Application Specification Pre-Insulated Diamond Grip (PIDG*) Terminals, Splices, and End Caps NOTE i 114-2157 09 SEP 08 Rev E 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 PIDG terminals, splices, and end caps in various operating environments. Each consists of a precision-formed metal wire barrel and a copper sleeve encased in insulating material made of nylon, polyvinyl chloride (PVC) or polyvinyl fluoride (PVF2). The insulation is color coded (solid primary color or a primary color with a color stripe) to correspond with a specific wire size or wire size range. The terminals, splices, and end caps accept a combination of solid and stranded wire. The wire barrel contains serrations that provide maximum contact and tensile strength after crimping the terminal, splice, or end cap onto the wire. The terminals are available with a variety of tongue lengths and configurations; and the terminals, splices, and end caps are available with various wire barrel lengths and diameters to accommodate different wire sizes, wire types, and combination of wire sizes. The terminals, splices, and end caps are available in loose piece form to be terminated with manual and pneumatically-powered hand held tools and tape mounted to be terminated with bench mount semi-automatic machines. When corresponding with 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. Terminal In-Line Ring Tongue Multiple Stud Hole Spring Spade Tongue Wire Barrel Copper Sleeve Tongue Insulation Flanged Spade Tongue Right Angle Ring Tongue Offset Ring Tongue Hook Tongue In-Line Rectangular Tongue Right-Angle Rectangular Tongue Knife Connect/Disconnect Figure 1 (Cont'd) E 2008 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 14 LOC B PIDG Terminals, Splices, and End Caps 114-2157 Butt Splice Opaque Insulation End Cap Transparent Insulation Window Wire Barrel Insulation Window Copper Sleeve Figure 1 (End) 2. REFERENCE MATERIAL 2.1. Revision Summary Revisions to this application specification include: S S S S Updated document to corporate requirements Added NOTE to Paragraph 3.5, I Added specifications to Paragraph 2.6 Removed Applicator 818057-2 and Machine 818380-1 2.2. Customer Assistance Reference Product Base Part Number 51864 and Product Code 3022 are representative of PIDG terminals, splices, and end caps. 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 local Representative or, after purchase, by calling PRODUCT INFORMATION at the number at the bottom of page 1. 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, call PRODUCT INFORMATION at the number at the bottom of page 1. 2.4. Specifications Product Specification 108-11023 provides test and performance results for insulated terminals and splices for Class 1 E Nuclear applications. 2.5. Instructional Material Instruction Sheets (408-series) provide product assembly instructions or tooling setup and operation procedures and Customer Manuals (409-series) provide machine setup and operation procedures. Documents available which pertain to this product are: 408-1261 408-1559 408-1610 408-1632 408-2095 408-2423 408-2498 408-2822 408-2823 408-3295 408-4099 408-4105 2 of 14 Hand Crimping Tools 59239-4 and 59287-2 Hand Crimping Tools 46121, 47386, and 47387 "T"-Head Crimping Tools 59250 and 59275 Terminal and Splice Crimping Dies 69344, 47806-2, 47807-1, 47808-5, and 47808-6 Hand Crimping Tool 69710-1 Crimping Die Assemblies for Tape-Mounted PIDG Terminals and Splices Crimping Head Cross Reference for Pneumatic Tools Crimping Die Assemblies 59826-1, 59827-1, and 59828-1 TETRA-CRIMP* Hand Crimping Tool 59824-1 Preparing (Reel-Wrap) Reel of Contacts for Applicator Tooling Pneumatic TETRA-CRIMP Adapter 679305-1 Straight Action