MAGNET WIRE TERMINALS AND TERMINATION SYSTEMS MAG-MATE terminals, SIAMEZE terminals, AMPLIVAR terminals and splices, and cluster blocks APPLIANCES /// MAGNET WIRE TERMINATION Magnet Wire Terminals and Termination Systems Catalog 82221 Table of Contents Standard MAG-MATE Terminals Introduction..................................................................................................................................... 1 Interconnection System .................................................................................................................. 2 Termination Sequence ................................................................................................................... 2 Test Results .................................................................................................................................... 3 300 Box Poke-In Terminals ............................................................................................................ 4 500 Box Poke-In Terminals ............................................................................................................ 6 Poke-In Tab Terminals ................................................................................................................... 7 MAG-MATE Terminals with extended leaf-spring .......................................................................... 8 300 Box Poke-In Terminals ............................................................................................................ 9 Tab Receptacle Terminals .............................................................................................................. 9 187 Box F-Crimp Terminals .......................................................................................................... 10 300 Box F-Crimp Terminals .......................................................................................................... 10 Posted PCB Terminals ................................................................................................................. 11 300 Box Posted PCB Terminals ................................................................................................... 11 MAG-MATE Edge Leaf Terminals ................................................................................................ 12 187 Box Posted PCB Terminals ................................................................................................... 13 187 Box Tab Terminals ................................................................................................................ 13 300 Box Tab Terminals ................................................................................................................ 14 Pin Receptacle Terminals ............................................................................................................. 15 Pin I/O Terminals .......................................................................................................................... 16 110 Series FASTON Tab Terminals .............................................................................................. 17 187 Series FASTON Tab Terminals .............................................................................................. 18 187 Series Combination Poke-In FASTON Terminals ................................................................. 18 250 Series FASTON Tab Terminals .............................................................................................. 21 Typical Plastic Cavity .................................................................................................................... 23 Slim Line MAG-MATE Terminals Introduction................................................................................................................................... 25 187 Series FASTON Tab Terminals .............................................................................................. 26 250 Series FASTON Tab Terminals .............................................................................................. 26 Posted PCB SOLDER Terminal ................................................................................................... 26 Offset Tab Terminals ..................................................................................................................... 27 Mini MAG-MATE Terminals Introduction................................................................................................................................... 29 Poke-In Terminal .......................................................................................................................... 30 Posted Terminal ........................................................................................................................... 31 FASTON Tab Terminals ................................................................................................................ 31 Crimp Wire Barrel Terminal ..........................................................................................................31 SIAMEZE Terminals Introduction................................................................................................................................... 32 Lead Lok Terminals Introduction .................................................................................................. 33 SIAMEZE Interconnection System ............................................................................................... 34 Lead Lok Interconnection System ................................................................................................ 35 Wire-to-Wire Terminals ................................................................................................................. 36 Receptacle Terminals (Wire to Blade) ......................................................................................... 37 Pin Terminals ................................................................................................................................ 37 Post Terminals .............................................................................................................................. 38 110 Series (2.8 mm wide) FASTON Tab Terminals ...................................................................... 39 187 Series (4.75 mm wide) FASTON Tab Terminals .................................................................... 40 250 Series (6.3 mm wide) FASTON Tab Terminals ...................................................................... 41 Typical Plastic Cavity Pockets ...................................................................................................... 42 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Table of Contents AMPLIVAR Splices Introduction................................................................................................................................... 44 General Application Guidelines .................................................................................................... 46 Suggested Splice Selection Procedure ....................................................................................... 46 Technical Documents ................................................................................................................... 46 9 Serrations --Pigtail Type ........................................................................................................... 47 7 Serrations --Pigtail Type ........................................................................................................... 47 5 Serrations --Thru Type ............................................................................................................. 48 5 Serrations --Pigtail Type ........................................................................................................... 49 Miniature Splice --Pigtail Type .................................................................................................... 49 AMPLIVAR Terminals Introduction................................................................................................................................... 50 Ring Tongue Terminals ................................................................................................................ 51 Stud Retaining Terminals ............................................................................................................. 52 Alternator Eyelet Terminal ............................................................................................................ 52 125 Series Blade .......................................................................................................................... 53 187 Series FASTON Tabs .......................................................................................................... 53 250 Series FASTON Tabs .......................................................................................................... 53 250 Series FASTON Receptacles .............................................................................................. 64 187 Series FASTON Flag Receptacles ....................................................................................... 55 250 Series FASTON Flag Receptacles ........................................................................................ 55 Pin Receptacles............................................................................................................................ 55 250 Series Stator Receptacles --7 Serrations ............................................................................ 56 Stator Terminal --Receptacle .250 x .032 [6.35 x 0.81] .............................................................. 56 Cluster Blocks Introduction................................................................................................................................... 57 Cluster Blocks 2.29 [.090] Pin Size (Lead Wire and Direct Connect)........................................... 58 Cluster Blocks 3.18 [.125] Pin Size (Lead Wire and Direct Connect)........................................... 60 MTM Crimpband Splices - NOT RECOMMENDED FOR NEW DESIGNS Introduction................................................................................................................................... 62 MTM Crimpband Interconnection System .................................................................................... 63 11 Serrations ................................................................................................................................ 64 9 Serrations .................................................................................................................................. 64 7 Serrations .................................................................................................................................. 65 RTM Crimpband Splices - NOT RECOMMENDED FOR NEW DESIGNS Introduction................................................................................................................................... 66 RTM Crimpband Interconnection System..................................................................................... 67 20 Ridges ..................................................................................................................................... 68 14 Ridges ..................................................................................................................................... 68 10 Ridges ..................................................................................................................................... 68 9 Ridges ....................................................................................................................................... 69 8 Ridges ....................................................................................................................................... 69 7 Ridges ....................................................................................................................................... 69 6 Ridges ....................................................................................................................................... 72 3 Ridges ....................................................................................................................................... 73 Power Splice Introduction................................................................................................................................... 74 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Table of Contents Application Tooling Introduction................................................................................................................................... 76 AMPLIVAR Product Terminator (APT) Machine............................................................................. 77 Power Splice Machine................................................................................................................... 77 AMPLIVAR Terminator for Parallel and End Connections............................................................. 78 AMP-O-LECTRIC Model G Terminator with Thru-Splice Applicator.............................................. 78 Crimpband Application Tooling - NO LONGER AVAILABLE.......................................................... 79 MPT-5 MAG-MATE Product Terminator........................................................................................ 80 MAG-MATE Terminal Cavity and Fixture Design........................................................................... 80 MPT-5 S/L Machine for SIAMEZE and Lead Lok Terminals.......................................................... 81 EMT -- Entry Level Magnet Wire Terminator................................................................................. 81 Manual Hand Tool.......................................................................................................................... 82 Manual Arbor Press....................................................................................................................... 82 Hand Insertion Tools...................................................................................................................... 82 Full Line of Crimp Tooling.............................................................................................................. 82 MAG-MATE Inserter MK I with Pneumatic Control........................................................................ 83 MAG-MATE Inserter MK I with Electro Pneumatic Control............................................................ 83 MAG-MATE and SIAMEZE Inserter MARK II with PLC................................................................. 83 MAG-MATE and SIAMEZE Inserter MARK II with PLC and Insertion Force Control.................... 84 Pneumatic Insertion Tool for MAG-MATE Terminals.................................................................... 84 Customer Specific Machines......................................................................................................... 85 Custom Built IDC Terminal Insertion Head.................................................................................... 85 Additional Data Technical Information .................................................................................................................... 86 Terminal Stud Hole Size................................................................................................................ 90 Part Number Index........................................................................................................................ 