Application Specification
Euro-Crimp 114-13196
LOC B
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E
2007 Tyco Electronics Corporation, Harrisburg, PA
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This controlled document is subject to change.
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visit our website at
www.tycoelectronics.com
Terminals and Splices
01 MAY 07 Rev A
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters. Unless
otherwise specified, dimensions have a tolerance of +0.13 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 Euro–Crimp Terminals and Splices for commercial
applications. The terminals and splices consist of precision formed metal wire barrel insulated with PVC with a
maximum operating temperature of 75
_
C. The terminals and splices accept solid or stranded wire for single
applications. The insulation allows insertion of wires that meet maximum voltage rating of 600 V.
The terminals and splices are colour coded to provide a visual reference applicable to the wire size range
suitable for the terminal or splice. In addition, terminals are marked on the tongue with the wire size range. The
serrations inside the wire barrel provide maximum contact and tensile strength after crimping. The terminals
suitable for mounting accept stud sizes M3 through M12. The terminals and splices are available in
loose–piece for terminating with manual and pneumatically–powered hand–held 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
Ring
Terminal Female Bullet
Terminal Male Bullet
Terminal
Piggy Back
Terminal Male Push On
Terminal Fully Insulated
Female Push On
Terminal
Pin
Terminal Hooked Blade
Terminal `Blade
Terminal
Parallel Splice
Terminal Butt
Terminal Fork
Terminal Female Push On
Terminal
NOTE
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2. REFERENCE MATERIAL
2.1. Revision Summary
S
Initial release of document
2.2. Customer Assistance
Reference Product Base Part Number 1838142 and Product Code A077 are representative numbers of
Euro–Crimp Terminals and Splices. 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 your local Tyco Electronics Representative.
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. If there is a conflict
between the information contained in the Customer Drawings and this specification or with any other technical
documentation supplied, contact your local Tyco Electronics Field Service Engineer.
2.4. Instructional Material
Instruction Sheets (408–series) provide product assembly instructions or tooling setup and operation
procedures. Documents available which pertain to this product are:
Document Number Document Title
408–2823 TETRA–CRIMP* Hand Crimping Tool 59824–1
408–7424 Checking Terminal Crimp Height or Gaging Die Closure
3. REQUIREMENTS
3.1. Special Characteristics
Terminals with an open–ended tongue, such as spade terminals, can be installed and removed without
complete removal of the mounting screw. The terminal flat sides provide a locking feature against lateral
stress; flanged ends reduce possibility of terminal separation.
3.2. Storage
A. Shelf Life
The terminals and splices should remain in the shipping containers until ready for use to prevent
deformation to the terminals and splices. The terminals and splices should be used on a first in, first out
basis to avoid storage contamination that could adversely affect signal transmissions.
B. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the terminal and
splice insulation material.
3.3. Chemical Exposure
Do not store terminals or splices near any chemical listed below as they may cause stress corrosion
cracking in the terminal or splices.
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfur Nitrites Tartrates
3.4. Wire Selection and Preparation
The terminals and splices will accept solid or stranded copper wire sizes 0.5 mm2 to 6 mm2 [22 to 10 AWG]
with an insulation diameter range of 2.03 to 6.35 mm. Proper strip length is necessary to properly insert the
wire into the terminal or splice. The strip length of the wire is shown in Figure 2.
Reasonable care must be taken not to nick, scrape, or cut any strands during the stripping operation.
CAUTION
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Stranded Wire Solid Wire
Strip Length
Conductor Insulation
Strip Length
Insulation
Conductor
TERMINAL OR SPLICE
WIRE INSULATION
WIRE STRIP LENGTH
SIZE
mm2[AWG] INSULATION
COLOUR
WIRE INSULATION
DIAMETER TERMINAL BUTT SPLICE PARALLEL SPLICE
0.5-1.5 [22-16] Red 2.03-3.56 5.16-5.94 6.35-7.14 7.87-8.64
1.5-2.5 [16-14] Blue 2.67-4.32 5.16-5.94 6.35-7.14 7.87-8.64
4.0-6.0 [12-10] Yellow 3.81-6.35 7.93-8.73 8.73-4.53 8.73-9.53
Figure 2
3.5. Wire Placement
Stranded wire conductors must be inside the terminal or splice wire barrel. No strands can be folded back over
the wire insulation. Conductor ends must be bottomed in the wire barrel. The wire insulation must be inside the
insulation of the terminal or splice, but must not enter the wire barrel, to provide strain relief for the wire.
3.6. Crimp Requirements
The terminal or splice must be crimped to the wire according to instructions packaged with applicable tooling.
A. Wire Barrel Crimp
The crimp applied to the wire barrel portion of the terminal or splice is the most compressed area and is
most critical in ensuring optimum electrical and mechanical performance of the crimped terminal or splice.
The crimped area must be symmetrical on both sides of the wire barrel of the terminal or splice. The crimp
may be off center on the wire barrel but not off the end of the wire barrel. See Figure 3.
B. Wire Conductor and Insulation Location
After crimping, all conductors must be held firmly inside the wire barrel. No strands can be folded back
over the wire insulation. The wire insulation must be inside the insulation barrel of the terminal or splice,
but must not enter the wire barrel. Conductor ends must be flush with, or extend slightly beyond, the end
of the wire barrel; or, in splices with a wire stop inside the center of the splice, conductor ends must butt
against the wire stop. See Figure 3.
Wire insulation shall NOT be cut or broken during the crimping operation. Reasonable care should be taken to provide
undamaged wire terminations.
C. Terminal or Splice Insulation
The terminal or splice insulation must not be deformed, cut, or show uneven stress marks. See Figure 3.