Crimper 217200-[ ] Tyco Electronics Corporation Rev E PIDG Terminals, Splices, and End Caps 408-7424 408-8044 408-8053 408-8082 408-9252 408-9586 408-9640 408-9816 409-1993 409-5842 409-5862 409-5878 114-2157 Checking Terminal Crimp Height or Gaging Die Closure Miniature Quick-Change Applicator for Tape-Mounted Closed Barrel Terminals Miniature Quick-Change Applicators Miniature Quick-Change Applicators (Side-Feed Type) with Air Feed PRO-CRIMPER* III Hand Crimping Tool 58433-3 Pneumatic Crimping Heads 314269-1, 314270-3, and 314537-1 Crimp Quality Monitor Applicators for Side-Feed and End-Feed Applications Handling of Reeled Products AMP-TAPETRONIC* Machine 69875 AMP-O-LECTRIC* Model "G" Terminating Machine 354500-1 626 Pneumatic Tooling Assemblies 189721-[ ] AMPOMATOR* CLS IV+ Lead-Making Machines 356500-[ ] 2.6. Standards and Publications Military specifications provide industry test and performance requirements. Documents available which pertain to this product are: MIL-T 7928/1, "Terminal, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Crimp Style, Copper, Insulated, Ring Tongue, for Thin Wall Wire, Type II, Class I for 105_C Total Conductor Temperature" MIL-T 7928/4, "Terminals, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Insulated, Ring Tongue, Bell-Mounted Type II, Class I for 150_C Total Conductor Temperature" MIL-T 7928/5, "Terminals, Lug and Splices, Conductor, Crimp Style" MIL-T 7928/6, "Terminals, Lug and Splices, Conductor, Crimp Style, Splice, Electric, (Permanent, Type II, Class 1) for 150_C Total Conductor Temperature" MS 17182, "Terminal, Lug, Crimp Style, Copper, Insulated (Servo Components), Type II, Class I for 125_C Total Conductor Temperature" MS 25036, "Terminal, Lug, Crimp Style, Copper, Insulated, Ring Tongue, Bell Mouthed, Type II, Class 1 for 105_C Total Conductor Temperature" MS 25274, "Cap, Electrical (Wire End, Crimp Style, Type II, Class 1) for 105_C Total Conductor Temperature" 3. REQUIREMENTS 3.1. Limitation These terminals and end caps are suitable for 300 volts maximum, and the splices are suitable for 600 volts maximum. The terminals, splices, and end caps having the following insulation can withstand the following temperature range: nylon -40 to 105_C [-40 to 221_F] PVC -10 to 90_C [14 to 194_F] PVF2 -65 to 150_C [-149 to 302_F] 3.2. Storage A. Ultraviolet Light Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the insulation. B. Reel Storage Tape-mounted reeled product should be stored horizontally to prevent sagging and possible stretching or distortion of the plastic tape which could adversely affect feeding of the product through the tooling. C. Shelf Life The product should remain in the shipping containers until ready for use to prevent inadvertent damage. The product should be used on a first in, first out basis to avoid storage contamination that could adversely affect signal transmissions. Rev E Tyco Electronics Corporation 3 of 14 PIDG Terminals, Splices, and End Caps 114-2157 D. Chemical Exposure Do not store product near chemicals listed below. They could cause stress corrosion cracking of product. Alkalies Amines Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Sulfur Compounds Tartrates 3.3. Wire Selection and Preparation Terminals and splices accept solid and/or stranded wire sizes 26 through 10 AWG and end caps accept solid and/or stranded wire sizes 22 through 10 AWG. The wire size used must be within the range stamped on the underside of the terminal tongue or on the center of the splice or end cap. Generally, the strip length of the wire should be equal to the wire barrel length plus 0.76 [.030]. Specific strip lengths are given in Figure 2. Strip Length Note: Not to Scale (See