91 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals Product Facts Standard MAG-MATE Terminals Terminates film-insulated copper and aluminum magnet wire E liminates need for pre-stripping conductors E liminates need to post insulate termination E xcess magnet wire is automatically trimmed during the termination process S imultaneously terminates two magnet wires of the same size in one terminal ( for splicing or bi-filing ) Various lead wire attachment options available Available in strip form for semi-automatic or fully automatic insertions Available in loose piece form for hand tool insertions Varnish resist tab terminals are available for special applications H igh speed, fully automated integrated systems provide uniform terminations reliably at the lowest possible applied cost C lean metal-to-metal interface produces stable, gas-tight electrical terminations free of oxides and other contaminants R ecognized under the C omponent R ecognition P rogram of U nderwriters Laboratories Inc., F ile N o. E 13288,Vol. 1, S ec 29 R Applications Motor windings and connections Coil connections Transformer windings and connections TE offers a full selection of Standard MAG-MATE Insulation Displacement Crimp (IDC) terminals for magnet wire terminations. MAG-MATE terminals are available in poke-in, poke-in tab, splice, crimp wire barrel, solder post, quick connect tab, pin and receptacle styles. Standard MAG-MATE terminates magnet wire ranging from 34-12 AWG [0.16 -2.05 mm ]. Each IDC slot size terminates a range of up to four consecutive magnet wire sizes. Two magnet wires with the same diameter can be terminated in one terminal except as noted. According to TE specifications MAG-MATE cavities are either integrated into coil bodies or specially designed cavity housings. The magnet wires are precisely positioned in the plastic cavity slots. The MAG-MATE Inserter cuts the terminals from the strip and places the terminals over the magnet wire into the plastic cavities. During this operation, small stripping shoulders in the IDC slot remove the film insulation from the magnet wire. Wiping action between the wire and terminal removes oxides or other contaminants present on both the conductor and the terminal slot side walls, producing a clean, stable, gas-tight electrical termination. Residual spring energy in the terminal causes the side walls of each IDC slot to function as opposing cantilever beams. This constant pressure results in an intimate metal-to-metal interface, providing a reliable, long-term connection. The MAG-MATE Inserter may be used as a semi-automatic bench machine or integr ated into production lines for fully-automatic applications. Bobbin connections Lighting ballasts Power supplies *Contact TE Engineering for guidance regarding aluminum www.te.com/appliances 1 Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) Standard MAG-MATE Interconnection System How the System Operates Trim Blade Locking Barbs This part cuts off the excess magnet wire and the wire support at the front of the cavity. Terminal retention is secured in the cavity by four locking barbs. Insertion Finger Integration of plastic cavities into final unit must be in accordance with TE Application Specifications. Consulting TE is required for design in. Plastic Cavity The insertion finger is part of the MAG-MATE Inserter. It pushes the terminal that was sheared from the carrier strip through the inserter "tube" into the positioned cavity. Cavity Slot for Wire The width has to be in accordance with the wire size (see Application Specification). Contact Various wire attachments in three different sizes,.187, .300,.500 cavity height (see tables). Magnet Wire The magnet wire is positioned down into the plastic cavity slots. IDC Slot In different sizes for magnet wire diameters from 34-12 AWG [0.16-2.05 mm]. Strain relief slots available for high vibration applications. Wire Support Block The block supports the magnet wire during the cutting process. The magnet wire is cut flush to the cavity front side. Stripping Shoulders During the insertion process, these shoulders strip the film insulation from the magnet wire in four areas. 11 Support Anvil The anvil supports the wire during the insertion process. Termination Sequence 11 A = Prepare B = Insert C = Finish Trim Blade A B C Insertion Finger Poke-In Contact Plastic Cavity Magnet Wire Support Anvil 2 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) Current Cycling-- Humidity-- Temperature Cycling 480 cycles with each cycle consisting of 15 minutes "ON" followed by 15 minutes "OFF" been submitted to the following tests without significant millivolt increase: 10 cycles between 25C and 65C at 95% RH Thermal Shock-- Heat Age-- 25 cycles with each cycle consisting of 30 minutes at 125C followed by 30 minutes at -65C 33 days at 118C 3" [ 7.62 mm ] I1 I2 Current Leads E1 E2 Voltage Resistance vs Thermal Shock (Copper Wire) 35 Mini MAG-MATE products have been submitted to the following tests in addition to those listed without significant millivolt increase: Standard MAG-MATE Terminals Test Results Standard and Slim Line MAG-MATE products have Vibration-- 10-55-01- Hz traversed in 1 minute at .06 inches total excursion; 2 hours in each of 3 mutually perpendicular directions. Industrial Gas with Chlorine-- 1000 exposure to 200 ppb each of sulphur dioxide, nitrogen dioxide, hydrogen sulphide and 50 ppb chlorine. Resistance vs Current Cycles (Copper Wire) 30 Milliohms Milliohms 25 20 15 10 5 0 0 5 10 15 20 25 15 AWG 16 AWG 19 AWG 22 AWG 24 AWG 27 AWG 26 AWG T (C) 33 AWG 30 AWG Test Current produces 100C Magnet Wire Operating Temperature Current Rating Curves The diagram shows the temperature rise of the contact, depending on the magnet wire size being applied. I (A) Product Specifications describe technical performance characteristics and verification tests. They are intended for the Design, Test and Quality Engineer. 108-2012 Standard .187 and .300 MAG-MATE Terminals 108-2053 Standard .500 Box MAG-MATE Terminals 108-1484 Slim Line MAG-MATE Terminals 108-2016 Mini MAG-MATE Terminals Note: For all applications, TE recommends that samples of the magnet wire to be used be submitted for engineering evaluation. www.te.com/appliances 3 Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) 300 Box Poke-In Terminals Material Tin plated brass Type Typical Cavity Size 2 (See page 23) A 300 Box Standard IDC Locking Poke-in .300 [ 7.62 ] .135 [ 3.43 ] .118 [ 3.00 ] B4 300 Box Standard IDC w/ Strain Relief Slot Locking Poke-In .300 [ 7.62 ] .118 [ 3.00 ] B Mating5 Tab Stock Strip Thickness Part Number* .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .010 0.25 .010 0.25 .012 0.30 .012 0.30 0.5-0.9 .135 x .020 3.40 x 0.50 .016 0.41 62935-1 20-18 0.5-0.9 20-18 0.5-0.9 0.81 20-18 0.5-0.9 .016 0.41 .016 0.41 .016 0.41 63658-1 0.64-0.81 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 19-17 2 0.91-1.15 20-18 0.5-0.9 30 0.25 20-18 0.5-0.9 29-28 0.29-0.32 20-18 0.5-0.9 28-26 0.32-0.40 20-18 0.5-0.9 27-23 0.36-0.57 20-18 0.5-0.9 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .016 0.41 .012 0.30 .012 0.30 .012 0.30 .016 0.41 34-33 0.16-0.18 20-18 0.5-0.9 33-31 0.18-0.23 20-18 0.5-0.9 31-28 0.23-0.32 20-18 0.5-0.9 30-27 0.25-0.36 20-18 0.5-0.9 27-23 0.36-0.57 20-18 25-22 2 0.45-0.64 22-20 2 20 A .135 [ 3.43 ] Copper Magnet Wire Range1 Lead Wire Range3 AWG mm AWG mm2 2 63662-1 62431-1 1217234-1 62429-1 62420-1 63591-1 62833-1 63786-1 1217011-1 1217368-1 63789-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64 mm] or larger unless otherwise noted. 3 Solid or overcoated stranded lead wire only. Product will also accept Poke-In Tab Terminal shown on page 7. 4 Strain relief slot for high vibration applications. 5 See page 7 for mating tab options. * Recognized under the Component Program of Underwriters Laboratories, Inc. Solid Lead Wire POKE-IN MAGMATE Terminal MAGMATE Terminal Solid Lead Wire SOLID WIRE SOLID WIRE LOCKS IN "V" NOTCH Cavity Magnet Wire Cavity POKE-IN SYSTEM: SOLID WIRE CONNECTION Stranded Lead Wire POKE-IN TAB Terminal Stranded Lead Wire MAGMATE Terminal POKE-IN MAGMATE Terminal POKE-IN TAB Terminal POKE-IN TAB Locking Grooves Tab locks into edges of leaf Magnet Wire Cavity Cavity POKE-IN SYSTEM: STRANDED LEAD WIRE AND POKE-IN TAB CONNECTION 4 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) Type .118 [ 3.00 ] A 300 Box Standard IDC Non-Locking Poke-In MKI A .300 [ 7.62 ] .135 [ 3.43 ] .118 [ 3.00 ] B B 300 Box Standard IDC Non-Locking Poke-In MKII Type .433 [ 11.00 ] .135 [ 3.43 ] .125 [ 3.20 ] C .433 [ 11.00 ] .135 [ 3.43 ] .125 [ 3.20 ] C 433 Box Standard IDC with Receptacle for Tabs .110 x .020 [2.8 mm x 0.5 mm] or .110 x .032 [2.8 mm x 0.8 mm] D 433 Box Standard IDC with Receptacle for Tabs .187 x .020 [4.8 mm x 0.5 mm] or .187 x .032 [4.8 mm x 0.8 mm] Copper Magnet Wire Range1 AWG mm 35-32 0.14-0.20 33-30 0.18-0.265 30-26 0.265-0.40 26-21.5 2 0.40-0.67 21.5-18.5 2 0.67-0.95 19.5-17 2 0.91-1.13 33-30 0.18-0.265 30-26 0.265-0.40 2 26-22 0.40-0.63 22-19.5 2 0.63-0.85 19.5-17 2 0.85-1.12 Copper Magnet Wire Range1 AWG mm 33-30 0.18-0.265 30-26 0.265-0.40 26-22 22-19.5 0.40-0.63 2 0.63-0.85 Stock Thickness .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .010 0.25 .010 0.25 .013 0.32 .016 0.41 .016 0.41 .016 0.41 .013 0.32 .013 0.32 .013 0.32 .013 0.32 .135 x .020 3.40 x 0.50 .013 0.32 964341-2 Feature Stock Thickness Strip Part Number w/o Dimple Dimple w/o Dimple Dimple w/o Dimple Dimple w/o Dimple Dimple .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 0.18-0.265 Dimple 26-23 0.40-0.57 w/o Dimple 22.5 - 20 2 0.60-0.80 w/o Dimple 19-172 0.90-1.13 w/o Dimple 1 0.90-1.12 w/o Dimple 19-17 Strip Part Number* Mating Tab3 33-31 Standard MAG-MATE Terminals .300 [ 7.62 ] .135 [ 3.43 ] 969082-1 926850-2 926851-2 926852-2 928770-2 1-928771-4 964337-2 964338-2 964339-2 964340-2 1-964114-1 964114-1 1-964108-1 964108-1 1-928854-1 928854-1 1-964106-1 964106-1 1740574-1 964252-1 964110-1 964111-1 1534234-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64 mm] or larger unless otherwise noted. 3 See page 7 for mating tab options. * Recognized under the Component Program of Underwriters Laboratories, Inc. D www.te.com/appliances 5 Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) 300 Box Poke-In Terminals (Continued) Material Tin plated brass .300 [7.62] .300 [ 7.62 ] .135 [3.43] Typical Cavity Size 2 B Type Note: Special cavity required for See Application Spec. 114-2046. .118 [ 3.00 ] A (See page 23) Tri-slot splice terminal. .455 [ 11.56 ] .118 [3.00] A3 300 Box Standard IDC w/Strain Relief Slot Non-Locking Poke-In Copper Magnet Wire Range1 Strip Stock Mating Tab4 Thickness Part Number AWG mm .016 .135 x .020 27-26 0.36-0.40 1217691-1 0.41 3.40 x 0.50 25.5-24 0.43-0.51 23.5-222 0.54-0.64 2 0.68-0.81 21.5-20 B 300 Box Standard IDC Non-Locking Poke-In 30-27 0.25-0.36 27-23 0.36 -0.57 23-202 0.57-0.81 19-17 0.91-1.15 27-23 2 19-17 2 182 0.36-0.57 0.91-1.15 0.8-0.9 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .016 0.41 .016 0.41 .016 0.41 .016 0.41 .016 0.41 .016 0.41 .016 0.41 1217690-1 .135 x .020 3.40 x 0.50 .016 0.41 63975-1 1217689-1 1217688-1 1217221-1 63632-1 1217533-1 1742347-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64 mm] or larger. 3 Strain relief slot for high vibration applications. 4 See page 7 for mating small tab options. * Recognized under the Component Program of Underwriters Laboratories, Inc. 500 Box Poke-In Terminals Material Typical Cavity Size 4 (See page 23) .281 [ 7.14 ] (See Type H, Page 7) .118 [ 3.00 ] .281 [ 7.14 ] C Note: Mating poke-in tab 1217324-1 .505 [ 12.83 ] .505 [ 12.83 ] Tin plated brass Type C 500 Box Standard IDC Non-Locking Poke-In D3 500 Box Standard IDC w/ Strain Relief Slot Non-Locking Poke-In .118 [ 3.00 ] D Range1 Copper Magnet Wire AWG mm 23-19.5 0.57-0.86 19-17 0.91-1.15 16-15 1.29-1.45 23-21.5 0.57-0.68 21-19.5 0.72-0.86 19-17 0.91-1.15 17-16 1.15-1.29 16-15 1.29-1.45 14-13 2 1.61-1.83 Stock Thickness .016 0.41 .016 0.41 .016 0.41 .016 0.41 .016 0.41 .016 0.41 .016 0.41 .016 0.41 .016 0.41 Strip Part Number 1217069-1 1217068-1 1217067-1 1217358-1 1217357-1 1217356-1 1742203-1 1217355-1 1217579-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. 3 Strain relief slot for high vibration applications. 6 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) Poke-In Tab Terminals Material .135 [ 3.43 ] .312 [ 7.92 ] .275 [ 6.98 ] .135 [ 3.43 ] .312 [ 7.92 ] .275 [ 6.98 ] .255 [ 6.48 ] .405 [ 10.29 ] .323 [ 8.20 ] .203 [ 5.28 ] B A .135 [ 3.43 ] Standard MAG-MATE Terminals .135 [ 3.43 ] Tin plated brass Optional Slot for #20 AWG [0.8 mm] Dia. Solid Copper Diode Slot Type A 90 Up .255 [ 6.48 ] B 90 Up w/Ins. Sup. .520 [ 13.21 ] C Straight D .208 [ 5.28 ] .312 [ 7.92 ] D Straight w/Ins. Sup. .135 [ 3.43 ] E E 90 Down C Lead Wire Size1 AWG mm2 22-18 Stock Thickness Strip Part Number 62895-1* .060-.100 1.52-2.54 .090-.140 2.29-3.56 .018 0.46 .020 0.51 .018 0.46 .018 0.46 .018 0.46 .020 0.51 .020 0.51 .020 0.51 .020 0.51 Ins. O.D. 0.3-0.9 24 0.2 22-18 0.3-0.9 18-14 0.8-2.0 22-18 0.3-0.9 18-14 0.8-2.0 .040-.060 1.02-1.52 .060-.100 1.52-2.54 .090-.140 2.29-3.56 63410-1 1742828-1 62896-1* 63218-1 62897-1* 63775-1 22-18 0.3-0.9 18-14 0.8-2.0 22-17 0.3-1.0 .118 MAX. 3.00 MAX. .018 0.45 281622-2 2 22-17 0.3-1.0 .118 MAX. 3.00 MAX. .018 0.45 281623-2 2 20-17 0.5-1.0 .063-.090 1.60-2.30 .018 0.45 964101-2 3 20-17 0.5-1.0 .063-.090 1.60-2.30 .018 0.45 964290-1 22-18 0.3-0.9 .018 0.46 63364-1 18-14 0.8-2.0 .018 0.46 1742125-1 62898-1* 63397-1 4 1 Stranded, fused stranded or solid lead wire. Note: All tab terminals accept stranded, fused stranded or solid lead wire. 2 Can be selectively bent inside applicator. With support flanges, can only be used in combination with modified cavity IA-84-5157 3 Can be selectively bent inside applicator, Non-locking 4 Can be selectively bent inside applicator. Non-locking;use with housing * Recognized under the Component Program of Underwriters Laboratories, Inc. 7 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) Poke-In Tab Terminals Material .340 [ 8.64 ] Tin plated brass Pre-Tin plated brass .245 [ 6.22 ] .312 [ 7.92 ] .106 [ 2.70 ] .315 [ 8.00 ] .135 [ 3.43 ] .135 [ 3.43 ] F Type .197 [ 5.00 ] .135 [ 3.43 ] .150 [ 3.81 ] .490 [ 12.45 ] J I Lead Wire Size1 AWG mm2 Ins. O.D. Stock Thickness .048-.078 1.22-1.98 .060-.100 1.52-2.54 .090-.140 2.29-3.56 Strip Part Number 1742410-1 K Bridge Contact L PCB Contact .020 0.51 1217041-1 I Flag - 300 Box only J Flag - 500 Box only .250 [ 6.35 ] .540 [ 13.72 ] .285 .347 [ 7.24 ] [ 8.81 ] .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 F 90 Down w/Ins. Sup. K .110 .370 [ 2.79 ] [ 9.40 ] 24-20 0.2-0.5 22-18 0.3-0.9 18-14 0.8-2.0 20-16 0.5-1.4 0.8-2.0 18-14 .080-.120 2.03-3.05 1742211-1 63458-1 1217406-1 1217324-1 1987199-1 Note: All tab terminals accept stranded, fused stranded or solid lead wire. .200 [ 30.48 ] L MAG-MATE Terminals with extended leaf-spring Material Pre-tinned copper alloy Type .55 [ 13.9 ] .41 [ 10.3 ] M Mag-Mate Terminal with extended Leaf-Spring *Single magnet wire .120 [ 3.05 ] Copper Magnet Wire Range AWG mm 33-30 0.18-0.265 30-26 0.265-0.40 26.5-22.5 0.375-0.60 22.5-20 0.60-0.80 19.5-17 0.85-1.12 Stock Thickness .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 Strip Part Number 1740603-1 1740698-2 1534110-1 969125-1* 1418686-1 Note: Special cavity is required,contact TE connectivity for information. .136 [ 3.45 ] M 8 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) 300 Box Poke-In Terminals Standard MAG-MATE Terminals Material Tin plated brass .300 [7.62] Series Box Typical Cavity Size 2 (See page 23) .300 [ 7.62 ] .300 [ 7.62 ] Note: Special cavity required for Tri-slot splice terminal. SPEC 114-2046 .455 [ 11.56 ] .120 [ 3.05 ] .135 [ 3.43 ] See application A Type A 300 Box Standard IDC Splice B 300 Box Standard IDC Tri-Slot Splice B Range1 Copper Magnet Wire AWG mm 22-20 0.64-0.81 19-17 0.91-1.15 28-24 0.32-0.51 23-20 2 27-23 4 18 19-17 2 25-223 4 18 23.5-20 2 .120 [ 3.05 ] Stock Thickness Strip Part Number .016 0.41 .020 0.51 .016 0.41 1217973-1 .016 0.41 1217853-1 .016 0.41 1217613-1 .016 0.41 1217209-1 0.57-0.81 0.36-0.57 0.8-0.9 0.91-1.15 0.45-0.64 0.8-0.9 0.54-0.81 1742159-14 1217858-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64 mm] or larger. 