D. Bellmouth
There shall be no rear bellmouth. The front bellmouth shall be evident as shown in Figure 3.
E. Tensile Strength
Crimped terminals or splices must hold the wire firmly and have a crimp pull–out test value meeting that
specified in Figure 4.
Adjust tensile testing machine for head travel of 25.4 mm per minute. Directly and gradually apply force for one
minute.
CAUTION
!
NOTE
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Wire Insulation
Location
Wire Conductor Location
Crimp Centered on Wire Barrel
(Crimp May Be Off Center, But Not
Off End of Wire Barrel)
Crimp Centered on Wire Barrel
(Crimp May Be Off Center, But Not Off End of Wire Barrel)
Wire Insulation
Location
Wire Conductor Location
Wire Insulation
Location
Wire Conductor Location
Front Bellmouth Must Be Visible
End of Conductors
Must Be Flush With, or
Extend Slightly Beyond
End of Wire Barrel
Terminal Plug Terminal
Splice
Front Bellmouth
Must Be Visible
SOLDER SLUG
TERMINAL OR SPLICE
SIZE
CRIMP HEIGHT (See Notes)
SIZE
mm2[AWG] DIAMETER CRESCENT CRIMP CRIMP PRODUCED BY
TETRA-CRIMP TOOLING
0.5-1.5 [22-16] 3.18 2.77-2.92 1.98-2.18
1.5-2.5 [16-14] 4.76 3.02-3.18 2.34-2.54
4.0-6.0 [12-10] 6.35 4.29-4.45 3.25-3.45
NOTE:
The resilience of the terminal and splice insulation prevents accurate direct measurement of crimp height. Crimp height can be obtained by
measuring a crimped solder slug (60% tin and 40% lead) with a diameter comparable to the wire size. The slug must be measured over the most
compressed area of the slug with a standard micrometer or crimp height comparator (refer to Instruction Sheet 408-7424 for specific
instructions). The solder slug diameter and crimp height must be within the dimensions provided.
NOTE:
Each crimp dimension represents the functional range of a wire/terminal or splice combination. 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.
Figure 3
WIRE SIZE (AWG) TENSILE FORCE
(N Min)
22 35.6
20 57.9
18 89.0
16 133.5
14 222.5
12 311.5
10 356.0
Figure 4
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F. Bend Allowance
The force applied during crimping may cause some bending between the wire barrel and wire. Such
deformation is acceptable within the following limits.
1. Up and Down
The crimped portion must not be bent beyond the limits shown in Figure 5.
2. Side–to–Side
The crimped portion must not be bent from one side to the other beyond the limits shown in Figure 5.
Figure 5
Up and Down Bend
Datum Line
11
_
11
_
Datum Line
11
_
11
_
Datum Line
11
_
11
_
11
_
11
_
Terminal
Plug Terminal
Splice
Side-to-Side Bend
Datum Line
Datum Line
11
_
11
_
11
_
11
_
11
_
11
_
Datum Line
11
_
11
_
Terminal
Plug Terminal
Splice
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3.7. Repair
Damaged terminals and splices or terminals and splices that do not meet crimp dimension requirements must
be removed from wires, discarded, and replaced with new ones. When removing a terminal or splice, cut the
wires as close as possible to the end of the wire barrel. Do NOT remove the terminal or splice from the wire
and re–terminate.
4. QUALIFICATION
Euro–Crimp Terminals and Splices are Listed by Underwriters Laboratories Inc. (UL) under File E13288.
5. TOOLING
Hand tools for manual application of loose piece terminals and splices are available to cover the full wire size
range. Tooling part numbers and instructional material packaged with the tooling are shown in Figure 6.
Modified designs and additional tooling concepts may be available to meet other application requirements. Tool
Engineers have designed machines for a variety of application requirements. For assistance in setting up prototype
and production line equipment, contact your local Tyco Electronics Representative.
Hand crimping tools consist of a handle assembly with integral fixed jaws or fixed dies, or a head that accepts
various die assemblies. The jaws or dies have one or more crimping chambers used to crimp terminals and
splices onto pre–stripped wire. The hand tool assemblies have a ratchet, except the hydraulic hand crimping
tool which uses hydraulic fluid, to ensure full crimping pressure is applied to the terminal or splice.
Figure 6
TETRA-CRIMP Hand
Crimping Tool 59824-1
(408-2823)
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6. VISUAL AID
Figure 7 shows a typical application of Euro–Crimp Terminals and Splices. 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 7
WIRE INSULATION
MUST BE UNDAMAGED
WIRE INSULATION MUST BE INSIDE INSULATION
BARREL BUT MUST NOT ENTER WIRE BARREL
INSULATION BARREL MUST
BE IN FIRM CONTACT WITH
WIRE INSULATION
WIRE SIZE MUST BE SAME
AS WIRE SIZE STAMPED
ON TERMINAL
THERE MUST BE NO
NICKED OR MISSING
CONDUCTOR STRANDS
WIRE MUST BE
FULLY INSERTED
END OF CONDUCTORS MUST BE
FLUSH WITH, OR EXTEND SLIGHTLY
BEYOND END OF WIRE BARREL
END OF CONDUCTORS MUST
BE AGAINST WIRE STOP OR
MUST BE FLUSH WITH, OR
EXTEND SLIGHTLY BEYOND,
END OF WIRE BARREL
ALL CONDUCTORS MUST BE HELD
FIRMLY INSIDE WIRE BARREL
TERMINAL MUST NOT BE BENT
OR DEFORMED IN ANY WAY
SPLICE MUST NOT BE
BENT OR DEFORMED
IN ANY WAY