Table) Insulation Conductor (Stranded Shown) TERMINAL, SPLICE, WIRE WIRE STRIP LENGTH OR END CAP SIZE (AWG) DIAMETER RANGE INSULATION COLOR TERMINAL SPLICE END CAP 26 0.66-1.40 [.026-.055] Yellow/Black 6.35-7.14 [.250-.281] 26-24 Multiple H Yellow 5.16-5.94 [.203-.234] 4.37-5.16 [.172-.203] 26-22 Multiple H Yellow 3.96-4.78 [.156-.188] 4.37-5.16 [.172-.203] 4.78-5.56 [.188-.219] 6.35-7.14 [.188-.281] 4 78 5 56 [[.188-.219] 4.78-5.56 188 219] 5 56 6 35 [[.219-.250] 5.56-6.35 219 250] 6.35-7.13 [.250-.281] 5 16 5 94 [[.203-.234] 5.16-5.94 203 234] 6 35 7 13 [[.250-.281] 6.35-7.13 250 281] 24 [24[ 24 20 24-20 0 79 1 40 [.031-.055] 0.79-1.40 [ 031 055] Multiple H Yellow/Blue White Natural/White 22 22 16 22-16 0.97-2.79 [.038-.110] Multiple H Red/Green Red 7.95-8.74 [.313-.344] Natural/Red 20 1.17-2.79 [.046-.110] Red/Red 6.35-7.13 [.250-.281] 18 1.42-2.79 [.056-.110] Red/White 6.35-7.13 [.250-.281] 16 1.60-3.30 [.063-.130] Blue/Blue 6.35-7.13 [.250-.281] 5 16 5 94 [[.203-.234] 5.16-5.94 203 234] 6 35 7 13 [[.250-.281] 6.35-7.13 250 281] 16 14 16-14 Multiple H Natural/Blue Blue D16-14D 14 12 10 12-10 Multiple H 1.98-3.30 [.078-.130] Multiple H 7.95-8.74 [.313-.344] Yellow/Black 7.93-8.71 [.312-.343] Blue/Green 6.35-7.13 [.250-.281] 7 93 8 71 [[.312-.343] 7.93-8.71 312 343] 8 71 9 53 [[.343-.375] 8.71-9.53 343 375] Natural/Yellow Yellow 8.74-9.53 [.344-.375] 12 2.41-5.08 [.095-.200] Yellow/Yellow 9.53-10.31 [.375-.406] 10 3.02-5.08 [.119-.200] Yellow/Brown 9.53-10.31 [.375-.406] H Contact PRODUCT INFORMATION at the number on page 1 for acceptable insulation diameter ranges [ Large sleeve terminal designed for Class I E Nuclear applications D For use with heavy-duty terminals having an insulation thickness of 1.02-1.27 [.040-.050] Figure 2 4 of 14 Tyco Electronics Corporation Rev E PIDG Terminals, Splices, and End Caps NOTE 114-2157 The wire conductor(s) must not be nicked, scraped, or cut during the stripping operation. i 3.4. Wire Placement The stripped wire must be inserted into the wire barrel until the wire insulation is against the wire barrel but not inside it. The wire insulation must be inside the metal sleeve. A gap between the wire insulation and wire barrel is allowed, but not to exceed the dimension given in Figure 3. Transparent Insulation Window Butt Splice Shown 1.59 [.062] Splice Maximum Gap Insulation Wire Insulation May Butt Against, Wire Barrel Metal Sleeve But Not Enter, Wire Barrel Wire Insulation Must Be Inside Metal Sleeve Figure 3 3.5. Crimp Requirements A. Crimp Height The spring-back of the terminal, splice, or end cap insulation prevents an accurate direct measurement of crimp height. However, crimping a slug of solder (60% tin and 40% lead) with a diameter slightly larger than the conductor outside diameter can verify proper termination. The crimp height of the resulting solder slug can be checked with a standard micrometer or comparator. The measurement must be made over the most compressed area of the solder slug. See Figure 4. NOTE i NOTE i Some tooling with multiple crimping chambers form an embossed dot code in the terminal, splice, or end cap insulation that indicates which crimping chamber was used. This dot code can be used as a visual inspection to ensure that the correct wire size and crimping chamber were used. The resilience of the 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 408-7424 for specific instructions). The solder slug diameter and crimp height must be within the dimensions provided in Figure 4. B. Wire Barrel Crimp Profile and Location The wire barrel crimp produced by the tooling (dies, heads, hand tools, pneumatic tools, or machines) must be either a confined crescent crimp which appears as a