3 Single solid or fused stranded lead wire only. 4 Special cavity required for 1742159-1. Tab Receptacle Terminals Material Tin plated phos. bronze .345 [8.76] .185 [4.70] Note: Special cavity required. Contact TE Engineering for .110 [2.79] details. .070 [1.78] C Type C 185 Box Standard IDC Tab Receptacle Copper Magnet Wire Range1 AWG mm 32-31 0.20-0.23 30-28 0.25-0.32 29-28 0.29-0.32 28-27 0.32-0.36 Mating Tab Stock Thickness .070 x .020 1.78 x 0.51 .070 x .020 1.78 x 0.51 .070 x .020 1.78 x 0.51 .070 x .020 1.78 x 0.51 .010 0.25 .010 0.25 .010 0.25 .010 0.25 Strip Part Number 1217538-1 1217457-1 1217458-1 1742781-1 1 Two magnet wires may be terminated in the same slot if diameters are equal. www.te.com/appliances 9 Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) 187 Box F-Crimp Terminals Material Tin plated brass .187 [4.75] Series Box .187 [ 4.75 ] .360 .187 [ 9.14 ] [ 4.75 ] Typical Cavity Size 1 .467 [ 11.86 ] (See page 23) .090 [ 2.29 ] B A Copper Magnet Wire Range1 AWG mm Type A 187 Box Standard IDC F-Crimp 0.18-0.23 26-22 0.12-0.3 30-28 0.25-0.32 26-22 0.12-0.3 27-25 0.36-0.46 26-22 0.12-0.3 26-24 0.40-0.51 22-18 0.3-1.0 0.51-0.64 26-22 0.12-0.3 0.36-0.46 22-18 0.3-1.0 24-22 B 187 Box F-Crimp w/Ins Sup. Lead Wire Range3 AWG mm2 33-31 2 27-25 .070 [ 1.78 ] .090 [ 2.29 ] .070 [ 1.78 ] Ins. O.D. Strip Part Number Stock Thickness .010 0.25 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .071-.088 1.80 -2.23 63039-1 63036-1 62609-1 4 1217146-1 62610-1 .012 0.30 4 63856-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. 3 Stranded, fused stranded or solid lead wire. 4 Strip rereeled to feed through mini-applicator to crimp lead wire first, magnet wire termination is secondary operation. 300 Box F-Crimp Terminals Material Type Tin plated brass Copper Magnet Wire Range1 AWG mm .300 [7.62] Series Box Typical Cavity Size 2, when 33-31 0.18-0.23 31-28 0.23-0.32 30-27 0.25-0.36 28-24 0.32-0.51 "C" dimension is .120 [3.05] (See page 23) Typical Cavity Size 6, when "C" dimension is .070 [1.78] (See page 23) C 300 Box Standard IDC F-Crimp .480 [ 12.19 ] .300 [ 7.62 ] 27-24 0.36-0.51 27-23 0.36-0.57 25-22 0.45-0.64 2 0.64-0.81 2 0.91-1.15 22-20 19-17 .135 [ 3.43 ] C 10 Dim. C .070 1.78 .120 3.05 .070 1.78 .070 1.78 .120 3.05 .120 3.05 .070 1.78 .120 3.05 .070 1.78 .120 3.05 .120 3.05 Lead Wire Range3 AWG mm 2 22-18 0.3-1.0 24-20 0.2-0.6 22-18 0.3-1.0 24-20 0.2-0.6 24-20 0.2-0.6 24-20 0.2-0.6 22-18 0.3-1.0 24-20 0.2-0.6 22-18 0.3-1.0 24-20 0.2-0.6 22-18 0.3-1.0 Stock Thickness .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .016 0.41 .012 0.30 .016 0.41 .016 0.41 Strip Part Number 63235-1 63420-1 63236-1 1742614-1 62992-1 63641-1 63237-1 62459-1 63690-1 62458-1 63504-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64 mm] or larger. 3 Stranded, fused stranded or solid lead wire. www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) 300 Box Posted PCB Terminals L Material .300 [ 7.62 ] Tin over Copper Alloy Cavity Size .132 [ 3.35 ] Application Spec. 114-74109 with 114-74109-5 Type A Multi-Spring Solderless PCB Tab Terminal Standa rd MAG-MATE Terminals Multi-Spring Solderless Terminal A Copper Magnet Wire Range1 AWG mm 33-29.5 0.18-0.265 29.5-26 0.265-0.40 26-22.5 22.5-19.5 19.5-17 .120 [ 3.05 ] 2 .583 14.80 .583 14.80 .583 14.80 .583 14.80 .583 14.80 0.40-0.63 2 Stock Thickness Tab Section Mag Wire Section .013 .031 0.32 0.80 .013 .031 0.32 0.80 .013 .031 0.32 0.80 .031 .013 0.80 0.32 .031 .013 0.80 0.32 Dim L 0.63-0.85 0.85-1.12 Strip Part Number 1247000-2 1247001-2 1247002-2 1247003-2 1247004-2 Note: PC Board hole size .057 [1.45]. 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. 22 awg [0.63 mm] and larger. 300 Box Posted PCB Terminals Solder Terminal .042 [ 1.07 ] L Material .300 [ 7.62 ] Tin over copper plated brass Typical Cavity Size (See page 23) .135 [ 3.43 ] Type C--Cavity Size 2 Type D--Cavity Size 6 L .300 [ 7.62 ] B Type B 300 Box Standard IDC PCB Post C PCB Post Shallow Box Copper Magnet Wire Range1 AWG mm C Dim. L 22-20 2 0.64-0.81 19-17 2 0.91-1.15 19-17 2 0.91-1.15 .540 13.72 .540 13.72 .540 13.72 .460 11.68 .460 11.68 .460 11.68 .570 14.48 0.18-0.23 .475 12.07 33-31 0.18-0.23 31-28 0.23-0.32 29-26 0.29-0.40 27-23 0.36-0.57 33-31 .070 [ 1.78 ] .135 [ 3.43 ] .120 [ 3.05 ] Stock Thickness Tab Section Mag Wire .010 0.25 .010 0.25 .012 0.30 .016 0.41 .016 0.41 .016 0.41 .016 0.41 .010 0.25 .010 0.25 .012 0.30 .016 0.41 .016 0.41 .016 0.41 .016 0.41 .020 0.51 .012 0.30 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. * Recognized under the Component Program of Underwriters Laboratories, Inc. Strip Part Number 63253-1 62928-1* 62958-1* 63659-1 63660-1 63661-1 1742708-1 1217302-1 Note: PC Board hole size .050 [1.27]. www.te.com/appliances 11 Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) MAG-MATE Edge Leaf Terminal Material Pre-tinned brass Brass Cavity 411-18517 Copper Magnet Wire Range AWG mm 16.2 A MAG-MATE Contact RAST 5D 7.6 3 A Cavity Size 33-30 0.18-0.265 2 30-26 0.265-0.40 2 26-22 0.40-0.63 2 22-20 0.63-0.80 2 20-17 0.85-1.12 2 Stock Thickness .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 Strip Part Number 1394429-2 1394430-2 1394431-2 1394432-2 1394433-2 Note: Special cavity required. Contact TE Connectivity for information 3.15 Material Unplated brass Cavity 411-18517 Type B MAG-MATE Edge Leaf Contact .64 [ 16.2 ] Copper Magnet Wire Range AWG mm 33-30 0.18-0.265 Cavity Size Stock Thickness Strip Part Number 2 .013 0.32 1-1987143-1 Note: Special cavity required. Contact TE Connectivity for information .31 [ 7.8 ] .12 [ 3.0 ] 12 B www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) 187 Box Posted PCB Terminals Tin plated brass Copper Magnet Wire Range1 AWG mm 33-31 Dim. L .267 6.78 0.18-0.23 (See page 23) .050 [ 1.27 ] L A 185 Box Standard IDC PCB Post .187 [ 4.75 ] 30-28 0.25-0.32 27-25 0.36-0.46 24-222 0.51-0.64 .010 0.25 .010 0.25 .330 8.38 .267 6.78 .287 7.29 .330 8.38 .330 8.38 .287 7.29 .330 8.38 Typical Cavity Size 1 Strip Part Number Stock Thickness Standard MAG-MATE Terminals Material Type 63565-1 62938-1 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 63160-1 63818-1 62430-1 62438-1 63819-1 62439-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. .090 [ 2.29 ] .070 [ 1.78 ] A 187 Box Tab Terminals Material Tin plated brass Typical Cavity Size 1 Type (See page 23) Dim. L Tab Size 0.25-0.32 .432 10.97 .110 x .020 2.79 x 0.51 .020 0.51 .012 0.30 63702-1 29-27 0.29-0.36 0.25-0.32 27-25 0.25-0.32 24-22 0.25-0.32 30 0.25 29-27 0.29-0.36 25-222 0.46-0.64 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .071 x .025 1.80 x 0.63 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .025 0.63 .032 0.81 .032 0.81 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 1217196-1 30-28 .432 10.97 .512 13.00 .512 13.00 .512 13.00 .550 14.00 .700 17.78 .700 17.78 Copper Magnet Wire Range1 AWG mm 30-28 B 187 Box Standard IDC F-Crimp L .187 [ 4.75 ] .090 [ 2.29 ] .070 [ 1.78 ] Stock Thickness Tab Section Mag Wire Strip Part Number 160810-2 160809-2 160897-2 1217405-1 1742605-1 1217013-1 1 Two magnet wires may be terminated in the same terminal if diameters are equal. 2 Single magnet wire only. B www.te.com/appliances 13 Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) 300 Box Tab Terminals Material Tin plated brass .870 [ 22.1 ] L Typical Cavity Size 2 (See page 23) .300 [ 7.62 ] .135 [ 3.43 ] .300 [ 7.62 ] .120 [ 3.05 ] .135 [ 1.78 ] C B A Type A 300 Box Standard IDC Straight Tab Copper Magnet Wire Range1 AWG mm 20 0.79 31 0.23 Dim. L Tab Size .750 19.05 .895 22.73 .870 22.10 .063 x .025 1.60 x 0.63 .063 x .025 1.60 x 0.63 .062 x .032 1.57 x 0.81 Stock Thickness Tab Section Mag Wire .025 .016 0.63 0.41 .025 .016 0.63 0.41 .010 .032 0.81 0.25 Strip Part Number 63965-12 1217595-1 2 63810-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Tinsel wire only. Typical Cavity Size 2 when "C" dimension is.120[3.05] (See page 23) Typical Cavity Size 6 when "C" dimension is.070[1.78] (See page 23) Type B 300 Box Standard IDC Twisted Tab Copper Magnet Wire Range1 AWG mm 33-31 0.18-0.23 31-28 0.23-0.32 27-24 0.36-0.50 212 0.72 2 19.5 0.86 Dim. C Tab Size .070 1.78 .070 1.78 .070 1.78 .120 3.05 .120 3.05 .125 x .020 3.17 x 0.51 .125 x .020 3.17 x 0.51 .125 x .020 3.17 x 0.51 .118 x .030 3.00 x 0.76 .118 x .030 3.00 x 0.76 Stock Thickness Tab Section Mag Wire .020 0.51 .020 0.51 .020 0.51 .030 0.76 .030 0.76 .012 0.30 .012 0.30 .012 0.30 .016 0.41 .016 0.41 Strip Part Number 63806-1 63807-1 63808-1 63463-1 63216-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. Material Type Tin plated brass Typical Cavity Size 2 (See page 23) L .300 [ 7.62 ] .120 [ 3.05 ] .132 [ 3.35 ] C 14 C 300 Box Standard IDC Timer Tab Copper Magnet Wire Range1 AWG mm 33-31 0.18-0.23 30 -28 0.25-0.32 27-23 0.36-0.57 25-222 0.45-0.64 2 23.5-21.5 0.54-0.68 27-23 0.36-0.57 23-202 0.57-0.81 19-172 0.91-1.15 18 Lead 1.02 Dim. L Tab Size .585 14.86 .585 14.86 .585 14.86 .585 14.86 .585 14.86 .585 14.86 .775 19.68 .775 19.68 .585 14.86 .585 14.86 .118 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 .125 x .020 3.17 x 0.51 .118 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 .125 x .020 3.17 x 0.51 .125 x .020 3.17 x 0.51 .118 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 Stock Thickness Tab Section Mag Wire .020 .010 0.51 0.25 .020 .010 0.51 0.25 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .016 .020 0.41 0.51 .016 .020 0.41 0.51 .016 .020 0.41 0.51 .020 .016 0.51 0.41 .016 .020 0.41 0.51 Strip Part Number 1217746-1 1217745-1 63973-1 63489-1 1217596-1 1217593-1 1742167-1 63899-1 63972-1 63974-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64 mm] or larger. www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) Pin Receptacle Terminals A: Tin plated brass B: Unplated brass .75 [ 19 ] .748 [ 19 ] Typical Cavity Size 2 .30 [ 7.6 ] .300 [ 7.62 ] (See page 23) .132 [ 3.35 ] .120 [ 3.05 ] .12 [ 3.0 ] A Type A Pin Receptacle Copper Magnet Wire Range1 AWG mm 30-27 0.25-0.36 26-23 0.40-0.57 2 0.72-1.00 26-23 0.40-0.57 2 0.72-1.00 21-18 21-18 30-27 B Pin Receptacle Standard MAG-MATE Terminals Material 0.25-0.36 26-23 0.40-0.57 3 0.72-1.00 21-18 B .138 [ 3.5 ] Mating Pin Dia. Stock Thickness .079 2.00 .079 2.00 .079 2.00 .150 3.80 .150 3.80 .150 3.80 .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 .150 3.80 .150 3.80 .013 0.32 .013 0.32 Strip Part Number 1394403-1 1394475-1 1394476-1 1394638-1 1394639-1 1740417-1 1740418-1 1740419-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 20.5 AWG [0.76 mm] or larger. 3 Single magnet wire only www.te.com/appliances 15 Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) Pin I/O Terminals Material Tin plated brass .300 [7.62] Series Box .048 [ 1.22 ] .060 [ 1.52 ] Styles A, B and C Typical Cavity Size 2 (See page 23) .789 [ 20.29 ] .300 [ 7.62 ] .500 [12.7] Series Box Style D Typical Cavity Size 4 (See page 23) .668 [ 16.76 ] .300 [ 7.62 ] .120 [ 3.05 ] .135 [ 3.43 ] .120 [ 3.05 ] .120 [ 3.05 ] A B .090 [ 2.29 ] .048 [ 1.22 ] .660 [ 16.76 ] .300 [ 7.62 ] .500 [ 17.7 ] .120 [ 3.05 ] .860 [ 21.84 ] .280 [ 7.11 ] .120 [ 3.05 ] .120 [ 3.05 ] C Type D Copper Magnet Wire Range1 AWG mm Pin Dia. Stock Thickness I/O Mag Wire Strip Part Number A 300 Box Straight Pin 27-23 0.36-0.57 .060 1.52 .010 0.25 .010 0.25 63722-1 B 300 Box Offset Pin-R.H. 33-31 0.18-0.23 .048 1.22 .010 0.25 .010 0.25 63443-1 33-31 0.18-0.23 0.23-0.32 .010 0.25 .010 0.25 .048 1.22 .048 1.22 .010 0.25 .010 0.25 .010 0.25 .010 0.25 63444-1 31-28 .048 1.22 .048 1.22 .016 0.25 .016 0.41 63570-1 .090 2.29 .090 2.29 .016 0.41 .016 0.41 .016 0.41 .016 0.41 63278-1 C 300 Box Offset Pin-L.H. D 500 Box Straight Pin 27-23 0.36-0.57 25-222 0.45-0.64 27-23 0.86-1.15 22-20 0.64-0.81 63569-1 63788-1 63277-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64 mm] or larger. 16 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) 110 Series FASTON Tab Terminals Standard MAG-MATE Terminals Material Tin plated brass Typical Cavity Size 2 (See page 23) .300 [ 7.62 ] .310 [ 7.87 ] Note:.110 [2.79] Tab Terminals Request Catalog 82004. .300 [ 7.62 ] .135 [ 3.43 ] mate with compatible FASTON receptacles. .660 [ 16.76 ] .625 [ 15.88 ] .625 [ 15.88 ] .135 [ 3.43 ] .120 [ 3.05 ] .120 [ 3.05 ] B A Type A4 300 Box Standard IDC .110[2.79] FASTON Tab B 4.5 300 Box Single IDC w/ Strain Relief Slot C 3.4 Poke-In Combination Tab .135 [ 3.43 ] Copper Magnet Wire Range1 AWG mm 30-27 0.25-0.36 27-23 0.36-0.57 23-20 2 0.45-0.64 19-17 0.91-1.15 27-23 0.36-0.57 3.5-202 0.54-0.81 28-24 0.32-0.51 2 0.45-0.64 25-22 Tab Size .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .120 [ 3.05 ] C Stock Thickness Tab Mag Wire .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .012 0.30 .016 0.41 .016 0.41 .020 0.51 .016 0.41 .016 0.41 .012 0.30 .012 0.30 Strip Part Number 63777-1 63746-1 63486-1 63145-1 63827-1 1217783-1 63062-1 63063-2 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64 mm] or larger. 3 Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] Solid or overcoated stranded lead wire or 90 Poke-In tab. 4 After insertion into plastic cavity, tab portion must be bent over 45-90 or potted in to prevent pullout when mating receptacle is disconnected. 5 Strain relief slot for high vibration applications. www.te.com/appliances 17 Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) 187 Series FASTON Tab Terminals Type Copper Magnet Wire Range1 Dim. L Tab Feature Dimple AWG mm Tin plated brass 33-31 0.18-0.23 .630 16.00 .660 16.76 Typical Cavity Size 30-27 0.25-0.36 .630 16.00 Material (See page 23) Type A--Cavity Size 2 Dimple Dimple Dimple 27-23 Hole or Dimple 0.36-0.57 3 A 300 Box Standard IDC .187 [4.75] FASTON Tab L .300 [ 7.62 ] 23 0.57 .630 16.00 .660 16.76 .630 16.00 0.64-0.81 Hole 2 Tin plated brass Hole Dimple A Material Hole .630 16.00 .120 [ 3.05 ] 187 Series Combination Poke-In FASTON Terminals Hole Dimple 22-202 .135 [ 3.43 ] Hole .630 16.00 20-18 0.81-1.02 19-17 0.91-1.15 .630 16.00 Dimple Hole Dimple Hole Tab Size .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 Stock Thickness Tab Mag. Wire Section Section .020 .010 0.51 0.25 .020 .012 0.51 0.30 .020 .012 0.51 0.30 .032 .012 0.81 0.30 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .032 .016 0.81 0.41 .032 .016 0.81 0.41 .020 .020 0.51 0.51 .020 .020 0.51 0.51 .020 .020 0.51 0.51 .020 .020 0.51 0.51 Strip Part Number 62513-1* 63584-1 62512-1* 62678-1* 62514-1* 63664-1 63461-1 63585-1 63776-1 62511-1* 63663-1 1217065-1 1217128-1 4 62904-1 63670-1 63273-12 1742160-11 63665-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. 3 After insertion into plastic cavity, tab portion must be bent over 45-90 or potted in to prevent pullout when mating receptacle is disconnected. 4 Single bare copper wire only. * Recognized under the Component Program of Underwriters Laboratories, Inc. These part numbers are available upon special request; contact TE Engineering for details. Typical Cavity Size (See page 23) Type Type B--Cavity Size 2 B 3.4 Poke-In Combination Tab .310 [ 7.87 ] .120 [ 3.05 ] .135 [ 3.43 ] Copper Magnet Wire Range1 mm AWG 33-31 0.81-0.23 27-222 0.35-0.63 22-19 2 0.64-0.89 19-17 2 0.90-1.15 17-16 2 1.20-1.30 Dim. L .630 16.00 .630 16.00 .630 16.00 .630 16.00 .630 16.00 Tab Feature Hole Hole w/o Hole Hole w/o Hole Hole w/o Hole Hole Tab Size .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 Stock Thickness Tab Mag. Wire Section Section .020 .010 0.51 0.25 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .016 .020 0.41 0.51 .020 .016 0.51 0.41 Strip Part Number 63018-1 316300-4 2-316300-7 316300-5 2-316300-8 316300-6 2-316300-9 6-316300-7 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64 mm] or larger. 3 Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] solid, fused stranded lead wire or 90 poke-in tab terminal. 4 After insertion into plastic cavity, tab portion must be bent over 45-90 or potted in to prevent pullout when mating receptacle is disconnected. B Note:.187 [4.75] Tab Terminals mate with compatible FASTON receptacles. Request Catalog 82004. Chart continued on next page 18 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) 187 Series FASTON Tab Terminals .187 [ 4.75 ] Hole or Dimple Material Standard MAG-MATE Terminals (Continued) Dimple L Tin plated brass .300 [ 7.62 ] .300 [ 7.62 ] Typical Cavity Size (See page 23) .120 [ 3.05 ] Type A--Cavity Size 5 Type B--Cavity Size 5 .135 [ 3.43 ] .120 [ 3.05 ] .135 [ 3.43 ] A Type A 300 Box Standard IDC Narrow Body Latch Type Copper Magnet Wire Range1 mm AWG 33-31 0.18-0.23 31-28 0.23-0.32 30-27 0.25-0.36 27-23 0.36-0.57 2 0.57-0.81 22-202 0.64-0.81 19-172 0.91-1.15 23-20 2 18 lead 0.80-0.92 B3 Narrow Body 2 Latch Type w/ 23.5-20 Strain Relief Slot mm 2 0.54-0.81 B Dim. L Tab Feature .630 16.00 .630 16.00 .630 16.00 Dimple .630 16.00 .630 16.00 .630 16.00 .630 16.00 Dimple Dimple Dimple Dimple Dimple Dimple Dimple Hole .630 16.00 .630 16.00 Dimple Tab Size .