Application Specification 114-- 10004 Type III+ (Size 16) Contacts NOTE i 14 SEP 09 Rev K 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 Type III+ (Size 16) Contacts. These contacts have a pin diameter of 1.57 mm [.062 in.]. A color dot appears on the loose piece or (loose piece only) contact spring which designates the applicable wire size and matches the color dot above the hand tool crimping section. These requirements apply to hand or automatic machine crimping tools for the insulated grip contacts. When corresponding with Tyco Electronics Personnel, use the terminology provided on this specification to help facilitate your inquiry for information. Basic terms and features of components are provided in Figure 1. Insulation Grip Contacts Insulation Barrel Wire Barrel Color Dot (Loose Piece Only) Wire Barrel Socket Insulation Barrel Pin Locking Lance Posted Socket Solder Tab Pin Solder Type Socket Figure 1 2. REFERENCE MATERIAL 2.1. Revision Summary S Updated document to corporate requirements S New logo and format 2.2. Customer Assistance Reference Base Part Number 66098 and Product Code 5022 are representative numbers of the Type III+ (Size 16) 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 the Product Information Center at the number at the bottom of this page. 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 10 LOC B Type III+ (Size 16) Contacts 114- 10004 2.3. Drawings Customer Drawings for product part numbers are available from 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. 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. 2.5. Specifications Product Specification 108--10042 provides product performance requirements and test information. 2.6. 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 provide setup, operation, and maintenance of machines. Document Number 408--1216 408--1379 408--3295 408--7347 408--7414 408--7424 408--7773 408--8039 408--8040 408--8059 408--8547 408--9640 408--9816 409--5128 409--5842 409--5852 409--5866 409--5870 409--5878 409--10012 409--10016 409--10027 409--10029 Document Title Extraction Tools 305183--[ ] Selection Charts for Multimate Pin and Socket Contacts Preparing Reel of Contacts for Application Tooling Insertion Tools 91002--[ ] Hand Crimping Tool 90225--2 Checking Terminal Crimp Height or Gaging Die Closure Hand Crimping Tool 90331--1 Heavy Duty Miniature Quick--Change Applicators (End--Feed Type) Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type) General Preventive Maintenance for Applicators CERTI--CRIMP* II Straight action Hand Tools Crimp Quality Monitor Applicators for Side--Feed and End--Feed Applications Handling of Reeled Products Basic AMP--O--LECTRIC* Model "K" Terminating Machine 565435--5 AMP--O--LECTRIC Model "G" Terminating Machines 354500--[ ] AMPOMATOR* CLS III--G Lead--Making Machine 122500--[ ] AMPOMATOR CLS IV Lead--Making Machine 217500--[ ] Crimp Quality Monitors (CQM) for AMPOMATOR CLS IV Lead--Making Machines AMPOMATOR CLS IV+ Lead--Making Machine 356500--[ ] AMP--O--MATIC* Side Feed Stripper--Crimper III Machine 1320895--[ ] Entry Level Terminator (ELT) Machine 1338600--[ ] Stripping Modules 1490500 and 1490502 Stripping Modules 1490501 and 1490503 3. REQUIREMENTS 3.1. Storage A. Ultraviolet Light Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the contacts. B. Reel Storage When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically. C. Shelf Life The contacts should remain in the shipping containers until ready for use to prevent deformation to the contact. The contacts should be used on a first in, first out basis to avoid storage contamination that could adversely affect signal transmissions. 2 of 10 Tyco Electronics Corporation Rev K Type III+ (Size 16) Contacts 114- 10004 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 Sulfur Nitrites Sulfur Compounds Tartrates Where the above environmental conditions exist, phosphor--bronze contacts are recommended instead of brass if available. 3.2. Special Characteristics The solder type and solder tab versions will accept various sizes of solid or stranded wire. For soldering requirements, follow the recommendations of the wire manufacturer and soldering equipment manufacturer. Refer to Manual 402--40. 