depressed oval shape or a flat rectangular crimp over the center of the wire barrel. The crimp must be evenly formed. Refer to Figures 4, 5, and 11. Crescent crimp tooling produces the crescent crimp, and TETRA-CRIMP tooling produces the flat rectangular crimp. For a tooling-to-crimp profile cross-reference, refer to Figure 10. C. Dot Code The dot code on the insulation must be well formed and correspond with the wire size or color code marking on the crimping chamber of the tooling used. See Figures 4 and 5. D. Bellmouths There shall be no rear bellmouth. The front bellmouth shall be evident on the top and bottom of the wire barrel as shown in Figure 5. Also see Figure 11. Rev E Tyco Electronics Corporation 5 of 14 PIDG Terminals, Splices, and End Caps 114-2157 Crimp Inspection Using Micrometer or Comparator Wire Barrel Crimp Profile and Location +%20.'4'2 02 04 0&' 0.1#2#402 04 *07/ 2+.1 6'/-8 02.'& 6'2 '/4'2 0( +2' #22'- '/4'2 0( 034 2'3%'/4 2+.1 0.12'33'& 2'# '('2 '12'33'& 6#- *#1' 40 #$-' (02 2+.1 '+)*4 -#4 '%4#/)5-#2 2+.1 04 0&' 04 *07/ 0-&'2 -5) C F Produced by Crescent Crimp Tooling Produced by TETRA-CRIMP Tooling SOLDER SLUG WIRE SIZE (AWG) TERMINAL SPLICE, TERMINAL, SPLICE OR END CAP CRIMP HEIGHT DOT CODE DIAMETER INSULATION COLOR CRESCENT CRIMP FLAT RECTANGULAR (Depressed Oval Shape) CRIMP '--07-#%, '--07 '--07 04 ! ! " !! " : ! ! " !! " : ! ! " ! ! " !! " ! " ! " ! " ! " ! " ! '--07-5' *+4' 043 #452#-*+4' '&2''/ 04 '& 04 !! " ! ! " #452#-'& '&'& 04 '&*+4' 04 -5'-5' 043 -5' 043 #452#--5' -5'2''/ D 043 '--07-#%, 04 '--07 '--07 04 '--07 !" ! " " 04 #452#- '--07 '--07207/ 04 D 02 53' 7+4* *'#68 &548 4'2.+/#-3 *#6+/) #/ +/35-#4+0/ 4*+%,/'33 2#/)' 0( ! " Figure 4 6 0( 8%0 -'%420/+%3 02102#4+0/ '6 E PIDG Terminals, Splices, and End Caps Note: 114-2157 Terminal Shown Same Applies to Splice and End Cap Dot Code (1 Dot Shown) is Well Formed and Corresponds With Crimping Chamber of Tooling Used Overstress Marks Not Wire Conductor(s) Visible Within This Apparent on Insulation Area (Except Splice and End Cap, No Rear Bellmouth Wire Insulation Inside Metal Sleeve But Not Inside Wire Barrel See Detail A and Detail B) Front Bellmouth Evident (Top and Bottom of Wire Barrel) No Flash in This Area Wire Size Marking Matches Wire Size Detail A Splice Detail B End Cap Wire Flush to End of Wire Barrel or Wire Bottomed Bottomed on Stop Inside Center of Splice in End Cap Cutaway Show for Clarity Figure 5 E. Flash There shall be no flash or extruded insulation material visible in the most compressed area of the wire crimp. See Figure 5. F. Terminal, Splice, or End Cap Insulation The insulation of the terminal, splice, or end cap must not be cut or show uneven stress marks or highlighted marks on the insulation. See Figure 5. G. Wire Location 1. Terminals shall have the wire ends flush or extended slightly beyond the end of the wire barrel as shown in Figure 5. 2. Splices shall have the end of the wire located against the wire stop inside the center of the splice. 3. End caps shall have the end of the wire bottomed in the end cap. H. Insulation Crimp Check The insulation crimp must capture the wire insulation. The wire insulation must not be crimped inside the wire barrel of the terminal, splice, or end cap. The wire insulation must be inside the metal sleeve to provide strain relief for the wire. See Figure 5. The hold of the insulation crimp can be tested by using the bend test which, if successful, indicates that the hold is not too loose. The bend test must be performed as follows: 1. Using an unstripped wire, make a test crimp. 