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 Stock Thickness Tab Mag. Wire Section Section .010 .020 0.25 0.51 .010 .020 0.25 0.51 .012 .020 0.30 0.51 .016 .020 0.41 0.51 .016 .020 0.41 0.51 .016 .020 0.41 0.51 .016 .020 0.41 0.51 .016 .020 0.41 0.51 .016 .020 0.41 0.51 .016 .020 0.41 0.51 .020 0.51 .016 0.41 Strip Part Number 63108-1 62743-1 63109-1 63107-1 1217493-1 63340-1 63429-1 62888-1 63782-1 1217592-1 1217004-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64 mm] or larger. 3 Strain relief slot for high vibration applications. These part numbers are available upon special request; contact TE Engineering for details. Chart continued on next page www.te.com/appliances 19 Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) 187 Series FASTON Tab Terminals (Continued) Material Tin plated brass Typical Cavity Size (See page 23) Type A--Cavity Size 4 Type B--Cavity Size 4 Type Hole or Dimple Copper Magnet Wire Range1 mm AWG 22-20 0.64-0.81 19-17 0.91-1.15 Dim. L Tab Feature .830 21.08 .830 21.08 Hole Hole Hole .505 [ 12.83 ] 17.5-16 .120 [ 3.05 ] 1.09-1.29 A3 500 Box Standard IDC Hole 1.29-1.45 .830 21.08 14.5-13 1.54-1.83 27-23 0.36-0.57 .830 21.08 .830 21.08 22-20 0.64-0.81 .830 21.08 19-17 0.91-1.15 .830 21.08 16-15 .187 [ 4.75 ] 3.4 Hole .505 [ 12.83 ] .281 [ 7.14 ] .120 [ 3.05 ] B Hole Dimple 2 L Hole Hole .280 [ 7.11 ] A .830 21.08 B 500 Box Single IDC w/ Strain Relief Slot 16-15 1.29-1.45 .830 21.08 Hole Hole Hole Hole Hole Hole Hole Tab Size .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 Stock Thickness Tab Mag. Wire Section Section .020 0.51 .020 0.51 .020 0.51 .020 0.51 .032 0.81 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .032 0.81 .020 0.51 .032 0.81 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 Strip Part Number 1742819-1 1742820-1 63667-1 63427-1 1217075-1 63666-1 63762-1 63353-1 1217902-1 1217042-1 63983-1 1217339-1 63995-1 1217090-1 63996-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. 3 After insertion into plastic cavity, tab portion must be bent over 45-90 or potted in to prevent pullout when mating receptacle is disconnected. 4 Strain relief slot for high vibration applications. 20 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) 250 Series FASTON Tab Terminals Tin plated brass Typical Cavity Size (See page 23) Type A--Cavity Size 2 Type B--Cavity Size 5 Type C--Cavity Size 3 receptacles. Request Catalog 82004. L .135 [ 3.43 ] .120 [ 3.05 ] A 3 A 300 Box Standard IDC .250 [6.35] FASTON Tab B Narrow Body Latch Type 33-31 0.18-0.23 30-27 0.25-0.36 28-24 0.32-0.51 27-23 0.36-0.57 22-20 0.64-0.81 19-17 0.91-1.15 33-31 1 1 30-27 0.25-0.36 27-23 0.36-0.57 23-20 C Wide Body Latch Type 0.18-0.23 2 0.57-0.81 33-31 0.18-0.23 31-28 0.23-0.32 30-28 0.25-0.32 30-27 0.25-0.36 27-23 0.36-0.57 22-20 2 0.64-0.81 19-17 2 0.91-1.15 Dim. L Tab Feature .750 19.05 .750 19.05 .750 19.05 .750 19.05 .750 19.05 .750 19.05 .750 19.05 .750 19.05 .750 19.05 .750 19.05 .750 19.05 .750 19.05 .750 19.05 .750 19.05 .750 19.05 .750 19.05 .750 19.05 Dimple Dimple Hole Dimple Dimple Dimple Dimple Dimple Dimple Dimple Hole Dimple Hole Dimple Hole Hole Dimple Dimple Hole 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64 mm] or larger. 3 After insertion into plastic holder, tab portion must be bent over 45-90 or potted in to prevent pullout when mating receptacle is disconnected. Locking Latch (2) .135 [ 3.43 ] .120 [ 3.05 ] .120 [ 3.05 ] B Copper Magnet Wire Range1 mm AWG L .300 [ 7.62 ] .300 [ 7.62 ] .135 [ 3.43 ] Type Hole or Dimple L .300 [ 7.62 ] Note:.250 [6.35] tab terminals mate with compatible FASTON Dimple Standard MAG-MATE Terminals Material Hole or Dimple C Tab Size .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 Stock Thickness Strip Tab Mag. Wire Part Number Section Section .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .010 0.25 .012 0.30 .016 0.41 .016 0.41 .016 0.41 .020 0.51 .010 0.25 .012 0.30 .016 0.41 .016 0.41 .010 0.25 .012 0.30 .012 0.30 .012 0.30 .016 0.41 .016 0.41 .016 0.41 62600-1* 62651-1* 63607-1 62652-1* 1217924-1 1742398-1 63026-1 63027-1. 1217860-1 1217870-1 63309-1 63403-2 1217152-1 63132-1 63499-1 63571-1 63128-1 63601-2 63614-1 * Recognized under the Component Program of Underwriters Laboratories, Inc. Chart continued on next page 21 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) 250 Series FASTON Tab Terminals (Continued) Hole or Dimple Hole or Dimple Material Tin plated brass L L .500 [ 12.7 ] Typical Cavity Size .500 [ 12.7 ] (See page 23) .120 [ 3.05 ] Type A--Cavity Size 4 Type B--Cavity Size 4 .120 [ 3.05 ] .280 [ 7.11 ] .280 [ 7.11 ] A Type A3 500 Box Standard IDC Wide Neck 3 B 500 Box Standard IDC Narrow Neck Copper Magnet Wire Range1 B Dim. L Tab Feature .952 24.18 .952 24.18 .952 24.18 Hole AWG mm 22-20 0.64-0.81 19-17 0.91-1.15 16-15 1.29-1.45 14-13 2 1.61-1.83 .952 24.18 22-20 0.64-0.81 19-17 0.91-1.15 16-15 1.29-1.45 2 1.61-1.83 .952 24.18 .952 24.18 .952 24.18 .952 24.18 .952 24.18 14-13 12 2 2.05 Hole Hole Dimple Hole Dimple Dimple Dimple Dimple Dimple Tab Size .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 Stock Thickness Strip Tab Mag. Wire Part Number Section Section .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 63495-1 63464-3 63459-2 63460-1 63816-1 63155-1 62923-1 63064-1 63465-1 63425-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. 3 After insertion into plastic holder, tab portion must be bent over 45-90 or potted in to prevent pullout when mating receptacle is disconnected. 22 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) Typical Plastic Cavity Technical Documents Application Specifications describe requirements for using the product in its intended application and or crimping information. They are intended for the Packaging and Design Engineer and the Machine Setup Person. 114-2050 --Poke-In Tab MAG-MATE Terminals 114-2069 --Standard MAG-MATE.187 [4.75] Box Height Terminals 114-2046 --Standard MAG-MATE.300 [7.62] Box Height Terminals 114-2066 --Standard MAG-MATE.500 [12.7] Box Height Terminals 114-2067 --Standard MAG-MATE .300 [7.62] Box Height Latch-In Terminals Narrow Body 114-2094 --Standard MAG-MATE .300 [7.62] Box Height Latch-In Terminals Wide Body .355 [ 9.08 ] Min. .235 [ 5.97 ] Min. .175 [ 4.45 ] Min. .150 [ 3.81 ] Min. Cavity Size 1 187 [4.75] Box MAG-MATE (Application Spec. 114-2069) .215 [ 5.46 ] Min. Cavity Size 2 .300 [7.62] Box MAG-MATE (Application Spec. 114-2046) .550 [ 13.97 ] Min. .375 [ 9.53 ] Min. .300 [ 7.62 ] Min. Cavity Size 4 .500 [12.70] Box MAG-MATE (Application Spec. 114-2066) Note: The MAG-MATE typical plastic cavities shown above are for reference only. They are not a purchased item. Refer to appropriate TE application specification for details. Plastic cavities, designed to TE specifications, may be molded as part of the coil bobbin or attached to a lamination stack in the area of the magnet wire coil. Each cavity is a rectangular box with two narrow slots on opposing walls and a plastic post or anvil extending upward from the bottom surface. During or after the winding process, the magnet wire is placed across the plastic cavities and into the slots, either manually or by coil winding equipment. .355 [ 9.08 ] Min. .355 [ 9.08 ] Min. .205 [ 5.21 ] Min. .235 [ 5.97 ] Min. .235 [ 5.97 ] Min. Cavity Size 3 .300 [7.62] Box Latch-In MAG-MATE Wide Body (Application Spec. 114-2094) .355 [ 9.08 ] Min. .215 [ 5.46 ] Min. .355 [ 9.08 ] Min. .215 [ 5.46 ] Min. .150 [ 3.81 ] Min. Cavity Size 5 .300 [7.62] Box Latch-In MAG-MATE, Narrow Body (Application Spec. 114-2067) Cavity Size 6 .300 [7.62] Box MAG-MATE (Application Spec. 114-2046) Unraveling is prevented by a slight friction fit, suitable bend or by wrapping the magnet wire around a tie-off post. Excess magnet wire is trimmed flush with the outside of the plastic cavity by a shear blade traveling with the terminal insertion ram. During insertion, two insulation displacing terminal slots strip the film insulation from the magnet wire producing a stable electrical termination. The plastic anvil supports the magnet wire, helping to prevent it from being dragged down when the terminal is inserted. Terminal retention is secured in the plastic cavities by either locking barbs or locking latches in addition to locking barbs for quick disconnect FASTON tab terminals. Standard MAG-MATE Terminals Illustrations shown are for reference only. They are not a purchased item. Manufacture only according to TE Specification. The sheared wire end can be tucked inside the plastic cavity, if necessary, by cutting the wire off before the terminal is fully seated allowing the terminal to drag the severed end of the wire into the pocket inside the cavity. TE will provide design and mold engineering resources to manufacture any specifically designed MAG-MATE cavity housing. www.te.com/appliances 23 Magnet Wire Terminals and Termination Systems Catalog 82221 Standard MAG-MATE Terminals (Continued) Typical Plastic Cavities Illustrations shown are for reference only. They are not a purchased item. Manufacture only according to TE Specification. .375 [ 9.53 ] Min. .270 [ 6.86 ] Min. .115 [ 2.92 ] Min. Slim Line MAG - MATE Reference Application Spec. 114-2147 24 .375 [ 9.53 ] Min. .250 [ 6.35 ] Min. .225 [ 5.71 ] Min. Mini MAG - MATE Reference Application Spec. 114-2047 Technical Documents Application Specifications Technical Documents Application Specifications describe requirements for using the product in its intended application and or crimping information. They are intended for the Packaging and Design Engineer and the Machine Setup Person. describe requirements for using the product in its intended application and or crimping information. They are intended for the Packaging and Design Engineer and the Machine Setup Person. 114-2140--Slim Line MAG-MATE Terminals 114-2047--Mini MAG-MATE Terminals www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Slim Line MAG-MATE Terminals Product Facts Slim Line MAG-MATE Terminals Terminates all magnet wire film insulations Eliminates need for pre-stripping conductors Eliminates need to post-insulate terminations Excess magnet wire is automatically trimmed during the termination process 187 and 250 Series Faston Tab and posted PCB Tab terminals available Terminates 33-17 AWG [0.18-1.15 mm ] magnet wire Simultaneously terminates two magnet wires of the same size in one terminal from 33-23 AWG [0.18-0.57 mm ] Available in strip form for semi-automatic or fully automatic insertions High speed, fully automated integrated systems provide uniform terminations reliably at the lowest possible applied cost Clean metal-to-metal interface produces stable, gas-tight electrical terminations free of oxides and other contaminants Recognized under the Component Recognition Program of Underwriters Laboratories Inc., File No. E13288 R Applications Motor windings and connections Coil Connections Transformer windings and connections Bobbin connections Lighting Ballasts TE offers a full selection of 187 and 250 Series Faston and posted PCB Slim Line MAG-MATE Tab insulation displacement (IDC) terminals for magnet wire terminations. Slim Line MAG-MATE terminals with a single IDC slot terminate 33-17 AWG [0.18 to 1.15 mm]. Each IDC slot terminates a range of up to four consecutive magnet wire sizes. Two magnet wires with the same diameter can be terminated in one terminal. Except as noted. MAG-MATE cavities are either integrated into coil bodies or especially designed cavity housings. The magnet wires are precisely positioned in the plastic cavity slots. The MAG-MATE Inserter cuts the terminals from the strip and places the terminals over the magnet wire into the plastic cavities. This constant pressure results in an intimate metal-to-metal interface, providing a reliable, longterm connection. During this operation, small stripping shoulders in the IDC slot remove the film insulation from the magnet wire. The MAG-MATE Inserter may be used as a semi-automatic bench machine or integrated in production lines for fully-automatic applications. Wiping action between the wire and terminals removes oxides or other contaminants present on both the conductor and the terminal slot side walls, producing a clean, stable, gas-tight electrical termination. Residual spring energy in the terminal causes the side walls of each IDC slot to function as opposing cantilever beams. Power Supplies www.te.com/appliances 25 Magnet Wire Terminals and Termination Systems Catalog 82221 Slim Line MAG-MATE Terminals (Continued) 187 Series FASTON Tab Terminals Material Tin plated brass Type .187 [ 4.75 ] .020 [ 0.51 ] Copper Magnet Wire Range1 mm AWG 0.18-0.23 .630 16.00 30-28 0.25-0.32 27-24 0.36-0.51 .630 16.00 .630 16.00 .760 19.31 23-202 0.57-0.81 .630 16.00 0.91-1.15 .630 16.00 33-31 Hole or Dimple L A .187 [4.75] FASTON Tab .135 [ 3.43 ] .016 [ 0.41 ] 2 19-17 A Dim. L Tab Feature Tab Size Hole Dimple .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 Hole Hole Dimple Hole Dimple Plain Hole Dimple Hole Hole Dimple Stock Thickness Tab Mag.Wire Section Section .020 .012 0.51 0.30 .032 .012 0.81 0.30 .020 .012 0.51 0.30 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .032 .016 0.81 0.41 .020 .016 0.51 0.41 Strip Part Number 63710-2 63738-2 1217666-1 63711-2 63737-2 63712-2 63736-2 1217497-1 63713-2 63735-2 1217516-1 63714-2 63734-2 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64] or larger. 250 Series FASTON Tab Terminals Material Tin plated brass .250 [ 6.35 ] Type .032 [ 0.81 ] Hole or Dimple B .250 [6.35] FASTON Tab L Copper Magnet Wire Range1 AWG mm 33-31 0.18-0.23 30-28 0.25-0.32 27-24 0.36-0.51 23-202 0.57-0.81 2 0.91-1.15 19-17 .135 [ 3.43 ] .016 [ 0.41 ] Dim. L Tab Feature Tab Size .752 19.10 .752 19.10 .752 19.10 .752 19.10 .752 19.10 Hole Dimple Hole Dimple Hole Dimple Hole Dimple Hole Dimple .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 Stock Thickness Tab Mag.Wire Section Section .032 .012 0.81 0.30 .032 .012 0.81 0.30 .032 .016 0.81 0.41 .032 .016 0.81 0.41 .032 .016 0.81 0.41 Strip Part Number 63716-2 63744-2 63717-2 63743-2 63718-2 63742-2 63719-2 63741-2 63720-2 63740-2 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64] or larger. B Posted PCB SOLDER Terminal Material Type Tin plated brass .0322 [ 8.20 ] .0125 [ 0.32 ] .132 [ 3.45 ] C 26 C .040 [1.00] PCB Tab Copper Magnet Wire Range1 AWG mm 33.5-30 0.17-0.25 29.5-26 0.27-0.40 26-22 0.40-0.63 22-20 0.63-0.81 21.5-19.5 0.67-0.85 Dim. L Tab Feature .323 8.20 Embossment .323 8.20 .323 8.20 .323 8.20 .323 8.20 Embossment Embossment Embossment Embossment Stock Thickness Tab Mag.Wire Section Section .024 .013 .040 x .024 0.32 1.00 x 0.60 0.60 .024 .013 .040 x .024 0.60 0.32 1.00 x 0.60 .024 .013 .040 x .024 0.60 0.32 1.00 x 0.60 .040 x .024 .024 .013 1.00 x 0.60 0.60 0.32 .040 x .024 .024 .013 1.00 x 0.60 0.60 0.32 Tab Size Strip Part Number 1534684-1 1534685-1 1534686-1 1740829-1 1534687-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64] or larger. www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Slim Line MAG-MATE Terminals (Continued) Offset Tab Terminals Slim Line MAG-MATE Terminals Mater l ial Tin Plated Brass Applications where I/O Tab spacing must be less than IDC connection spacing Example: automotive accessory coils .139 [ 3.53 ] .032 [ 0.81 ] .059 [ 1.50 ] .135 [ 3.43 ] Type L A Combination Diode Slot/Tab .220 [ 5.59 ] .013 [ 0.33 ] Copper Magnet Wire Range1 mm AWG 33-31 0.18-0.23 33-31 0.18-0.23 Dim. L Diode Size Tab Size .725 18.42 .725 18.42 #20 0.8 #22.5 0.6 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 Stock Thickness Tab Mag.Wire Section Section 0.032 0.012 0.81 0.30 0.032 0.012 0.81 0.30 Strip Part Number 63888-1 63903-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. A Posted PCB Terminals Multi-Spring Solderless Terminal Material Tin Plated Copper Alloy Cavity Size Application Spec. Contact TE Engineering Type L .289 [ 9.33 ] .132 [ 3.35 ] .013 [ 0.32 ] B Multi-Spring Solderless PCB Tab Terminal Copper Magnet Wire Range1 AWG mm 33-29.5 0.18-0.265 29.5-26 0.265-0.40 26-22.5 0.40-0.63 22.5-19.5 2 0.63-0.85 19.5-17 2 0.85-1.12 Dim. L .583 14.80 .583 14.80 .583 14.80 .583 14.80 .583 14.80 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. 