3.3. Wire Selection and Preparation The total wire size range for these contacts is 30 through 14 AWG. The wire must be stripped to the dimensions shown in Figure 2. NOTE i CAUTION 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. See Section 5, TOOLING. DO NOT nick, scrape, or cut the wire conductor during the stripping operation. ! Strip Length 4.34-- 3.58 [.171-- .141] Conductor Insulation WIRE BARREL CRIMP WIRE SIZE, AWG INSULATION DIAMETER HEIGHT WIDTH INSULATION BARREL CRIMP WIDTH 30 26 30--26 0.36--0.76 [.014--.030] 1.02--1.52 [.040--.060] 1.05--0.89 [.0415--.035] 1.05--0.89 [.0415--.035] 1.75--1.57 [.069--.062] 1.75--1.57 [.069--.062] 1.60--1.20 [.063--.047] 1.98--1.58 [.078--.062] 0.89--1.40 [.035--.055] 2.03--2.54 [.080--.100] 0.84--0.74 [.033--.029] 1.04--0.86 [.041--.034] 1.57--1.40 [.062--.055] 1.75--1.57 [.069--.062] 1.98--1.58 [.078--.062] 3.25--2.85 [.128--.112] 1.52--3.43 [.060--.135] 1.02--2.03 [.040--.080] 0.97--0.76 [.038--.030] 1.05--0.86 [.0415--.034] 1.75--1.57 [.069--.062] 1.75--1.57 [.069--.062] 3.25--2.84 [.128--.112] 2.49--2.09 [.098--.082] 0.89--1.40 [.035--.055] 1.52--3.43 [.060--.135] 1.02--2.03 [.040--.080] 0.89--0.74 [.035--.029] 1.07--0.86 [.042--.034] 1.07--0.97 [.042--.038] 1.57--1.40 [.062--.055] 1.75--1.57 [.069--.062] 1.75--1.57 [.069--.062] 1.98--1.58 [.078--.062] 3.25--2.84 [.128--.112] 2.49--2.09 [.098--.082] 2.03--2.54 [.080--.100] 1.52--3.43 [.060--.135] 1.04--0.91 [.041--.036] 1.75--1.57 [.069--.062] 3.25--2.85 [.128--.112] 1.02--0.81 [.040--.032] 1.75--1.57 [.069--.062] 3.25--2.84 [.128--.112] 1.02--2.03 [.040--.080] 1.05--0.91 [.0415--.036] 1.75--1.57 [.069--.062] 2.49--2.09 [.098--.082] 26 24 (2) 24 22 Figure 2 (cont'd) Rev K Tyco Electronics Corporation 3 of 10 Type III+ (Size 16) Contacts WIRE SIZE, AWG 20 18 16 14 INSULATION DIAMETER 114- 10004 WIRE BARREL CRIMP INSULATION BARREL CRIMP WIDTH HEIGHT 1.12--0.94 [.044--.037] 1.12--0.91 [.044--.036] 1.12--0.95 [.044--.0375] 1.37--1.24 [.054--.049] WIDTH 1.75--1.57 [.069--.062] 1.75--1.57 [.069--.062] 1.75--1.57 [.069--.062] 2.46--2.29 [.097--.090] 2.03--2.54 [.080--.100] 2.79--3.81 [.110--.150] 1.35--1.24 [.053--.049] 1.55--1.24 [.061--.049] 1.47--1.24 [.058--.049] 1.78--1.68 [.070--.066] 2.20--2.03 [.087--.080] 2.46--2.29 [.097--.090] 2.20--2.03 [.087--.080] 2.46--2.29 [.097--.090] 3.25--2.85 [.128--.112] 4.16--3.76 [.163--.147] 3.25--2.85 [.128--.112] 4.16--3.76 [.163--.147] 2.03--2.54 [.080--.100] 1.78--1.68 [.070--.066] 2.46--2.29 [.097--.090] 3.25--2.85 [.128--.112] 2.03--2.54 [.080--.100] 1.52--3.43 [.060--.135] 1.02--2.03 [.040--.080] 2.79--3.81 [.110--.150] 2.03--2.54 [.080--.100] 2.79--3.81 [.110--.150] 3.25--2.85 [.128--.112] 3.25--2.84 [.128--.112] 2.49--2.09 [.098--.082] 4.16--3.76 [.163--.147] Figure 2 (end) 3.4. Crimped Contact Requirements The contact must be crimped onto the wire according to instructions packaged with applicable tooling. After crimping, the contact should appear as shown in Figure 3. A typical pin contact is shown as it should appear after crimping; these requirements apply equally to the socket contact. CAUTION The wire insulation must not be damaged during the crimping process. ! A. Wire Barrel Crimp 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 contact wire barrel crimp height must be within the dimension provided in Figure 2. 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 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 Section 5, TOOLING. C. Bellmouths Front and rear bellmouths shall be evident 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. 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. A slight cut in the insulation by the insulation barrel is permissible as this causes no problems in actual use. Insulation crimp shall comply to width and height provided in Figure 3. H. Wire Location The wire conductor and insulation must be visible in the transition area between the wire and insulation barrels. 