2. Hold the terminal, splice, or end cap in one hand. Use the side of one finger on the other hand at approximately 76 [3] to push the wire up 90_ and down 180_, one time each. Refer to Figure 6. If the wire insulation comes out during the bend test, the insulation crimp is not tight enough, and the tooling must be adjusted to produce a tighter insulation crimp. Figure 8, Detail A shows a crimp that is too loose, providing little or no support for the wire. Rev E Tyco Electronics Corporation 7 of 14 PIDG Terminals, Splices, and End Caps 114-2157 If the crimp passes the bend test, the insulation crimp must be tested by pulling the wire from the terminal, splice, or end cap. If the wire insulation is only slightly deformed, the crimp is correct. Figure 8, Detail B shows a desired crimp, providing adequate support without damage to either the insulation or the wire conductor(s). If there is visible damage, such as tearing or piercing of the insulation, the crimp is too tight, and the tooling must be adjusted to produce a looser insulation crimp. Figure 8, Detail C shows a crimp that is too tight, damaging the insulation and possibly breaking wire conductor(s) or reducing circular mil area (CMA) by wire extrusion. Bend Test (Test Crimp Using Unstripped Wire) Note: Not to Scale 90 1st Push Hold Here 180 2nd Push 76.2 [3] (Approx) Figure 6 3.6. Tensile Strength Crimped terminals, splices, or end caps should hold the wire conductor(s) firmly and have a pull-test tensile value meeting that specified in the table in Figure 7. NOTE Adjust tensile testing machine for head travel of 25.4 [1.0] per minute. Directly and gradually apply force for 1 minute. i WIRE SIZE (AWG) TENSILE FORCE (Pull Test) Newtons [lb-force] COMMERCIAL REQUIREMENTS MILITARY REQUIREMENTS 26 13.4 [3] 31.1 [7] 24 22.3 [5] 44.5 [10] 22 35.6 [8] 66.7 [15] 20 57.9 [13] 84.5 [19] 18 89.0 [20] 169.0 [38] 16 133.5 [30] 222.5 [50] 14 222.5 [50] 311.5 [70] 12 311.5 [70] 489.3 [110] 10 356.0 [80] 667.2 [150] Figure 7 8 of 14 Tyco Electronics Corporation Rev E PIDG Terminals, Splices, and End Caps 114-2157 Cross-Section of Insulation Crimp at Wire End of Terminal, Splice, or End Cap (Illustrations Represent Uppermost Wire Insulation Range of Terminal, Splice, or End Cap (Thinner Wire Insulation May Appear Slightly Different, But Will Perform the Same, Refer to Figure 2) Detail A Too Loose Detail B Correct Detail C Too Tight Wire Insulation Metal Terminal, Splice, or Sleeve End Cap Insulation Figure 8 3.7. Bend Allowance Upward and downward bend of the terminated terminal, splice, or end cap must be within the tolerance provided in Figure 9. Terminal 11 Center of Crimp Datum Line 11 Splice 11 11 Center of Splice Datum Line 11 11 End Cap 11 Center of Crimp Datum Line 11 Figure 9 3.8. Repair Damaged or defective terminal, splice, or end cap must not be used. If damage is evident, the terminal, splice, or end cap should be cut from the wire and replaced with a new one. Crimped terminals, splices, or end caps MUST NOT be re-terminated or re-used by removing the wire. Rev E Tyco Electronics Corporation 9 of 14 PIDG Terminals, Splices, and End Caps 114-2157 4. QUALIFICATIONS Most, but not all, PIDG terminals, splices, and end caps are Listed by Underwriters Laboratories Inc. (UL) in File E13288 and Certified by CSA International in File LR7189 NOTE To determine whether a terminal, splice, or end cap (identified by part number) meets the requirements of an agency, contact PRODUCT INFORMATION at the number at the bottom of page 1. i 5. TOOLING Hand tools for manual application of loose piece terminals, splices, or end caps, and automatic and semi-automatic machines for power assisted application of tape-mounted terminals, splices, or end caps are available to cover the full wire size range. Tooling part numbers and instructional material packaged with the tooling are shown in Figure 10. NOTE Selection of tooling will depend on the terminal, splice, or end cap requirements such as quantity of terminations, operator training and skill, and the available support equipment (electrical, pneumatic, etc.) in the work area. Modified i designs and additional tooling concepts may be available to meet other production requirements. For additional information, contact one of the service groups at the bottom of page 1. 