22 awg [0.63 mm] and larger. Stock Thickness Tab Mag.Wire Section Section .031 .013 0.81 0.32 .031 .013 0.81 0.32 .031 .013 0.81 0.32 .031 .013 0.81 0.32 .031 .013 0.81 0.32 Strip Part Number 2120743-2 2120744-2 2120745-2 2120746-2 2120747-2 Note: PC Board hole size .057 [1.45] B www.te.com/appliances 27 Magnet Wire Terminals and Termination Systems Catalog 82221 Slim Line MAG-MATE Terminals (Continued) Posted PCB Solder Terminals Material Unplated brass Type A MAG-MATE Terminal with MQS Pins A Copper Magnet Wire Range AWG mm 0.256-0.40 33-30 0.40-0.561 331 30-26 0.256-0.40 30-261 0.40-0.561 26-22 0.40-0.63 26-231 0.40-0.561 22-20 0.63-0.80 20-17 0.85-1.12 Stock Thickness Strip Part Number Varied thickness Varied thickness Varied thickness Varied thickness Varied thickness 1-1987222-1 1-1987223-1 1-1987224-1 1-1987225-1 1-1987226-1 1 For double magnet wires 28 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Mini MAG-MATE Terminals Product Facts Mini MAG-MATE Terminals Terminates all fine gauge magnet wire film insulations Eliminates need to pre-strip conductors Eliminates need to post insulate terminations Terminates 52-30 AWG [0.02-0.25 mm ] diameter copper magnet wire Poke-In leaf style accepts 22 -18 AWG [0.3-0.9 mm ] overcoated stranded or solid lead wire Available in strip form for semi-automatic or fully automatic insertions High speed, fully automated integrated systems provide uniform terminations and reliability at the lowest possible applied cost Recognized under the Component Recognition Program of Underwriters Laboratories Inc, File No. E13288 R Applications Ignition coils Small motors Synchronist timers Electric meter coils Solenoids Relays TE offers Mini MAG-MATE poke-in, crimp wire barrel, post and quick disconnect tab insulation displacement (IDC) terminals for fine gauge magnet wire terminations. Mini MAG-MATE terminals are designed to terminate 52-30 AWG [0.02-0.25 mm] diameter copper magnet wire. receiving slot and wire tie-off post that is either integrated into coil bodies or specially designed cavity housings. The magnet wire is wrapped around the tie-off post and placed across the cavity slot. After the coil is wound, the finish end of the magnet wire is dressed through the second cavity slot and tied to its tie-off post. the termination process. The fully seated terminal fits squarely into the cavity,while the serrated leg of the terminal cams against the pre-positioned magnet wire to penetrate the film insulation and provide a stable electrical termination. The Mini MAG-MATE Inserter shears the terminal from the carrier strip and inserts the terminal into the cavity by a dual ram The terminal design uses the insertion mechanism. AMPLIVAR serrated burr technology to penetrate the As the unexpanded terminal approaches the bottom of film insulation of copper the cavity, the upper ram magnet wire. stops. The lower ram continues to push to a Mini MAG-MATE cavity prescribed depth to expand pockets, designed to TE specifications, include a wire the terminal and complete Poke-in leaf terminals accept 22-18 AWG [0.3-0.9 mm2] overcoated stranded or solid lead wire. www.te.com/appliances 29 Magnet Wire Terminals and Termination Systems Catalog 82221 Mini MAG-MATE Terminals (Continued) Wire Split ram Wire tie-off post Wire Upper ram stops Lower ram continues Sheared post and excess wire to scrap chute Lower ram stops Termination Complete Poke-In Terminal Material .010 [0.25] tin plated brass .138 [ 3.51 ] .345 [ 8.76 ] .060 [ 1.52 ] A Lead Wire Poke-In A .138 [ 3.51 ] B .345 [ 8.76 ] .060 [ 1.52 ] .047 [ 1.20 ] L .345 [ 8.76 ] Type B Tab Poke-In Stock Thickness Mating Strip Tab Poke-In Beam Mag Wire Part Number 0.010 0.010 -- 62781-1 0.3-0.9 0.25 0.25 0.010 0.010 -- 62780-1 0.3-0.9 0.25 0.25 0.010 0.010 -- 62606-1 0.3-0.9 0.25 0.25 .060 x .020 0.010 0.010 -- 63613-1 1.52 x 0.51 0.25 0.25 .060 x .020 0.010 0.010 -- 63795-12 1.52 x 0.51 0.25 0.25 .060 x .020 0.010 0.010 -- 63844-22 1.52 x 0.51 0.25 0.25 .040 x .020 0.010 0.010 -- 1718165-1 1.00 x 0.51 0.25 0.25 Copper Magnet Wire Range Lead Wire Range1 AWG mm AWG mm2 52-42 0.02-0.06 22-18 44-36 0.05-0.13 22-18 38-30 0.10-0.25 22-18 52-42 0.02-0.06 -- 44-36 0.05-0.13 -- 38-30 0.10-0.25 -- 0.08-0.15 -- C Skinny Mini 40-34.5 1 Solid or overcoated stranded lead wire only. 2 Radius on beam leaf tip. C 30 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Mini MAG-MATE Terminals (Continued) Posted Terminal Mini MAG-MATE Terminals Material Tin over premilled brass .138 [ 3.51 ] .060 [ 1.52 ] .169 [ 4.29 ] Copper Magnet Wire Range AWG mm Type .540 [ 13.72 ] A PCB Post 38-30 0.10-0.25 Post Size .024 x .020 0.62 x 0.51 Stock Thickness Post Mag Wire 0.020 0.010 0.51 0.25 Strip Part Number Stock Thickness Post Mag Wire .020 .010 0.51 0.25 .020 .010 0.51 0.25 Strip Part Number 63675-4 A FASTON Tab Terminals Material Tin over premilled brass .138 [ 3.51 ] .690 [ 17.53 ] .060 [ 1.52 ] Copper Magnet Wire Range G W A m m Type B .187 [4.75] FASTON Tab B 44-36 0.05-0.13 38-30 0.10-0.25 Tab Size .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 63778-1 1217529-1 Crimp Wire Barrel Terminal Material Tin plated brass .060 [ 1.52 ] .138 [ 3.51 ] .620 [ 15.75 ] Type C Crimp Wire Barrel Copper Magnet Wire Range AWG mm 38-30 0.10-0.25 Lead Wire Range AWG mm2 22-18 0.3-0.9 Stock Thickness Crimp Barrel Mag Wire 0.010 0.25 0.010 0.25 Strip Part Number 63199-11 1 Wire and insulation barrel reversed so lead wire exits over magnet wire termination area. C www.te.com/appliances 31 Magnet Wire Terminals and Termination Systems Catalog 82221 SIAMEZE Terminals Product Facts Terminates all copper magnet wire film insulations Eliminates need for pre-stripping conductors Moving Beam contact design connects a wide range of magnet wire sizes with a single terminal Standard range terminals connect 34-18 AWG [0.16-1.0 mm ] magnet wire Fine range terminals connect 36-27 AWG [0.13-0.38 mm ] magnet wire Medium range terminals connect 23-12 AWG [0.56-2.03 mm ] magnet wire Excess magnet wire is automatically trimmed during the termination process Available in strip form for semi-automatic or fully automatic insertions Loose piece terminals available for manual tool insertions High-speed automatic coil winding machine terminations provide uniform reliability at the lowest possible applied cost Clean metal-to-metal interface produces stable, gas-tight electrical terminations free of oxides and other contaminants Recognized under the Component Program of Underwriters Laboratories Inc.,File No. E13288 R Applications Motor windings and connections Coil connections Transformer windings and connections Ballasts Power supplies Solenoids Actuators TE offers a full selection of SIAMEZE insulation displacement (IDC) terminals for interconnecting copper magnet wires, lead wires, and other components. The SIAMEZE insulation displacement (IDC) terminal technology eliminates the need to strip the film insulation from copper magnet wires and lead wires. Terminals are available in wire-to-wire, Lead Lok, quick disconnect tabs, posts, pin and receptacle terminals. Available with either Moving Beam contacts whereby a single terminal connects toa very wide range of magnet wire sizes, or a Compliant Beam for contacting two magnet wires of the same diameter in one terminal for splicing or bi-filar applications. Tab terminals are available with single barbs or multiple retention barbs for higher retention. According to TE specifications SIAMEZE cavities are either integrated into coil bodies or specially designed cavity housings. The magnet wires are positioned in the "U"shaped slots. The SIAMEZE terminal Inserter cuts the terminals from the strip and places the terminals over the magnet wire into the plastic cavities. During this operation the small stripping devices penetrate the film insulation from the magnet wire. Residual spring energy in the terminal causes the side walls of the IDC slot to function as opposing cantilever beams. This constant pressure results in an intimate metal-to-metal interface, providing a reliable, long-term connection. The wiping action between the wire and terminals remove all oxides or other contaminants present on both the conductor and the terminal slot side walls, producing a clean, stable, gas-tight electrical termination. The SIAMEZE terminal Inserter may be used as a semi-automatic bench machine or integrated in production lines for fully-automatic applications. 32 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 SIAMEZE Terminals (Continued) Lead Lok Terminals Product Facts SIAMEZE Terminals Provides perpendicular and parallel lead wire strain relief retention forces in excess of 20 lbs ( 90 N ) . Inserter automatically positions and secures lead wire during insertion Manual, semi-automated, fully automated systems allow for lead wire termination Accepts #18 - #22 [0.3mm 2-0.8 mm2 ] AWG solid or stranded lead wire with .115 [2.92 ] max.insulation diameter No lead wire stripping required TE features the Lead Lok strain relief terminal system that provides optimum lead wire retention when used in conjunction with SIAMEZE insulation displacement terminals. After the one-step insertion of SIAMEZE wire-towire terminals into TE specified plastic cavities, the application is ready for the secondary lead wire attachment. The lead wire is manually positioned over the magnet wire terminated SIAMEZE wire-to-wire terminal. The Lead Lok Inserter cuts the Lead Lok terminals from the strip and places the terminal over the lead wire in the plastic cavities. During this operation, the lead wire is automatically seated, the insulation pierced and the exposed solid or stranded conductor is terminated in the IDC slot of the SIAMEZE wire-to-wire terminal. Residual spring energy in the terminal causes the side walls of the IDC slot to function as opposing cantilever beams. This constant pressure results in an intimate metal-to-metal interface, providing a reliable, longtermconnection. Perpendicular and parallel lead wire strain relief retention forces in excess of 20 lbs are achieved. The Lead Lok Inserter may be a secondary station in the SIAMEZE Wire-toWire semi-automatic bench machine. Information regarding terminal insertion equipment may be found in Magnet Wire Termination Overview #138516. TECHNICAL DOCUMENTS Cavity Specifications - Provide dimensional design guidelines & criteria for a cavity to be used with a SIAMEZE IDC terminal. The appropriate Cavity Specification number is shown on the following pages adjacent to the terminal number. As a general reference, overall dimensions are shown at the end of this section. Product Specifications ( These describe the performance characteristics and verification tests ) 108-2085 Standard Range SIAMEZE Insulation Displacement 108-2293 High Temperature Standard Range SIAMEZE Insulation Displacement 108-2244 Fine Range SIAMEZE Insulation Displacement 108-2239 Medium Range SIAMEZE Insulation Displacement 108-2316 Heavy Range SIAMEZE Insulation Displacement Application Specifications ( These describe the requirements for using the product in its intended application ) 114-13166 Standard and Fine Range SIAMEZE Insulation Displacement 114-13210 Medium and Heavy Range SIAMEZE Insulation Displacement 33 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 SIAMEZE Terminals (Continued) SIAMEZE Interconnection System How the System Operates Magnet Wire The magnet wire is positioned in "U" slot manually or automatically by coil winding equipment. Plastic Cavity Design must comply with TE connectivity specifications(for cavity drawing numbers see tables). ConsultingTE is required for design in. Terminal Insertion Finger The terminal insertion finger is part of the SIAMEZE Inserter. It pushes the terminal that was sheared from the carrier strip through the"tube" into the cavity. Cavity Slot for Wire The width has to be in accord ance with the wire size (see cavity drawings). Wire Cutoff Block The wire cutoff block supports the magnet wire during the trimming process. The magnet wire is cut plain to the cavity front side. Contact Various wire attachments in standard, fine, mediumand heavy duty terminals are available (See tables). IDC Slot The IDC slot in the terminal will terminate a wide range of magnet wire sizes. Stripping Burrs During the insertion process, these burrsstrip the film insulation from the magnet wire. Retention Barbs Terminal retention is provided in the cavity by single or multiple locking barbs. Test Results SIAMEZE products have been submitted to the following tests without significant millivolt increase: Trim Blade The trim blade cuts the excess magnet wire and the wire cutoff block at the front of the cavity. 11 Terminal Insertion Complete The magnet wire termination is complete when the terminal is fully seated in the cavity. Current Cycling-- 250 cycles with each cycle consisting of 15 minutes 11 "ON" followed by 15 minutes "OFF" Thermal Shock-- 25 Cycles -40C to +125C, 25 Cycles -40C to +175C for High Temperature terminals Humidity-- Temperature Cycling 10 cycles between 25C and 65C at 80 to 100% RH 34 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 SIAMEZE Terminals (Continued) Lead Lok Interconnection System How the System Operates SIAMEZE Terminals Lead Lok Insertion Finger The Lead Lok insertion finger pushes the Lead Lok that was sheared from the carrier strip and positions the Lead Lok and lead wire into the IDC slot. Lead Lok Terminal The Lead Lok terminal provides maximum lead wire retention in the cavity. Retention Barbs The Lead Lok multiple barbs provide retention in the cavity. Lead Wire Stranded, solid and bonded lead wire with 105C PVC insulation can be used. Contact TE Engineering for other lead wires and insulation under consideration. IDC Slot The IDC slot will pierce the lead wire during insertion. Lead Wire Insertion Complete The lead wire termination is complete when the Lead Lok is fully seated in the cavity. HOW TO CONNECT MULTIPLE MAGNET WIRES OR OTHER COMPONENTS Bussed High Carrier Terminals Bridging of two SIAMEZE terminals that is accomplished by leaving the carrier strip between two adjacent terminals intact. Bussed High Carry SIAMEZE Plastic Cavity Bussed cavity pocket designs are available for double or triple bussed terminals. Magnet Wire Magnet wire may be equal or differ in size for bi-filar applications. 35 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 SIAMEZE Terminals (Continued) Wire-to-Wire Terminals Material Brass .300 [ 7.62 ] .300 [ 7.62 ] .146 [ 3.71 ] .146 [ 3.71 ] A .300 [ 7.62 ] .146 [ 3.71 ] .020 [ 0.51 ] .020 [ 0.51 ] B C .020 [ 0.51 ] .250 [ 6.35 ] .550 [ 13.97 ] .300 [ 7.62 ] .146 [ 3.71 ] .020 [ 0.51 ] D E F Lead Wire Range AWG mm2 18-34 1.02-0.16 18-226 0.8-0.3 27-36 0.36-0.13 18-226 0.8-0.3 18-34 1.02-0.16 20 0.5 18-34 1.02-0.16 18 0.8 1601433 1601440 18-34 1.02-0.16 18-226 0.8-0.3 1601046-1 2-1601046-11 4-1601046-12 6-1601046-13 8-1601046-14 1601433 27-36 0.36-0.13 20 0.5 1601237-1 2-1601237-11 4-1601237-12 6-1601237-13 1601436 12-23 2.06-0.56 16-20 1.3-0.5 1601136-1 2-1601136-11 4-1601136-12 6-1601136-13 18-22 0.8-0.3 1601140-1 2-1601140-11 4-1601140-1 Recommended Pocket7 A Moving Beam 1601421 B Wire Specific 8 1601421 C High Carrier F Lead Lok .032 [ 0.81 ] .025 [ 0.46 ] Copper Magnet Wire Range AWG mm Type D High Carrier Specific8 E Medium Range .150 [ 3.81 ] .280 [ 7.11 ] 1601421 1601433 1601440 Part Number Reeled Loose 1601000-1 1601000-25 1601117-1 2-1601117-11 1601056-1 2-1601056-11 1601074-1 2-1601074-11 4-1601000-12 4-1601000-22,5 4-1601117-12 4-1601056-12 4-1601074-12 1 Reversed Reeled--Consult TE drawing for orientation. 2 Loose Single. 3 Loose Bussed (Bridged) Double. 4 Loose Bussed (Bridged) Triple. 5 Finish is Post Plated Tin over Copper (Consult TE drawing for specifics). 6 Lead wire may be stranded, solid or bonded with 105C PVC insulation. Contact TE Engineering when using other types of insulation. 7 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 8 Wire Specific terminals have a top contact designed to penetrate difficult Lead Wire Insulation (e.g Irradiated types). 36 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 SIAMEZE Terminals (Continued) Receptacle Terminals (Wire to Blade) Material Brass .146 [ 3.71 ] .550 [ 13.97 ] .146 [ 3.71 ] .020 [ 0.51 ] .020 [ 0.51 ] A .280 [ 7.11 ] B .310 [ 7.87 ] .480 [ 12.19 ] .032 [ 0.81 ] .032 [ 0.81 ] C D L Dim. Mating Tab Size 1.02-0.16 .300 7.62 .020 0.51 18-34 1.02-0.16 .300 7.62 .020 0.51 Part Number Reeled Loose 1601075-12,1 4-1601075-12 2-1601075-11 6 1601075-2 4-1601075-22,6 2-1601075-21,6 - 2-1601075-31,7 4-1601196-12 1601196-1 6-1601196-13 2-1601196-11 8-1601196-14 1601436 15-23 1.47-0.56 .550 13.97 .032 0.81 1601232-27 2-1601232-21,7 4-1601232-22,7 1601437 15-23 1.47-0.56 .310 7.87 .032 0.81 1601137-2 6 2-1601137-21,6 4-1601137-22,6 Copper Magnet Wire Range AWG mm Type Recommended Pocket 5 A Wire2Blade In Line 1601425 18-34 1601426 B Wire2Blade High Carrier In Line C Wire2Blade In Line Medium Range D Wire2Blade Off Line Medium Range SIAMEZE Terminals .300 [ 7.62 ] .300 [ 7.62 ] 1 Reverse Reeled -Consult TE drawing for orientation. 