Application Specification 114-13196 Euro-Crimp Terminals and Splices NOTE i 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. Ring Terminal Female Bullet Terminal Piggy Back Terminal Male Push On Terminal Pin Terminal Parallel Splice Terminal Male Bullet Terminal Fully Insulated Female Push On Terminal Hooked Blade Terminal Butt Terminal Blade Terminal Fork Terminal Female Push On Terminal Figure 1 E This controlled document is subject to change. All International Rights Reserved For latest revision and Regional Customer Service, TE logo and Tyco Electronics are trademarks. visit our website at 2007 Tyco Electronics Corporation, Harrisburg, PA *Trademark. Other products, logos, and company names used are the property of their respective owners. www.tycoelectronics.com 1 of 7 LOC B Euro-Crimp Terminals and Splices 114-13196 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 Title Document Number 408-2823 408-7424 TETRA-CRIMP* Hand Crimping Tool 59824-1 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 Amines Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Sulfur Compounds 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. CAUTION Reasonable care must be taken not to nick, scrape, or cut any strands during the stripping operation. ! 2 of 7 Tyco Electronics Corporation Rev A Euro-Crimp Terminals and Splices 114-13196 Stranded Wire Solid Wire Strip Length Conductor TERMINAL OR SPLICE Strip Length Insulation Conductor Insulation WIRE STRIP LENGTH WIRE INSULATION DIAMETER TERMINAL BUTT SPLICE PARALLEL SPLICE SIZE mm2 [AWG] INSULATION COLOUR 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. CAUTION 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. NOTE Adjust tensile testing machine for head travel of 25.4 mm per minute. Directly and gradually apply force for one minute. i Rev A Tyco Electronics Corporation 3 of 7 Euro-Crimp Terminals and Splices 114-13196 Terminal Plug Terminal Wire Conductor Location Front Bellmouth Must Be Visible Wire Insulation Location End of Conductors Must Be Flush With, or Extend Slightly Beyond End of Wire Barrel Splice Front Bellmouth Must Be Visible Crimp Centered on Wire Barrel (Crimp May Be Off Center, But Not Off End of Wire Barrel) Wire Conductor Location Wire Conductor Location Wire Insulation Location Wire Insulation Location Crimp Centered on Wire Barrel (Crimp May Be Off Center, But Not Off End of Wire Barrel) SOLDER SLUG TERMINAL OR SPLICE CRIMP HEIGHT (See Notes) SIZE 2 mm [AWG] 0.5-1.5 [22-16] 1.5-2.5 [16-14] 4.0-6.0 [12-10] NOTE: NOTE: DIAMETER CRESCENT CRIMP 3.18 4.76 6.35 2.77-2.92 3.02-3.18 4.29-4.45 CRIMP PRODUCED BY TETRA-CRIMP TOOLING 1.98-2.18 2.34-2.54 3.25-3.45 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. 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 TENSILE FORCE WIRE SIZE (AWG) (N Min) 22 20 18 16 14 12 10 35.6 57.9 89.0 133.5 222.5 311.5 356.0 Figure 4 4 of 7 Tyco Electronics Corporation Rev A Euro-Crimp Terminals and Splices 114-13196 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. Up and Down Bend Terminal 11_ Datum Line Plug Terminal 11_ 11_ Datum Line 11_ 11_ Splice 11_ Datum Line 11_ 11_ Side-to-Side Bend Terminal 11_ Datum Line 11_ Plug Terminal 11_ Datum Line 11_ Splice 11_ 11_ Datum Line 11_ Rev A Figure 5 Tyco Electronics Corporation 11_ 5 of 7 Euro-Crimp Terminals and Splices 114-13196 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. NOTE 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 i 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. TETRA-CRIMP Hand Crimping Tool 59824-1 (408-2823) Figure 6 6 of 7 Tyco Electronics Corporation Rev A Euro-Crimp Terminals and Splices 114-13196 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. WIRE INSULATION MUST BE UNDAMAGED WIRE INSULATION MUST BE INSIDE INSULATION BARREL BUT MUST NOT ENTER WIRE BARREL WIRE SIZE MUST BE SAME ALL CONDUCTORS MUST BE HELD AS WIRE SIZE STAMPED FIRMLY INSIDE WIRE BARREL ON TERMINAL END OF CONDUCTORS MUST BE INSULATION BARREL MUST FLUSH WITH, OR EXTEND SLIGHTLY BE IN FIRM CONTACT WITH BEYOND END OF WIRE BARREL WIRE INSULATION TERMINAL MUST NOT BE BENT OR DEFORMED IN ANY WAY WIRE MUST BE THERE MUST BE NO FULLY INSERTED NICKED OR MISSING CONDUCTOR STRANDS END OF CONDUCTORS MUST BE AGAINST WIRE STOP OR SPLICE MUST NOT BE MUST BE FLUSH WITH, OR BENT OR DEFORMED EXTEND SLIGHTLY BEYOND, IN ANY WAY END OF WIRE BARREL Figure 7 Rev A Tyco Electronics Corporation 7 of 7