5.1. Hand Tools Hand tools consisting of a handle assembly with integral fixed jaws or dies and hand tools that accept various die assemblies are available for loose piece terminals, splices, or end caps. Both types feature a ratchet to ensure full crimping pressure is applied to the terminal, splice, or end cap. 5.2. Die Assemblies Die assemblies are precision tools that form the wire barrel of the terminal, splice, or end cap onto the conductor(s) of the wire and form the optimum crimp height. The die assemblies consist of stationary and movable dies that are designed for a specific wire size and terminal, splice, or end cap. A. Loose Piece Terminal, Splice, or End Cap These die assemblies can be used in either manual or power assist tools. B. Tape-Mounted Terminal, Splice, or End Cap These die assemblies are designed for use in applicators installed in power units. 5.3. Applicators Applicators are used in power units for large production applications. They feature an automatic feed mechanism, adjustable crimp height pads, and precision crimping dies. They have been designed to simplify tooling changes and avoid unnecessary duplication of power units. 5.4. 626 Pneumatic Tooling System This pneumatically operated tooling system will crimp the full wire size range of the terminal, splice, or end cap. The system is a pneumatic power unit available with a logic control for foot pedal operation or without foot pedal for hand operation. It is designed to accept various types of crimping heads, including those that will accept die assemblies for loose piece terminals, splices, or end caps. 5.5. Power Units Power units provide the force needed to operate the applicator. A. Bench-Mounted AMP-O-LECTRIC Model "G" terminating machine and AMP-TAPETRONIC machine are designed to accept hand-fed pre-stripped wires. B. Floor Standing The AMPOMATOR CLS IV+ lead-making machine can be set up to automatically cut the wire to length and terminate it at a high rate of speed. 10 of 14 Tyco Electronics Corporation Rev E PIDG Terminals, Splices, and End Caps 114-2157 Loose Piece Terminal, Splice, or End Cap Hand Tools and Die Assemblies (Refer to Table for Part Numbers) Double Action Hand Tools T"-Head Hand Tools TETRA-CRIMP Hand PRO-CRIMPER III Hand (DAHT) (408-1559) (T-HD HT) (408-1610) Crimping Tool (408-2823) Crimping Tool (408-9252) Heavy Head Hand Tools Hand Crimping Tool 69710-1 Terminal and Splice (HHHT) (408-1261) (Accepts All Die Assemblies Die Assemblies Listed in Table) (408-2095) (408-1632) 626 Pneumatic Tooling System Tool Holder Assembly Straight Action Crimper 189928-1 (Straight Action) 217200-[ ] (Accepts All Die Assemblies Listed in Table) (408-4105) Tool Holder Assembly Pneumatic Crimping Heads 189767-[ ] (Large) (Refer to Table) (408-9586) 626 Pneumatic Tooling Assemblies 189721-[ ] (409-5862) Tool Holder Assembly TETRA-CRIMP Pneumatic 189766-[ ] (Small) Adapter (Refer to Table) (408-4099) HAND TOOL PNEUMATIC TOOLING WIRE SIZE (AWG) DIE DAHT C T-HD HT C TETRA-CRIMP Hand Tool F PRO-CRIMPER Hand Tool HHHT C C Crimping Head C TETRA-CRIMP Adapter F ASSEMBLY VC 26-22 46121 59275 314537-1 0-69344-0 22-18 59250 22-16 47386 59250 59824-1 58433-3 314270-3 47806-2 H16-14H 47387 59250 59824-1 58433-3 