4 of 10 Tyco Electronics Corporation Rev K Type III+ (Size 16) Contacts 114- 10004 I. Conductor Extension The conductor may extend beyond the wire barrel to the maximum shown. J. Wire Barrel Seam The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam. Periodic inspections must be made to ensure crimped contact formation is consistent as referenced. NOTE i Wire Conductors and Insulation Must Both be Visible in This Area 0.81 [.032] Max Conductor Location Insulation Barrel Crimp Width Locking Lance Undamaged Wire Barrel Seam Closed with No Conductor Strands Showing Crimp Length 0.51 [.020] Max Front Bellmouth 0.20-- 0.64 [.008-- .025] Rear Bellmouth X X 0.25 [.010] Max Wire Barrel Flash Cutoff Tab 0.25 [.010] Max. 0.08 [.003] Max. Burr Wire Barrel Crimp Width Wire Barrel Crimp Height Section X- X Figure 3 3.5. Axial Concentricity The axial concentricity of a crimped contact must be within an area defined by the diameter of a circle that has the same center as the centerline of the contact. The diameter of the circle will depend on the wire sizes. See Figure 4. This measurement does not apply to posted contacts. Rev K Tyco Electronics Corporation 5 of 10 Type III+ (Size 16) Contacts WIRE SIZE, AWG CIRCLE DIAMETER 30 -- 28 3.40 [.134] 26 -- 20 3.40 [.134] 18 -- 14 4.16 [.164] 114- 10004 Circle Diameter Contact and Circle Diameter Centerlines Contact Figure 4 3.6. Posted Sockets The posted sockets accept TERMI--POINT* Connectors or wrap--type terminations. They can accommodate up to three terminations per post. For terminating requirements, follow the instructions pertaining to specific choice of termination method and tooling types used. 3.7. Solder Tab Pin and Sockets Observe all guidelines and procedures when solder type contacts are required. Solder, clean, and dry all wire leads to the contacts according to the following: A. Flux Selection The wire lead and contact wire barrel interior shall be fluxed prior to soldering using a mildly active rosin. Selection of the proper flux will depend on the type of pc board and other components mounted on the board. Additionally, the flux will have to be compatible with the wave solder line, manufacturing, and safety requirements. 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 list of common cleaners that will not affect the connectors for the times and temperatures shown. See Figure 5. DANGER Consideration must be given to toxicity and other safety and health requirements as recommended in the Material Safety Data Sheet supplied by the solder cleaner solvent manufacturer. CLEANER TIME (Minutes) TEMPERATURES (Maximum) NAME ALPHA 2110 TYPE Aqueous 1 CELSIUS 132 FAHRENHEIT 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 Room Ambience Figure 5 C. Drying When drying cleaned assemblies and pc boards, make certain that temperature limitations of --55_ to 105_C [--67_ to 222_F] are not exceeded. Excessive temperatures may cause housing degradation. D. Soldering Guideline Refer to Paragraph 2.4, Manuals, for information on soldering requirements. 6 of 10 Tyco Electronics Corporation Rev K Type III+ (Size 16) Contacts 114- 10004 3.8. Repair/Replace Contacts are not repairable once a termination has been made. Any defective or damaged contact must be removed and replaced with a new one. Use Extraction Tool 305183 to remove individual contacts from housings for replacement or for relocation to another housing cavity. 4. QUALIFICATION No qualifications or approvals are required for Type III+ Contacts. 5. TOOLING These contacts can be terminated to wire using hand, semi--automatic, or automatic crimping tools. Recommended tooling is provided in Figure 6. NOTE i Tyco Electronics Tooling 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 Hand Crimping Tool 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 Applicator 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 located 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. S Insertion/Extraction Tooling Insertion Tools are designed for contacts crimped to small fragile wire. They are designed to stabilize the contact during insertion. For use of Insertion Tool 91002 which may be