3 Loose Bussed (Bridged) Double. 5 Magnet wire 30 AWG [0.25] and smaller also requires a wrap post per Specification 1601447. 7 Finish is Post Plated Tin over Nickel (Consult TE drawing for specifics). 8 2 Loose Single. 4 Loose Bussed (Bridged) Triple. 6 Finish is Pre Plated Tin (Consult TE drawing for specifics). 8 Overall Height of terminal does not include inserted Blade (Tab). Pin Terminals Dia. [ 2.13 ] Material Brass L . [ 0.51 ] [ 3.71 ] E Type Recommended Pocket 2 E Round Pin 1601424 Copper Magnet Wire Range AWG mm 18-34 1.02-0.16 L Dim. Pin Dia. .718 18.24 .084 2.13 Part Number Loose Reeled 1601077-1 3 4-1601077-1 2-1601077-11 1 Reverse Reeled -Consult TE drawing for orientation. 2 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 3 Loose piece single. 37 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 SIAMEZE Terminals (Continued) Post Terminals Material Brass L L L L L L .146 [ 3.71 ] .020 [ 0.51 ] A Type A PC Tab B Extended PC Tab C Long Narrow Blade D Long Narrow Blade Mult-Barb .146 [ 3.71 ] .020 [ 0.51 ] .146 [ 3.71 ] B Recommended Pocket7 1601424 1601425 1601431 1601425 E Medium Width Blade Mult-Barb 1601475 F Medium Width Blade Medium wire range 1601438 .020 [ 0.51 ] .146 [ 3.71 ] C 18-34 1.02-0.16 29** 0.29 27-36 0.36-0.13 18-34 1.02-0.16 27-36 0.36-0.13 1.02-0.16 18-34 1.02-0.16 18-34 1.02-0.16 27-36 0.36-0.13 12-23 0.56-2.06 1 Reverse Reeled -Consult TE drawing for orientation. 3 Finish is Post Plated Tin (Consult TE drawing for specifics). 5 Finish is Post Plated Tin over Nickel (Consult TE drawing for specifics). 7 Magnet wire 30 AWG [0.25] and smaller also requires a wrap post per Specification 1601447 38 .146 [ 3.71 ] D Copper Magnet Wire Range AWG mm 18-34 .020 [ 0.51 ] .280 [ 7.11 ] .020 [ 0.51 ] E .032 [ 0.81 ] F Part Number Tab Size L Dim. .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .047 x .032 1.20 x. 0.81 .059 x .032 1.50 x. 0.81 .059 x .032 1.50 x. 0.81 .059 x .032 1.50 x. 0.81 .059 x .032 1.50 x. 0.81 .071 x .025 1.80 x 0.64 .345 8.76 .405 10.29 .345 8.76 .345 8.76 .456 11.57 .485 12.32 .485 12.32 .754 19.16 .669 17.00 .756 19.21 .904 22.96 1.005 25.53 .974 24.74 Reeled 1601009-45 2-1601009-41,5 1601214-2 5 2-1601214-21,5 1601155-35 2-1601155-31,5 1601120-45 2-1601120-41,5 1601095-2 4 2-1601095-22,4 1601041-35 2-1601041-31,5 1601128-3 5 2-1601128-3 1,5 1601110-2 6 2-1601110-21,6 1601099-2 5 2-1601099-21,5 1601063-2 6 2-1601063-21,6 1601037-2 6 2-1601037-21,6 1601066-2 6 2-1601066-2 1,6 1601104-2 6 2-1601104-21,6 .059 x .032 1.50 x 0.81 .805 20.45 293214-1 2-293214-11 -- . .118 x .020 3.00 x 0.51 .118 x .025 3.00 x 0.64 .533 13.54 .952 24.18 1601243-2 3 2-1601243-21,3 1601119-2 6 2-1601119-21,6 4-1601243-2 2,3 .130 x .032 3.30 x 0.81 .872 22.15 1601138-1 2-1601138-11 4-1601138-12 Loose 4-1601009-4 2,5 4-1601214-2 2,5 4-1601155-3 2,5 4-1601120-4 2,5 4-1601095-2 2,4 4-1601041-3 2,5 4-1601128-3 2,5 4-1601110-2 2,5 4-1601099-2 2,5 4-1601063-2 2,6 4-1601037-2 2,6 4-1601066-2 2,6 4-1601104-2 2,6 4-1601119-2 2,6 2 Loose Piece Single. 4 Finish is Post Plated Tin over Copper (Consult TE drawing for specifics). 6 Finish is Pre Plated Tin (Consult TE drawing for specifics) ** Compliant contact can connect 2 wires of the same diameter. www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 SIAMEZE Terminals (Continued) 110 Series (2.8 mm wide) FASTON Tab Terminals Material Brass SIAMEZE Terminals L L L .146 [ 3.71 ] A Type A Single Barb B Single Barb Low Transition C Multi-Barb Recommended Pocket 8 1601425 1601431 1601425 .020 [ 0.51 ] Copper Magnet Wire Range AWG mm 18-34 18-34 18-34 27-36 1.02-0.16 1.02-0.16 1.02-0.16 0.36-0.13 .146 [ 3.71 ] B .146 [ 3.71 ] .020 [ 0.51 ] C Thickness L Dim. .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .032 0.81 .032 0.81 .020 0.51 .020 0.51 .032 0.81 .032 0.81 .032 0.81 .640 16.26 .640 16.26 .846 21.49 .846 21.49 .925 23.50 .945 24.00 1.195 30.35 .655 16.63 .655 16.63 .630 15.99 1.240 31.50 1.240 31.50 .020 [ 0.51 ] Part Number Reeled Loose 1601005-1 4-1601005-1 2 1 2-1601005-1 1601204-26,7 4-1601204-2 2,6,7 2-1601204-21,6,7 1601045-1 4-1601045-1 2 2-1601045-11 1601059-17 2-1601059-11,7 1601073-1 2-1601073-11 1601097-36,7 2-1601097-31,6,7 1601194-23,7 2-1601194-21,3,7 1601039-1 2-1601039-11 1601039-26 2-1601039-21,6 1601064-17 2-1601064-11,7 1601112-2 6,7 2-1601112-21,6,7 1601133-2 6,7 2-1601133-21,6,7 4-1601059-12,7 4-1601073-1 2 4-1601097-3 2,6,7 4-1601194-2 2,3,7 4-1601039-1 2 4-1601039-2 2,6 4-1601064-1 2,7 4-1601112-2 2,6,7 4-1601133-2 2,6,7 1 Reverse Reeled-Consult TE drawing for orientation. 2 Loose Piece Single. 3 Finish is Post Plated Tin over Nickel (Consult TE drawing for specifics). 4 Finish is Post Plated Tin (Consult TE drawing for specifics). 5 Finish is Pre-Plated Tin over Copper (Consult TE drawing for specifics). 6 Finish is Pre-Plated Tin (Consult TE drawing for specifics). 7 No hole in Tab. 8 Magnet wire 30 AWG [0.25] and smaller also requires a wrap post per Specification 1601447. 39 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 SIAMEZE Terminals (Continued) 187 Series (4.75 mm wide) FASTON Tab Terminals Material Brass (except High Temp listed below) L L L L L .146 [ 3.71 ] .020 [ 0.51 ] .146 [ 3.71 ] A Type Recommended Pocket 8 A Single Barb 1601425 B Single Barb Short Pocket C Multi-Barb D Multi-Barb Short Profile E Multi-Barb .187/.250 Profile 1601427 1601425 1601434 1601425 B Copper Magnet Wire Range AWG mm 18-34 18-34 18-34 .020 [ 0.51 ] .146 [ 3.71 ] 1.02-0.16 1.02-0.16 1.02-0.16 20-23** 0.58-0.81 18-34 1.02-0.16 18-34 1.02-0.16 18-34 1.02-0.16 1 Reverse Reeled-Consult TE drawing for orientation. 3 High Temperature Copper Alloy. 5 Finish is Pre Plated Tin (Consult TE drawing for specifics). 7 Extra Short Tab-Does not meet UL & NEMA length requirements. ** Compliant contact can connect 2 wires of the same diameter .020 [ 0.51 ] C Thickness L Dim. .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .020 0.51 .032 0.81 .032 0.81 .020 0.51 .020 0.51 .020 0.51 .605 15.37 .505 12.83 .590 14.99 .985 25.02 .618 15.70 .655 16.64 .791 20.09 0.832 21.14 .625 15.88 .655 16.64 .655 16.64 .745 18.92 .655 16.64 0.492 12.50 0.571 14.50 .655 16.64 .655 16.64 .805 20.45 .146 [ 3.71 ] .020 [ 0.51 ] .146 [ 3.71 ] .020 [ 0.51 ] D E Part Number Reeled 1601006-25 2-1601006-21,5 1601011-1 2-1601011-11 1601018-2 5,6 2-1601018-21,5,6 1601033-25,6 2-1601033-21,5,6 1601021-25,6 2-1601021-21,5,6 6 1601013-1 2-1601013-11 Loose 4-1601006-2 2,5 4-1601011-12 4-1601018-22,5,6 4-1601033-2 2,5,6 4-1601021-2 2,5,6 4-1601013-12 3-1601072-25,6 4-1601072-22,5,6 1601068-25,6 2-1601068-21,5,6 4-1601068-22,5,6 1601174-25,6 2-1601174-21,5,6 1601035-1 2-1601035-11 1601035-25 2-1601035-21,5 293029-1 5 2-293029-11,5 1601142-1 2-1601142-11 1601058-25,7 2-1601058-21,5,7 1601226-13,6 2-1601226-11,3,6 1601020-1 2-1601020-11 1601020-2 5 2-1601020-21,5 1601049-2 5 2-1601049-21,5 4-1601174-22,5,6 4-1601035-12 4-1601035-22,5 _ 4-1601142-12 4-1601058-22,5,7 4-1601226-12,3,6 4-1601020-12 4-1601020-22,5 4-1601049-2 2,5 2 Loose Piece Single. 4 Finish is Post Plated Tin (Consult TE drawing for specifics). 6 No hole in Tab., 8 Magnet wire 30 AWG [0.25] and smaller also requires a wrap post per Specification 1601447. 40 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 SIAMEZE Terminals (Continued) 250 Series (6.3 mm wide) FASTON Tab Terminals Material Brass SIAMEZE Terminals L L L .146 [ 3.71 ] .280 [ 7.12 ] .020 [ 0.51 ] A Type Recommended Copper Magnet Wire Range Pocket 6 AWG mm 27-36 A Multi-Barb B Single Barb Medium Range C Single Barb Heavy Range 1601425 1601438 1601435 18-34 0.36-0.13 1.02-0.16 .032 [ 0.81 ] B Hole .250 x .032 6.35 x 0.81 Dimple .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 Part Number Loose Reeled 1601118-23 3 4-1601118-2 2-1601118-21,3 3 1601002-2 4-1601002-23 2-1601002-21,3 1601028-23 4-1601028-23 2-1601028-21,3 1601028-1 4-1601028-1 2-1601028-11 7 284937-1 -- 2-284937-11,7 3 1601061-2 4-1601061-23 2-1601061-21,3 2,4 1601052-2 4-1601052-2 2 2-1601052-21,2,4 Tab Feature Tab Size .745 18.92 .745 18.92 Hole .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 Hole 1.281 32.53 Hole 12-23 2.03-0.56 .778 19.76 -- .250 x .032 6.35 x 0.81 1601139-23 2-1601139-21,3 12-20 2.03-0.8 Hole 16-175 1.27-1.15 5 1.60-1.40 .885 22.48 .885 22.48 .885 22.48 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 1601115-1 2-1601115-11 1601159-1 2-1601159-11 1601161-1 2-1601161-11 14-15 .032 [ 0.81 ] C L Dim. .805 20.45 .315 [ 8.00 ] Hole Hole 4-1601139-23 4-1601115-1 4-1601159-1 4-1601161-1 1 Reverse Reeled -Consult TE drawing for orientation. 2 Finish is Pre-Plated Tin over Copper (Consult TE drawing for specifics). 3 Finish is Pre-Plated Tin (Consult TE drawing for specifics). 4 Double Carrier Strip. 5 Two magnet wires may be terminated in the same slot if diameters are equal. 6 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 7 Hole size and position complies with DIN standard. 41 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 SIAMEZE Terminals (Continued) Typical Plastic Cavity Pockets Note:The overall dimensions shown on these pages are for general reference only. For design purposes refer to the TE Cavity Specification. Plastic cavities, designed to TE specifications, may be molded as part of the coil bobbin or attached to a lamination stack in the area of the magnet wire coil. Each cavity is a rectangular box with two narrow slots on opposing walls and a plastic cutoff or tie-off post. During or after the winding process, the magnet wire is placed across the plastic cavities and into the slots, either manually or by coil winding equipment. Unraveling is prevented by a slight friction fit, suitable bend or by wrapping the magnet wire around the wrap post. Excess magnet wire is trimmed flush with the outside of the plastic cavity by a shear blade traveling with the During insertion, the insulation terminal insertion ram. displacing terminal slot strip TE can provide design and the film insulation from the magnet wire producing a mold engineering resources stable electrical termination. to manufacture most Terminal retention is retained specifically designed in the plastic cavities by single SIAMEZE cavity housings. or multiple barbs (Refer to Product Spec for force requirements). .380 [ 9.65 ] Min. .276 [ 7.01 ] Min. .380 [ 9.65 ] Min. .270 [ 6.86 ] Min. .276 [ 7.01 ] Min. .204 [ 5.18 ] Min.* Cavity Specification 1601421 Cavity Specification 1601424 .380 [ 9.65 ] Min. .496 [ 12.60 ] Min. .104 [ 2.63 ] Min. Cavity Specification 1601426 .104 [ 2.63 ] Min. .276 [ 7.01 ] Min. .104 [ 2.63 ] Min. Cavity Specification 1601425 [ 8.38 ] Min. [ 7.75 ] Min. [ 7.01 ] Min. [ 2.63 ] Min. Cavity Specification 1601427 [ 7.01 ] Min. [ 2.95 ] Min. Cavity Specification 1601431 * Minimum dimension with Lead Lok slot. 42 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 SIAMEZE Terminals (Continued) Typical Plastic Cavity Pockets (Continued) .380 [ 9.65 ] Min. .473 [ 12.01 ] Min. .116 [ 2.95 ] Min. Cavity Specification 1601432 .490 [ 12.60 ] Min. .446 [ 11.33 ] Min. .135 [ 3.44 ] Min. Cavity Specification 1601435 .410 [ 10.41 ] Min. .350 [ 8.89 ] Min. .580 [ 14.72 ] Min. .135 [ 3.44 ] Min. Cavity Specification 1601436 .380 [ 9.65 ] Min. .716 [ 18.19 ] Min. .135 [ 3.44 ] Min. Cavity Specification 1601438 Cavity Specification 1601434 .630 [ 16.00 ] Min. .520 [ 13.21 ] Min. .410 [ 10.41 ] Min. .104 [ 2.63 ] Min. .276 [ 7.01 ] Min. .204 [ 5.18 ] Min.* Cavity Specification 1601433 .535 [ 13.59 ] Min. .293 [ 7.44 ] Min. .204 [ 5.18 ] Min.* SIAMEZE Terminals .380 [ 9.65 ] Min. Cavity Specification 1601440 .135 [ 3.44 ] Cavity Specification 1601437 .050 [ 1.27 ] .050 [ 1.27 ] Min. Wrap Post Specification 1601447 .353 [ 8.97 ] Min. .276 [ 7.01 ] Min. .116 [ 2.95 ] Min. Cavity Specification 1601475 * Minimum dimension with Lead Lok slot. www.te.com/appliances 43 Magnet Wire Terminals and Termination Systems Catalog 82221 AMPLIVAR Splices Product Facts Compression crimp eliminates cold solder points, weld burns and wire embrittlement usually connected with thermal-type terminations Excellent tensile strength-- vibration resistant Provides a superior electrical connection that is free of many contaminants such as stripper residue and solder flux Precision formed, strip-fed splices terminated in automatic machines for high production rates per hour High termination rates, low wire consumption and the elimination of rejects caused by solder flux or heat damage results in the lowest applied costs Precisely controlled crimp termination helps eliminate human error for maximum reliability Splice up to 3 magnet wires together with stranded lead in one barrel Applications Motor windings and connections Coil connections Transformer windings and connections Solid wire connections Lighting ballasts Power supplies Starters and alternators TE Connectivity offers a full selection of AMPLIVAR splices that are specifically designed to terminate magnet wire to itself or in combination with standard solid or stranded lead wire. AMPLIVAR splices have machined, sharp edged serrations inside the crimp barrels. These serrations, made by a special production process, pierce the insulating layer of magnet wires in a manner that provides a large contact area. In a one-step operation the magnet wire is automatically multiple ring-stripped of its insulation as it is forced into the serrations during the precisely controlled crimp. The resulting termination produces a high tensile strength, air-sealed connection that is as resistant to corrosion as the insulated conductor. As many as three magnet wires can be terminated simultaneously in one splice. In addition, copper or aluminum magnet wire, or a combination of both, can be terminated. When required, copper or aluminum magnet wire can be combined with standard, pre-stripped solid or stranded lead wires. Depending on your specific application, AMPLIVAR splices are available in 5, 7 and 9 serration versions for terminations in the 100 to 22,000 CMA range as well as miniature and subminiature designs for terminations in the 100 to 1850 CMA range. The crimping of AMPLIVAR splices is done by semiautomatic crimping machines for high output per hour production rates. Stranded Wire on top Magnet Wire on bottom Section AA 44 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 AMPLIVAR Splices (Continued) Technical Features Test Results The AMPLIVAR products have been subjected to the following tests without significant millivolt losses. Temperature Cycling -- 25 cycles with each cycle consisting of 30 minutes at +125C followed by 30 minutes at -65C Heat Age -- 96 hours at +150C Thermal Shock -- 25 cycles with each cycle consisting of 30 minutes at +150C followed by 30 minutes at -65C Salt Spray -- 96 hours at +35C with a 5% salt solution spray Humidity -- 96 hours at 90-95% relative humidity and +40C Current Cycling -- 10,000 cycles with each consisting of 3 minutes on and 3 minutes off at a current (25 A) which establishes a wire temperature AMPLIVAR Splices Applicable Types of Wire -- Cu, Al (Solid) together or in combination with stranded lead wire Wire Size Range -- from 300 to 13,000 CMA (0.1 mm2 to 6.6 mm2) Terminal Base Material -- Brass, phosphor bronze Surface Finish -- plain and tin plated except where noted Temperature Range -- -65C to +150C Rated Current -- according connected wire size Rated Voltage -- according terminated winding 45 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 AMPLIVAR Splices (Continued) General Application Guidelines Suggested Splice Selection Procedure To assist you in obtaining the optimum AMPLIVAR product termination, the following guidelines are recommended: Use the following guide to help you to determine the proper splice for your application: 1. All magnet wires must be placed in the bottom of the wire barrel before crimping. If lead wire is to be crimped in the same termination, it should be placed on top of the magnet wires. 