314269-1 47807-1 59824-1 58433-3 16-14 D and 12-10 59239-4 or 59287-2 H For use with terminals having an insulation thickness range of 0.51-0.84 [.020-.033]. D For use with heavy duty terminals having an insulation thickness of 1.02-1.27 [.040 -.050]. Z For use with wire having a maximum insulation diameter of 7.62 [.300]. Z C F 679305-1 D 47808-6 or 47808-5 Z Produces Crescent Crimp Produces Flat Rectangular Crimp V For use with Tool 69710-1 or Crimper 217200-[ ] Figure 10 (Cont'd) Rev E Tyco Electronics Corporation 11 of 14 PIDG Terminals, Splices, and End Caps 114-2157 Tape-Mounted Terminal, Splice, or End Cap Die Assemblies and Applicators Power Units Die Assemblies 69872, 69873, 69874, 69877, and 69897 (408-2423) Die Assemblies 59826-1, 59827-1, and 59828-1 (408-2822) AMP-TAPETRONIC Machine AMP-O-LECTRIC Model G" 69875(409-1993) Terminating Machine 354500-1 (409-5842) Miniature Quick-Change Applicator 567200-3 (408-8082) Miniature Quick-Change Applicator 687658-1 (408-8044 ) AMPOMATOR CLS IV+ Lead-Making Machine 356500-[ ] (409-5878) APPLICATOR WIRE SIZE (AWG) DIE ASSEMBLY 26-22 69877 C 22-16 69872 C or 59826-1F H16-14H 69873 C or 59827-1F 16-14 D and 12-10 69874 59828-1 Z AMP-TAPETRONIC Machine AMP-O-LECTRIC Model G" Terminating Machine AMPOMATOR CLS IV+ Lead-Making Machine Included with Machine 567200-3 687658-1 ZC or F or 69897C H For use with terminals having an insulation thickness range of 0.51-0.84 [.020-.033]. D For use with heavy duty terminals having an insulation thickness of 1.02-1.27 [.040 -.050]. Z For use with wire having a maximum insulation diameter of 7.62 [.300]. C Produces Crescent Crimp F Produces Flat Rectangular Crimp Figure 10 (End) 12 of 14 Tyco Electronics Corporation Rev E PIDG Terminals, Splices, and End Caps 114-2157 6. VISUAL AID Figure 11 shows a typical application of PIDG terminals, splices, and end caps. This illustration should be used by production personnel to ensure a correctly applied terminal, splice, or end cap. 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. FRONT BELLMOUTH MUST BE EVIDENT CRIMP MUST BE EVENLY FORMED ACROSS CENTER OF WIRE BARREL INSULATION OF TERMINAL, SPLICE, OR END CAP MUST BE FORMED OVER WIRE INSULATION WIRE MUST BE VISIBLE AT END OF WIRE BARREL IF APPLICABLE, DOT CODE MUST BE WELL FORMED AND CORRESPOND WITH WIRE SIZE MARKING ON TOOLING END OF TERMINAL, SPLICE, OR END CAP MUST NOT BE BENT OR DEFORMED EACH WIRE MUST BE FLUSH TO END OF WIRE BARREL OR BOTTOMED ON STOP TERMINAL, SPLICE, OR END CAP INSULATION OF TERMINAL, SPLICE, OR MUST BE STRAIGHT AND NOT END CAP MUST NOT BE CUT OR TORN TWISTED ALONG AXIS INSULATION OF TERMINAL, SPLICE, OR END CAP MUST BE EVENLY FORMED WITHOUT OVERSTRESS MARKS WIRE INSULATION MUST BE INSIDE METAL SLEEVE OF TERMINAL, WIRE MUST BE BOTTOMED SPLICE, OR END CAP IN END CAP FIGURE 11. VISUAL AID (CONT'D) Rev E Tyco Electronics Corporation 13 of 14 PIDG Terminals, Splices, and End Caps 114-2157 PROPER CRIMP CRIMP CENTERED ON WIRE BARREL SMALL AMOUNT OF SPACE BETWEEN WIRE CONDUCTOR(S) Detail A AND WIRE BARREL Detail B (Insulation and Metal Sleeve Removed) FRONT BELLMOUTH ON TOP AND BOTTOM OF WIRE BARREL FRONT BELLMOUTH ON TOP OF INSULATION IMPROPER CRIMP CRIMP TOO FAR FRONT ON WIRE BARREL NO SPACE BETWEEN WIRE CONDUCTOR(S) Detail A AND WIRE BARREL Detail B (Insulation and Metal Sleeve Removed) NO BELLMOUTH ON TOP OF WIRE BARREL NO BELLMOUTH ON TOP OF INSULATION CRIMP TOO FAR BACK ON WIRE BARREL TOO MUCH SPACE BETWEEN WIRE CONDUCTOR(S) AND WIRE BARREL Detail A Detail B (Insulation and Metal Sleeve Removed) NO BELLMOUTH ON BOTTOM OF WIRE BARREL FRONT BELLMOUTH ON TOP OF INSULATION TOO LARGE FIGURE 11. VISUAL AID (END) 14 of 14 Tyco Electronics Corporation Rev E