used with these contacts, refer to Instruction Sheet 408--7347. Extraction Tools are designed to release the locking lance inside the connector housing without damaging the housing or contacts. For use of Extraction Tool 305183 which may be used with these contacts, refer to Instruction Sheet 408--1216. WIRE SIZE RANGE, AWG 30--26 INSULATION DIAMETER RANGE HAND TOOL (DOCUMENT) APPLICATOR (408-- 8040) 1.02--1.52 [.040--.060] 91515--1 (408--8547) 466598--2 0.36--0.76 [.014--.030] 90225--2 (408--7414) 466585--3 466321--3 26--24 0.89--1.40 [.035--.055] 91515--1 (408--8547) 466321--4 466908--2 POWER UNIT (DOCUMENT) 565435--5 (409--5128) 1338600--3, --4 (409--10016) 565435--5 (409--5128) 1338600--3, --4 (409--10016) 122500--2, --3 (409--5852) 217500--1, --2 (409--5866) 356500--1, --2 (409--5878) 354500--1 (409--5842) 565435--5 (409--5128) 1338600--3, --4 (409--10016) 1320895--1, --3 (409--10012) Figure 6 (cont'd) Rev K Tyco Electronics Corporation 7 of 10 Type III+ (Size 16) Contacts WIRE SIZE RANGE, AWG INSULATION DIAMETER RANGE 1.02--2.03 [.040--.080] 2.03--2.54 [.080--.100] 114- 10004 HAND TOOL (DOCUMENT) 91505--1 (408--8547) 91515--1 (408--8547) 90225--2 (408--7414) 91523--1 (408--8547) 24--20 1.52--3.43 [.060--.135] 90331--1 (408--7773) APPLICATOR (408-- 8040) POWER UNIT (DOCUMENT) 466323--3 122500--2, --3 (409--5852) 217500--1, --2 (409--5866) 356500--1, --2 (409--5878) 466323--4 354500--1 (409--5842) 565435--5 (409--5128) 1338600--3, --4 (409--10016) 466907--2 1320895--1, --3 (409--10012) 466324--1 122500--2, --3 (409--5852) 217500--1, --2 (409--5866) 356500--1, --2 (409--5878) 466324--2 354500--1 (409--5842) 565435--5 (409--5128) 1338600--3, --4 (409--10016) 466942--1 1320895--1, --3 (409--10012) 466383--4 354500--1 (409--5842) 565435--5 (409--5128) 1338600--3, --4 (409--10016) 466979--1 1320895--1, --3 (409--10012) 567363--1 122500--2, --3 (409--5852) 217500--1, --2 (409--5866) 356500--1, --2 (409--5878) 567363--2 354500--1 (409--5842) 565435--5 (409--5128) 1338600--3, --4 (409--10016) 567363--3 18--16 2.03--2.54 [.080--.100] 2.03--2.54 2 03 2 54 [.080--.100] [ 080 100] 91505--1 (408--8547) 91523--1 (408--8547) 2.79--3.81 [.110--.150] GSee Instruction Sheet 408-- 8039. 8 of 10 567806--1 1320895--1, --3 (409--10012) 466325--1 122500--2, --3 (409--5852) 217500--1, --2 (409--5866) 356500--1, --2 (409--5878) 466325--2 354500--1 (409--5842) 565435--5 (409--5128) 1338600--3, --4 (409--10016) 466906--1 1320895--1, --3 (409--10012) 466923--2G 1320895--1, --3 (409--10012) 466326--3 122500--2, --3 (409--5852) 217500--1, --2 (409--5866) 356500--1, --2 (409--5878) 466326--4 354500--1 (409--5842) 565435--5 (409--5128) 1338600--3, --4 (409--10016) 567364--2 354500--1 (409--5842) 565435--5 (409--5128) 1338600--3, --4 (409--10016) 466958--1 1320895--1, --3 (409--10012) 91519 1 (408--8547) 91519--1 (408 8547) 18--14 91521--1 (408--8547) 354500--1 (409--5842) Figure 6 (cont'd) Tyco Electronics Corporation Rev K Type III+ (Size 16) Contacts 114- 10004 Extraction Tool 305183--[ ] Insertion Tool 91002--[ ] ELT Machine 1338600--[ ] with Optional Stripping Module 1490500--[ ] (Stripping Module Only 1490502--[ ]) Typical Hand Tool AMP--O--MATIC Side Feed Stripper--Crimper II Machine 1320895--[ ] Typical Heavy Duty Mini (HDM) Applicator AMP--O--LECTRIC Model "G" Terminating Machine 354500--[ ] with Optional Stripping Module 1490501--[ ] (Stripping Module Only 1490503--[ ]) AMPOMATOR CLS Lead--Making Machines 122500--[ ]; 217500--[ ]; 356500--[ ] AMP--O--LECTRIC Model "K" Terminating Machine 565435--5 Figure 6 (end) Rev K Tyco Electronics Corporation 9 of 10 Type III+ (Size 16) Contacts 114- 10004 6. VISUAL AID Figure 7 shows a typical application of a Type III+ (Size 16) Contact. 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. REAR BELLMOUTH MUST BE VISIBLE WIRE BARREL SEAM MUST BE CLOSED, WITH NO CONDUCTOR STRANDS SHOWING LOCKING LANCE MAY NOT BE DEFORMED WIRE AND INSULATION MUST BE VISIBLE IN THIS AREA WIRE MUST BE FLUSH WITH END OF WIRE BARREL, OR PROTRUDE SLIGHTLY CONTACT MUST BE STRAIGHT FIGURE 7. 10 of 10 VISUAL AID Tyco Electronics Corporation Rev K