1. Use 9-serration splices, tin plated when terminating aluminum magnet wire or combinations with aluminum magnet wire. 5. Calculate the total magnet wire diameters (see pages 90 and 91). 3. Use splices identified with an asterisk [*] when terminating 7-serration 26 AWG [0.40 mm] or smaller wires and 9-serration 28 AWG [0.32 mm] or smaller wires. 7. Calculate the sum of the magnet wire diameters plus two splice stock thicknesses. If this total is less than the crimp width of the splice selected, it may be used. If the total is greater than the crimp width, a splice with a greater crimp width must be selected. Consult TE for special wide tooling recommendations. 2. Wire barrels are designed to accept a maximum of three insulated magnet wires plus stranded lead wires. 3. The ratio of magnet wire diameters crimped in any wire barrel should not exceed 2:1. This ratio is approximately a range from the largest to the smallest magnet wire of six sizes. 4. The sum of the circular mil area (CMA) of the magnet wires and any lead wires should not exceed the capacity of the splice. 5. The sum of the diameters of the individual magnet wires plus twice the terminal stock thickness must be equal to or less than the crimp width. 6. Magnet wire of 26 AWG [0.40 mm] or smaller should be used with 7-serration splices having "shallow serrations," and magnet wire of 28 AWG [0.32 mm] or smaller should be used with 9-serration splices having "shallow serrations" (part numbers identified with asterisk [*] are in the tabular data on the following technical pages). 7. Magnet wire of 20 AWG [0.81 mm] or larger having an insulation thickness heavier than "single film coated," should not be used with splices having "shallow serrations" (those part numbers marked with an asterisk [*] in the tabular data on the following technical pages). 8. When aluminum magnet wire is used, splices and terminals must be tin plated. 9. Consult TE for splice and terminal selection and recommendations for all non-standard applications. 2. Use 9-serration splices for hermetic and severe environment applications. 4. Calculate the total CMA of the magnet wires plus any lead wires to be terminated. Always use the coated magnet wire for CMA (see pages 90-91). Example: Application specifications describe requirements for using the product in its intended application and or crimping information. They are intended for the packaging and design engineer and the machine setup person. 114-2002 114-2003 114-2005 AMPLIVAR 7serration pigtail splices AMPLIVAR 9serration pigtail splices AMPLIVAR subminiature thru splices 114-2006 114-2009 114-2016 AMPLIVAR subminiature pigtail splices AMPLIVAR 5serration thru splices AMPLIVAR miniature pigtail splices Selection of a pigtail splice to terminate the following wires: One 28 AWG [0.32 mm] copper magnet wire. One 22 AWG [0.64 mm] aluminum magnet wire. One 18 AWG [0.8-0.9 mm2] 19-strand copper lead wire. Technical Documents 6. Select a splice for trial calculations. It should have the proper CMA range. Plating finish should be considered at this time. Calculate the total CMA (Procedure 4): 28 AWG [0.32 mm] coated magnet wire 22 AWG [0.64 mm] coated magnet wire 18 AWG [0.8-0.9 mm2] stranded lead wire = 185 CMA = 708 CMA = 1608 CMA Total = 2501 CMA 28 AWG [0.32 mm] coated magnet wire 22 AWG [0.64 mm] coated magnet wire = .0136 [0.35] = .0266 [0.68] Total = .0402 [1.03] CMA range Stock thickness Crimp width = 600-3000 = .016 [0.41] = .110 [2.79] Calculate the sum of the magnet wire diameters (Procedure 5): Select a terminal for trial calculations. Splice No. 62305-2, page 47 (Procedure 6): 9-serration, tin plated for aluminum magnet wire (Procedure 1). Splice identified with asterisk [*] for 28 AWG [0.32 mm] (Procedure 3). Calculate the sum of the magnet wire diameters plus two splice stock thicknesses (Procedure 7): .0402 + (.016 x 2) = .0722 [1.02 + (0.41 x 2) = 1.84 .0722 [1.84] is less than the splice crimp width of .110 [2.79]; therefore, Part No. 62305-2 may be used. 46 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 AMPLIVAR Splices (Continued) 9 Serrations -- Pigtail Type Product Facts (Plus All 7 Serration Facts) Serration depths are varied within the splice to give optimum electrical/ mechanical performance on all wire sizes Serration sidewall angles are varied to allow better wire stripping and serration fill Flat bottom of splice helps keep magnet wires on bottom as required during crimping Magnet wires 28 AWG [0.32 mm] and larger may be terminated without requiring shallow serrations Additional serrations enhance stability of crimp 7 Serrations -- Pigtail Type Product Facts AWG/ mm2 24-18.5 0.26-0.80 22-15.5 0.38-1.54 22-15.5 0.38-1.54 18.5-13.5 0.80-2.54 18.5-13.5 0.80-2.54 15.5-12 1.54-3.46 13.5-10 2.54-4.90 12-9 3.46-6.38 10-8 4.90-8.60 . 9-6.5 7.07-9.45 . Taper on both crimper and anvil improves flex life of termination Longer "flat" on tooling improves electrical performance (.125 vs. .080 [3.18 vs. 2.03]) Radius on wire entry end of splice helps prevent nicking wires and improves mechanical performance Serrations are offset to sheared end to place additional serrations in "electrical" portion of crimped splice Splice CMA ranges are overlapped so that two splices are available for any given CMA Wire Range Wire Range Stock Solid Dia. CMA Thickness .020-.039 .016 400-1500 0.55-1.00 0.41 .028-.055 .020 600-3000 0.70-1.40 0.51 .028-.055 .016 600-3000 0.70-1.40 0.41 .039-.071 .020 1500-5000 1.00-1.80 0.51 .039-.071 .016 1500-5000 1.00-1.80 0.41 .055-.083 .020 3000-7000 1.40-2.10 0.51 .071-.098 .025 5000-10,000 1.80-2.50 0.64 .083-.112 .025 7000-14,000 2.10-2.85 0.64 .098-.130 .030 10,000-17,000 2.50-3.31 0.76 .118-.137 .030 14,000-22,000 3.00-3.47 0.76 Crimp Width .080 2.03 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .140 3.56 .180 4.57 .180 4.57 .250 6.35 .250 6.35 Dim. L .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .265 6.73 .265 6.73 .265 6.73 .340 8.64 .340 8.64 Material Part Number Tin Plated Brass 62303-2* Tin Plated Brass 62304-2* Tin Plated Brass 62305-2* Tin Plated Brass 62306-2* Tin Plated Brass 62307-2* Tin Plated Brass 62308-2* Tin Plated Brass 62309-2* Tin Plated Brass 62310-2* Tin Plated Brass 62311-2 * Tin Plated Brass 1742898-1 AMPLIVAR Splices Splice length is increased on larger CMA splices for improved performance *These splices are recommended for applications using wire size 28 AWG [0.32 mm] or smaller. Special high force application equipment required. 1 AWG/ mm2 22-15.5 0.38-1.54 22-15.5 0.38-1.54 22-15.5 0.38-1.54 22-15.5 0.38-1.54 22-15.5 0.38-1.54 18.5-13.5 0.80-2.54 18.5-13.5 0.80-2.54 18.5-13.5 0.80-2.54 15.5-12 1.54-3.46 15.5-12 1.54-3.46 15.5-12 1.54-3.46 12-10 2.10-6.0 12-10 2.10-6.0 12-9 2.10-6.38 Wire Range Solid Dia. .028-.055 0.70-1.40 .028-.055 0.70-1.40 .028-.055 0.70-1.40 .028-.055 0.70-1.40 .028-.055 0.70-1.40 .039-.071 1.00-1.80 .039-.071 1.00-1.80 .039-.071 1.00-1.80 .055-.083 1.40-2.10 .055-.083 1.40-2.10 .055-.083 1.40-2.10 .085-.110 2.10-2.85 .085-.110 2.10-2.85 .085-.115 2.10-3.47 Wire Range CMA 600-3000 600-3000 600-3000 600-3000 600-3000 1500-5000 1500-5000 1500-5000 3000-7000 3000-7000 3000-7000 7000-12,000 7000-12,000 7000-13,000 Stock Thickness .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .025 0.64 .025 0.64 .025 0.64 Crimp Width .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .140 3.56 .140 3.56 .140 3.56 .250 6.35 .250 6.35 .180 4.57 Dim. L .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 Material Part Number Brass 62000-1* Brass 62157-1* Tin Plated Brass 62000-2* Tin Plated Brass 62157-2* Tin Plated Brass 62200-21 Brass 62040-2* Tin Plated Brass 62040-1* Phosphor Bronze 964156-1 Brass 62001-1* Tin Plated Brass 62001-2* Tin Plated Brass 62201-21 Tin Plated Brass 62295-1* Brass 62295-2* Tin Plated Brass 62002-2* *These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller. 1 Flat bottom. www.te.com/appliances 47 Magnet Wire Terminals and Termination Systems Catalog 82221 AMPLIVAR Splices (Continued) 7 Serrations -- Thru Type Product Facts L Crimp bellmouth provides retention in circular cavity slot in bobbin AWG/ mm2 22-15.5 0.38-1.54 Wire Range Solid Dia. .028-.055 0.70-1.40 Wire Range CMA 600-3000 Stock Thickness .020 0.51 Crimp Width .110 2.79 Dim. L .225 5.72 Material Part Number Tin Plated Brass 1217384-1** *These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller. 5 Serrations -- Thru Type A B Product Facts Wide range of thru splice s Serrations centered in splic e to achieve optimu m electrical and mechanica l performance in a thru splic e Type A CMA range accepts a wid e variety of wire sizes an d combination s B AWG/ Wire Range Wire Range Stock mm2 Solid Dia. CMA Thickness 17-12.5 .045-.075 .020 2000-5400 1.00-2.80 1.15-1.85 0.51 10-8 .100-.125 .032 10,000-16,000 5.00-8.00 2.55-3.20 0.80 10-7.5 .100-.150 .030 10,400-22,900 5.00-11.50 2.60-3.80 0.76 22-15.5 .028-.055 .020 600-3000 0.38-1.54 0.70-1.40 0.51 22-15.5 .028-.055 .020 600-3000 0.38-1.54 0.70-1.40 0.51 22-15.5 .028-.055 .020 600-3000 0.38-1.54 0.70-1.40 0.51 22-15.5 .028-.055 .020 600-3000 0.38-1.54 0.70-1.40 0.51 22-15.5 .028-.055 .020 600-3000 0.38-1.54 0.70-1.40 0.51 18.5-13.5 .039-.071 .020 1500-5000 0.80-2.54 1.00-1.80 0.51 18.5-13.5 .039-.071 .020 1500-5000 0.80-2.54 1.00-1.80 0.51 18.5-13.5 .039-.071 .020 1500-5000 0.80-2.54 1.00-1.80 0.51 18.5-13.5 .039-.071 .020 1500-5000 0.80-2.54 1.00-1.80 0.51 18.5-13.5 .039-.071 .020 1500-5000 0.80-2.54 1.00-1.80 0.51 15.5-12 .055-.083 .020 3000-7000 1.54-3.46 1.40-2.10 0.51 15.5-12 .055-.083 .020 3000-7000 1.54-3.46 1.40-2.10 0.51 15.5-12 .055-.083 .020 3000-7000 1.54-3.46 1.40-2.10 0.51 15.5-12 .055-.083 .020 3000-7000 1.54-3.46 1.40-2.10 0.51 12-10 .083-.110 .025 7000-12,000 3.46-6.00 2.10-2.80 0.64 12-9 .083-.112 .025 7000-13,000 3.46-6.38 2.10-2.85 0.64 12-9 .083-.112 .025 7000-13,000 3.46-6.38 2.10-2.85 0.64 12-9 .083-.112 .025 7000-13,000 3.46-6.38 2.10-2.85 0.64 12-9 .083-.112 .025 7000-13,000 3.46-6.38 2.10-2.85 0.64 Crimp Width .110 5.08 .180 4.57 .300 7.62 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .110 2.79 .140 3.56 .140 3.56 .140 3.56 .140 3.56 .250 6.35 .180 4.57 .180 4.57 .180 4.57 .180 4.57 Dim. L .235 5.97 .267 6.78 .310 7.87 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 .225 5.72 Material Part Number Brass 63564-1 Tin Plated Brass 63561-1 Tin Plated Brass 63562-1 Brass 42076 Brass 42192-1* Tin Plated Brass 42192-2* Brass 42778-1*1 Tin Plated Brass 42778-2*1 Brass 41765 Tin Plated Brass 41899 Brass 42119-1* Brass 42776-1*1 Tin Plated Brass 42776-2*1 Brass 41766 Tin Plated Brass 41900 Brass 42779-11 Tin Plated Brass 42779-21 Tin Plated Brass 61074-11,2 Brass 41770 Tin Plated Brass 41904 Brass 42780-11 Tin Plated Brass 42780-21 * These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller. Increased terminal pitch. 2 Increased U-diameter. 1 48 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 AMPLIVAR Splices (Continued) 5 Serrations -- Pigtail Type Product Facts Serration depths are varied within the splice to give optimum electrical / mechanical performance on all wire sizes Flat bottom of splice helps keep magnet wires on bottom as required during crimping L AWG/ mm2 20-17 0.50-1.00 Wire Range Solid Dia. .030-.045 0.80-1.15 Wire Range CMA 1000-2000 Stock Thickness .016 0.41 Crimp Width .100 2.54 Dim. L .225 5.72 Material Part Number Tin Plated Brass 62670-2*1 *These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller. 1 Flat bottom. AMPLIVAR Splice Miniature Splice -- Pigtail Type Product Facts The miniature AMPLIVAR splice was developed for crimping thinner copper magnet wires having a diameter between .003 and .016 [0.08 and 0.40 mm] and has to be connected with a stranded conductor The diameter of one conductor strand should not exceed the magnet wire diameter to be applied AWG/ mm2 27-21 0.10-0.40 25-18 0.16-0.90 24-18.5 0.20-0.75 24-18.5 0.20-0.75 24-18 0.20-0.80 Wire Range Solid Dia. .014-.030 0.35-0.75 .015-.045 0.45-1.10 .020-.039 0.55-1.00 .020-.039 0.55-1.00 .020-.040 0.55-1.00 Wire Range CMA AWG/ mm2 30-26 0.05-0.15 24-19 0.26-0.60 24-19 0.26-0.60 Wire Range Solid Dia. .010-.015 0.30-0.50 .020-.035 0.55-0.90 .020-.035 0.55-0.90 Wire Range CMA 200-850 300-1850 480-1500 480-1500 480-1700 Stock Thickness .012 0.30 .012 0.30 .014 0.36 .014 0.36 .016 0.41 Crimp Width .055 1.40 .070 1.78 .080 2.03 .080 2.03 .070 1.78 Dim. L .195 4.95 .195 4.95 .195 4.95 .195 4.95 .195 4.95 Stock Thickness .010 0.25 .016 0.41 .016 0.41 Crimp Width .042 1.08 .070 1.78 .070 1.78 Dim. L .080 2.03 .100 2.54 .100 2.54 Material Part Number Tin Plated Brass 63431-1 Copper-Nickel 61166-1 Tin Plated Brass 62341-1 Brass 62341-2 Brass 62044-1 Material Part Number Tin Plated Brass 63621-2 Tin Plated Brass 62194-2 Gold Plated Brass 62194-4 Subminiature Splice -- Thru or Pigtail Type Product Facts The compactness of these splices makes them ideal for use in small subfractional motors, transformers, relays, solenoids, indicator lamps and small appliance terminations These splices provide the same reliability as the larger AMPLIVAR splices 100-300 400-1300 400-1300 49 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 AMPLIVAR Terminals Products Facts Ring tongue terminals available for 2 to 3/8 stud diameters FASTON tab terminals accept .125 [3.18], .187 [4.75] and .250 [6.35] receptacle terminals FASTON receptacle terminals accept .187 [4.75] and .250 [6.35] tab terminals FASTON stator receptacle accept .250 x .032 [6.35 x 0.81] tab terminal Pin receptacle terminals accept .062 [1.57] and .090 [2.29] diameter pins Applications Motor windings Transformers Power supplies Starters and alternators AMPLIVAR magnet wire terminals are designed to terminate copper and/or aluminum magnet wire. Terminals are insulation displacing; therefore, magnet wires do not require a separate prestripping operation. The unique wire barrel design, with serrations and burrs, produces a superior metal-to-metal compression crimp with excellent tensile strength. Terminals are available in a variety of ring tongue, FASTON straight, flag and stator receptacles and tab quick-disconnect style terminals. Direct connection to magnet wire eliminates the need for separate stranded wire terminal connection to input/output devices. Product specifications describe the product qualification test results completed by TE for consideration of product use in a specific application. They are intended for the Design and Product Reliability Engineer. 108-16000 --AMPLIVAR ring tongue terminals 108-1718 --AMPLIVAR .125 blade terminals [Type A] Matched with automated application tooling allows high production rates for stripform terminals. Technical Documents Application Specifications describe requirements for using the product in its intended application and or crimping information. They are intended for the Packaging and Design Engineer and the Machine Setup Person. 