSULATION MUST BE VISIBLE IN THIS AREA UNDAMAGED WIRE CONDUCTORS AND INSULATION MUST BOTH BE VISIBLE IN THIS AREA (NO WIRE INSULATION MAY BE IN THE WIRE BARREL) REAR BELLMOUTH FRONT BELLMOUTH MAY MUST BE VISIBLE SHOW SLIGHTLY CUTOFF TAB MUST THERE MUST BE NO DAMAGE OR BE VISIBLE DISTORTION TO CONTACT OR THERE MUST BE NO RETENTION FEATURE TWIST, ROLL, OR BEND HERE FIGURE 8. VISUAL AID Rev T Tyco Electronics Corporation 11 of 11