114-2145 114-2146 114-2070 50 AMPLIVAR .125 Blade Terminals AMPLIVAR FASTIN-FASTON Series 187 Tab Terminals AMPLIVAR FASTON Series 250 Tab Terminals 114-2144 114-2152 AMPLIVAR FASTON Series .250 Straight Receptacle Terminals AMPLIVAR Flag FASTON Series 187 & 250 Receptacle Terminal 114-2080 114-2128 AMPLIVAR Pin Receptacle Terminals [Type A] AMPLIVAR Stator Receptacle with FASTON Mating End www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 AMPLIVAR Terminals (Continued) Ring Tongue Terminals A Wire Size Range 29-22 AWG [0.287-0.643 mm] Type Insulation Dia. Range Hole Dia. Stud Size Stock Thk. Material B .040-.060 1.02-1.52 .197 5 10 .020 0.51 Tin Plated Brass Dimensions L E .833 .662 21.16 16.81 C .312 7.92 W .342 8.69 .300 7.62 .342 8.69 .300 7.62 Dimensions L E .833 .662 21.16 16.81 .700 .550 17.78 13.97 .833 .662 21.16 16.81 .695 .545 17.65 13.84 C .312 7.92 .230 5.84 .312 7.92 .230 5.84 Dimensions W L E .420 .872 .662 10.67 22.15 16.81 .290 .500 .355 7.37 12.7 9.02 .420 .702 .492 10.67 17.83 12.5 .290 .500 .355 7.37 12.7 9.02 C .312 7.92 .195 4.95 .312 7.92 .195 4.95 Wire Size Range 23-19 AWG [0.574-0.912 mm] Type B B A B A Insulation Dia. Range Hole Dia. .100-.140 2.54-3.56 .125-.165 3.18-4.19 .100-.140 2.54-3.56 .125-.165 3.18-4.19 .171 4.34 .171 4.34 .197 5 .197 5 Stud Size 8 8 10 10 Stock Thk. .020 0.51 .020 0.51 .020 0.51 .020 0.51 Material Tin Plated Brass Tin Plated Brass Tin Plated Brass Tin Plated Brass Wire Size Range 22-18 AWG [0.643-1.024 mm] C Type Insulation Dia. Range Hole Dia. B .125-.165 3.18-4.19 E -- C -- .265 6.73 .145 3.58 .265 6.73 .171 4.34 E -- Stud Size 1/4 6 1/4 8 Stock Thk. .025 0.64 .025 0.64 .025 0.64 .025 0.64 Material Tin Plated Brass Tin Plated Brass Tin Plated Brass Brass Tin Plated Brass Wire Size Range 20-16 AWG [0.813-1.29 mm] D E Type Insulation Dia. Range Hole Dia. Stud Size A .125-.165 3.18-4.19 .171 4.34 8 H -- -- 8 L -- -- 3/8 M -- -- 3/8 B .243 [6.15] .020 0.51 .020 0.51 .020 0.51 .020 0.51 Material Tin Plated Brass Brass Brass Brass W .300 7.62 .340 8.64 .625 15.88 .645 16.38 Dimensions L E C .695 .545 .230 17.65 13.84 5.84 1.220 .660 .500 30.98 16.76 12.7 .939 .627 .467 23.85 15.93 11.86 .950 .627 .467 24.12 15.93 11.86 W .342 8.69 .342 8.69 .342 8.69 .370 9.4 .365 9.27 Dimensions L E .833 .662 21.16 16.81 .833 .662 21.16 16.81 .833 .662 21.16 16.81 .915 .730 23.24 18.54 .882 .700 22.4 17.78 C .312 7.92 .312 7.92 .312 7.92 .380 9.65 .380 9.65 W .310 7.87 .310 7.87 Dimensions L E .692 .505 17.58 12.83 .692 .505 17.58 12.83 C .312 7.92 .312 7.92 Wire Size Range 18-14 AWG [1.024-1.628 mm] Type F Stock Thk. D 1High Insulation Dia. Range Hole Dia. .100-.140 2.54-3.56 .100-.140 2.54-3.56 .100-.140 2.54-3.56 .080-.120 2.03-3.05 .080-.120 2.03-3.05 .171 4.34 .171 4.34 .197 5 .173 4.39 .185 4.7 Stud Size 8 8 10 8 8 Stock Thk. .020 0.51 .020 0.51 .020 0.51 .028 0.71 .028 0.71 Material Brass Tin Plated Brass Brass Lu-Bronze1 Lu-Bronze1 Part Number 63399-1 Part Number 60321-2 60323-2 60319-2 60325-2 Part Number 63612-1 63649-1 AMPLIVAR Terminals W .342 8.69 62835-1 63446-1 63446-2 Part Number 060322-2 505071-1 505075-1 505072-1 Part Number 060320-1 060320-2 060318-1 485079-1 485044-1 conductivity copper-tin-zinc alloy. Wire Range 17-13.5 AWG [1.151-1.78 mm] Type F G Insulation Dia. Range Hole Dia. Stud Size -- -- 8 -- -- 8 Stock Thk. .020 0.51 .020 0.51 Material Brass Tin Plated Brass Part Number 63147-1 63147-2* *Available on request .243 [6.15] Wire Size Range 14-12 AWG [1.628-2.05 mm] or (2) 15 AWG [1.45 mm] Type Insulation Dia. Range Hole Dia. Stud Size Stock Thk. Material G -- -- 8 .025 0.64 Brass W .342 8.69 Dimensions L E C .945 .750 .570 24.00 19.05 14.48 Part Number 062755-1 www.te.com/appliances 51 Magnet Wire Terminals and Termination Systems Catalog 82221 AMPLIVAR Terminals (Continued) Stud Retaining Terminals H 45 J Wire Size Range 13-11 AWG [1.83-2.3 mm] Type Insulation Dia. Range Hole Dia. A .085-.150 2.16-3.81 .180 4.57 .180 4.57 .197 5.00 C -- -- Stud Size 8 8 10 Stock Thk. .025 0.64 .025 0.64 .025 0.64 Material Brass Tin Plated Brass Tin Plated Brass Dimensions L E .833 .662 21.16 16.81 .665 .495 16.89 12.57 .665 .495 16.89 12.57 C .312 7.92 .312 7.92 .312 7.92 W .340 8.64 Dimensions L E .955 .660 24.26 16.76 C .500 12.7 505044-1 W Dimensions L E C Part Number W .342 8.69 .342 8.69 .342 8.69 Wire Range (1) 18 AWG [1.024 mm] and (1) 20.5 AWG [0.768 mm] 45 Type Insulation Dia. Range Hole Dia. Stud Size Stock Thk. Material J -- -- 8 .020 0.51 Brass Wire Range (2) 17 AWG [1.51 mm] or (2) 15 AWG [1.45 mm] K Type Insulation Dia. Range B .150-.190 or (2) .115 3.18-4.83 or (2) 2.92 .150-.190 or (2) .115 3.18-4.83 or (2) 2.92 Part Number 061710-1 350571-1 640212-1 Part Number Hole Dia. Stud Size Stock Thk. Material .171 4.34 8 .025 0.64 Tin Plated Brass .342 8.69 .827 .656 21.01 16.66 .312 7.92 60752-2 .197 5.00 10 .025 0.64 Tin Plated Brass .342 8.69 .827 .656 21.01 16.66 .312 7.92 61151-1 W .340 8.64 Dimensions L E 1.220 .660 30.99 16.76 C .500 12.7 W .240 6.1 .240 6.1 Dimensions L E .620 .500 15.75 12.7 .620 .500 15.75 12.7 C .165 4.19 .165 4.19 W .342 8.69 Dimensions L E .827 .656 21.00 16.66 C .312 7.92 L .376 [9.55] Wire Range 16-13.5 AWG [1.29-1.78 mm] .388 [9.85] M Type Insulation Dia. Range Hole Dia. Stud Size Stock Thk. Material K -- -- 10 .020 0.51 Brass Stock Thk. Material Wire Range 14.5 AWG [1.539 mm] Type N Insulation Dia. Range Hole Dia. Stud Size -- -- 2 -- -- 2 .025 0.64 .025 0.64 Tin Plated Brass Brass Wire Range (2) 13 AWG [1.83 mm] Alternator Eyelet Terminal N 52 Type Insulation Dia. Range Hole Dia. Stud Size Stock Thk. Material B .150-.190 3.81-4.83 .171 4.34 8 .025 0.64 Tin Plated Brass Part Number 505079-1 Part Number 505036-1 505036-3 Part Number 63864-1 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 AMPLIVAR Terminals (Continued) A 125 Series Blade B Stock Thickness .330 [8.38] .125 [3.18] A = .013 [0.33] B = .020 [0.51] .810 [20.57] .020 [.508] Mates with power blade receptacle terminals 61603-1, 61604-1, 770642-1 and 1217039-1 Type AWG 27-20.5 Housings A Contact TE engineering for housing options available 24-18 18.5-13.5 27-20.5 B 24-18 18.5-13.5 .125 [3.18] .020 [.508] Magnet Wire Range mm2 Solid Dia. .015-.030 0.10-0.45 0.35-0.75 .020-.040 0.2-0.8 0.50-1.00 .040-.070 0.75-2.5 0.50-1.80 .015-.030 0.10-0.45 0.35-0.75 .020-.040 0.2-0.8 0.50-1.00 .040-.070 0.75-2.5 0.50-1.80 200-850 Tin Plated Brass 400-1600 Tin Plated Brass 1500-5000 Tin Plated Brass 200-850 Tin Plated Brass 400-1600 Tin Plated Brass 1500-5000 Tin Plated Brass Material Thickness .013 0.33 .013 0.33 .016 0.41 .013 0.33 .020 0.51 .020 0.51 Part Number 63871-1 63889-1 63870 1217072-1 1217029-1 1217073-1 AMPLIVAR Terminals A 187 Series FASTON Tabs1 Material CMA .940 [23.88] .370 [9.40] B Board Thickness A = .062-.072 [1.57-1.83] Stock Thickness A = .020 [0.51] B = .032 [0.81] Type B A 2 Wire Range AWG mm2 Dim. L Material 27-23 0.1-0.2 Tin Plated Brass 24-21 0.2-0.4 Tin Plated Brass 22-16 0.3-1.4 Tin Plated Brass 15-13 1.6-2.6 Tin Plated Brass 15-12 1.6-3.0 Tin Plated Brass .935 23.75 .935 23.75 1.015 25.78 .935 23.75 1.015 25.78 Part Number 63484-12 61440-3 62447-1 61442-3 62445-1 Varnish resist coating. These part numbers are available upon special request, contact TE engineering for details. 250 Series FASTON Tabs1 Stock Thickness .032 [0.81] Wire Range AWG mm2 14-12 2.0-3.0 1Mates with FASTON receptacles. See Catalog 82004. Material Part Number Quick-Change Applicator3 Tin Plated Brass 62922-12 466510-1 Varnish resist coating. 3 Quick-change applicator for AMP-O-LECTRIC machine 565435-5. For AMPOMATOR machine and other machines not listed, contact TE. 2 53 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 AMPLIVAR Terminals (Continued) 250 Series FASTON Tabs1 (Continued) Stock Thickness .032 [0.81] Mates with FASTON receptacles. See Catalog 82004. Wire Range AWG mm2 Material 28-23.5 0.08-0.2 Tin Plated Brass 25-19.5 0.16-0.6 Tin Plated Brass 23-19 0.2-0.6 Tin Plated Brass Dimensions L E .580 .342 14.73 8.69 .650 .450 16.51 11.43 .225 .583 5.72 14.81 W .250 6.35 .250 6.35 .250 6.35 T Part Number 45 63136-1 30 63140-1 15 63165-1 Part Number Applicator No. 250 Series FASTON Receptacles1 .280 [7.11] .690 [17.53] Stock Thickness .016 [0.41] .290 [7.37] Mates with FASTON tabs. See catalog 82004. Magnet Wire Range CMA mm2 Dia. Insulation Diameter Mating Tab Thk. Material Material Thickness 24-19 0.51-0.98 .050-.080 1.30-2.00 .020 0.51 Brass Tin Plated Brass .016 0.41 63623-11 63623-21 567451-22 23-19 or (2) 24 or (2) 26 20-16 or (2) 23 or (2) 20 0.60-0.98 or (2) 0.57 or (2) 0.45 0.85-1.37 or (2) 0.63 or (2) 0.88 .050-.100 1.30-2.55 .025 0.64 Brass .016 0.41 62069-1 567343-22 .032 [0.81] Brass Tin Plated Brass 60384-1 60384-2 466010-12 20-16 0.85-1.37 .020 0.51 Brass .016 0.41 62080-1 466010-12 18-14 or (2) 17 1.02-1.71 .032 [0.81] Tin Plated Brass .016 0.41 60385-2 466816-12 63622-11 466816-12 1217835-11 466816-12 18-14 or (2) 19 18-14 or (2) 19 1 2 54 1.02-1.71 1.02-1.71 .100-.140 or (2) .060 Max. 2.55-3.55 .100-.140 2.55-3.55 .120-.170 or (2) .060 Max. 3.05-4.30 .120-.170 3.05-4.30 .120-.170 3.05-4.30 .020 0.51 .020 0.51 Brass Brass .016 0.41 .016 0.41 .016 0.41 Low insertion force Quick-change applicator for AMP-O-LECTRIC machine 565435-5. www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 AMPLIVAR Terminals (Continued) 187 Series FASTON Flag Receptacles Stock Thickness .045 [1.14] .016 [0.41] .240 [6.10] .232 [5.89] Magnet Wire Range CMA mm2 Dia. 1 0.56-0.79 24-20 AWG 0.51-0.81 1500-2350 0.99-1.22 2000-4050 1.14-1.63 2000-4050 1.14-1.63 Mating Tab Thk. .020-.040 0.51-1.02 .020-.040 0.51-1.02 .020-.040 0.51-1.02 .020-.040 0.51-1.02 .020-.040 0.51-1.02 .020 0.51 .032 0.81 .020 0.51 .020 0.51 .032 0.81 Material Tin Plated Brass Tin Plated Brass Tin Plated Brass Tin Plated Brass Tin Plated Brass Material Thickness Part Number .016 0.41 .016 0.41 .016 0.41 .016 0.41 .016 0.41 Applicator No. 63942-1 566411-11 1217624-1 566411-11 63941-1 566410-11 63940-1 680353-32 1217417-1 680353-32 Standard applicator for AMP-O-LECTRIC Model G splice terminator No. 356462-2. Quick-change applicator for AMP-O-LECTRIC Model G splice terminator No. 356462-1. AMPLIVAR Terminals 2 500-960 Insulation Diameter .4.35 [11.05] 250 Series FASTON Flag Receptacles Stock Thickness .018 [0.45] .070 [1.78] .600 [15.24] .305 [7.75] .125 [3.16] .31 8 [8.09] .300 [7.62] Magnet wire range CMA mm2 Dia. 1 Pin Receptacles 500-1900 -- 1000-2700 -- 1500-4220 -- 4000-8500 -- .530 [13.46] .305 [7.75] Insulation Diameter .100-.120 2.54-3.05 .100-.120 2.54-3.05 .075-.125 1.90-3.18 .110-.150 2.79-3.81 Material Thickness 0.0157 0.4 0.0157 0.4 0.0157 0.4 0.0157 0.4 Mating Tab Thk. 6.35 0.81 6.35 0.81 6.35 0.81 6.35 0.81 Part Number Applicator No. 1742881-1 1855633 1742882-1 1855634 1742977-1 1855680 1742979-1 1855681 Quick-change applicator for AMP-O-LECTRIC Model G splice terminator No. 356462-1. A B Stock Thickness .016 [0.41] Type A B Wire Range AWG mm2 29-22 21-16 0.07-0.3 0.4-1.4 Insulation Dia. Range Material .040-.060 1.02-1.52 Tin Plated Brass -- Tin Plated Phos. Bronze Dimensions W Max. L .084 .590 2.13 14.99 .235 .660 5.97 16.76 C .195 4.95 .250 6.35 Part Number 63506-1 60177-2 www.te.com/appliances 55 Magnet Wire Terminals and Termination Systems Catalog 82221 AMPLIVAR Terminals (Continued) 250 Series Stator Receptacles -- 7 Serrations .070 [1.78] .860 [21.84] .305 [7.75] .300 [7.62] AWG 27-22 21-15 22-15.5 Magnet Wire Range mm2 Solid Dia. CMA .014-.026 0.10-0.3 0.35-0.66 200-700 .028-.060 0.4-1.6 0.71-1.52 800-3600 .053-.086 0.3-1.5 1.35-2.18 2800-7400 Mating Tab Thickness Stock Thickness Crimp Width .032 0.81 .032 0.81 .032 0.81 .018 0.44 .018 0.44 .018 0.44 .070 1.77 .110 2.79 .155 3.94 Material Part Number Tin Plated Brass 63480-1 Tin Plated Brass 62381-1 Tin Plated Brass 63964-1 Stator Terminal -- Receptacle .250 x .032 [6.35 x 0.81] Stator Terminal with Receptacle .250 x .032 [6.35 x 0.81] Plastic Cavity Production only according to TE Specifications (contact TE engineering for details). For design and material selection TE engineering has to be contacted before decision. The terminal is separated from the strip and placed automatically into the cavity. Wire Clamping Barrel AMPLIVAR Terminal Crimp The magnet wire is positioned via posts into the AMPLIVAR crimp barrel and fixed inside clamping barrel. The application equipment crimps the AMPLIVAR product connection and cuts the extending clamping barrel in one operation. Additional versions upon request. Application tooling for production line integrating available upon request. 56 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Cluster Blocks Product Facts Connects to sealed hermetic headers Versions available to accept 2.29 [.090] and 3.18 [.125 ] header pins Accepts Lead wire range 18-16 AWG [0.8-1.4 mm 2] and 14-12 AWG [2.0-3.0 mm 2] AMPLIVAR product versions accept up to 3 copper or aluminum magnet wires without the need to remove insulation Impervious to many oils and refrigerants Insulation compatibility High-performance electrical and mechanical contact High-impact resistant Assemblies accept pins from one side only to prevent reversed polarity High-speed application of pin receptacle terminals with automatic terminating machines and quick-change applicators for high volume production rates at the lowest installed cost Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 R TE features cluster blocks that offer manufacturers of air conditioning and refrigeration products a low-cost, fully insulated, quick-connect means for electrically connecting sealed hermetic header pins on compressors. Cluster blocks feature high impact resistance to shock and abuse, and long-life performance in the presence of oils and refrigerants. Since the connectors accept pins from only one side, the danger of reversing polarity at the time of installation is prevented. The one-piece housings are molded from thermoplastic polyester. The connector accepts 2.29 [.090] and 3.18 [.125] diameter pin sizes in either standard or reverse pin layouts. Housings accept both lead wire and AMPLIVAR direct connect pin receptacle Cluster Blocks Housings available to accept standard and reversed header p in layouts Housing versions available for compressor interior and exterior terminals. These are precision formed and available on reels for highspeed application. High retention pin receptacle terminals are available to provide optimum terminal retention housings. Pin Receptacle Terminal (Crimped to Wire) PRODUCT SPECIFICATIONS: 108-2008,108-5205 &108-5541 APPLICATION SPECIFICATIONS: 114-2019 & 114-5235 Typical Assembly www.te.com/appliances 57 Magnet Wire Terminals and Termination Systems Catalog 82221 Cluster Blocks 2.29 [.090] Pin Size (Lead Wire and Direct Connect) .108 [2.74] Housings .530 Dia. [13.46] .108 [2.74] .683 Dia. [17.35] .324 [8.23] .108 [2.74] .229 [5.82] .108 [2.74] .090 .001 [2.29 0.03] Pin Dia. 3 Plcs. .459 [11.66] .090 .001 [2.29 0.03] Pin Dia. 4 Plcs. .324 [8.23] Pin Location E Pin Location B, C and D Pin Location A .324 [8.23] K W H L B A W K H H L C D Type A 2 Position with Standoff B 3 Position Center Forward C 3 Position Center Back D 3 Position Center Back Extra Wide Header Pin Circle Dia. mm / inch 13.46 [.530] 13.46 [.530] 13.46 [.530] 13.46 [.530] Economy Models E 4 Position 58 L K W 17.35 [.683] Dim L E Material / Use Accepts Receptacle Style Part Number A, B & C 1969357-1 A, B & C 360050-1 Dim W Dim H Dim K mm / inch 22.45 [.884] 31.50 [1.240] mm / inch 21.08 [.830] 18.05 [.710] mm / inch 14.23 [.560] 8.15 [.320] mm / inch 21.35 [.840] PBT Interior PBT Interior 31.00 [1.220] 17.65 [.695] 6.60 [.260] 20.85 [.820] PBT Interior A, B & C 521078-1 30.48 [1.200] 17.65 [.695] 7.87 [.310] 20.40 [.803] PBT Exterior A, B & C 1380145-1 2 30.48 [1.200] 17.65 [.695] 7.87 [.310] 20.40 [.803] PBT Exterior A, B & C 1380145-2 3 30.48 [1.200] 30.48 [1.200] 30.48 [1.200] 17.65 [.695] 17.65 [.695] 17.65 [.695] 9.70 [.382] 9.70 [.382] 9.70 [.382] 20.40 [.803] 20.40 [.803] 20.40 [.803] PBT Exterior PA6+GF Exterior A, B & C 2232327-1 3 A, B & C 2232327-2 4 PBT Exterior A, B & C 2232326-1 3 30.48 [1.200] 30.80 [1.21] 31.10 [1.225] 17.65 [.695] 17.80 [.701] 20.55 [.810] 9.70 [.382] 7.40 [.0291] 8.15 [.320] 20.40 [.803] 20.40 [.803] 21.35 [.840] PA6+GF Exterior PBT Exterior PBT Interior A, B & C 2232326-2 4 A, B & C 235280-1 A, B & C 360033-1 30.50 [1.200] 30.50 [1.200] 30.50 [1.200] 17.65 [.695] 17.70 [.697] 17.70 [.697] 7.85 [.310] 7.90 [.311] 7.80 [.307] 20.40 [.805] 20.40 [.805] 20.40 [.805] PBT Interior PBT Exterior PA6+GF Exterior A, B & C 281006-4 31.60 [1.244] 31.60 [1.244] 31.60 [1.244] 28.10 [1.110] 28.10 [1.110] 22.70 [.893] 22.70 [.893] 22.70 [.893] 22.70 [.893] 22.70 [.893] 9.30 [.366] 9.30 [.366] 9.30 [.366] 7.60 [.299] 7.60 [.299] 21.50 [.846] 21.50 [.846] 21.50 [.846] 18.10 [.712] 18.10 [.712] PBT Filled Interior PBT Filled Exterior PA6+GF Exterior PBT Filled Exterior PBT Filled Exterior D&E 171370-3 D&E 171370-5 D&E 171370-6 4 F 2825082-1 5 F 2825082-2 4 37.85 [1.490] 22.85 [.900] 9.00 [.355] 21.45 [.845] PBT Interior A, B & C 1217262-1 N/A Notes A, B & C 880631-5 2 A, B & C 1955415-1 4 3 Notes: 1.Interior use designates that the material can be subjected to refrigerants and lubricants often found in a compressor. 3.Flammability rating UL94 V-0 Consult TE Connectivity Product specification for additional information. 4.Flammability rating UL94 V-0. Glow Wire compliant to 750C with No Flame per IEC 60335-1. 5.Flammability rating UL94 HB 2.Flammability rating UL94 V-2 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Cluster Blocks 2.29 [.090] Pin Size (Lead Wire and Direct Connect) .670 [17.02] .670 [17.02] .313 [7.95] Pin Receptacles .313 [7.95] .180 [4.57] .180 [4.57] .115 [2.92] A Lead Wire Standard Retention .115 [2.92] B Lead Wire High Retention C Lead Wire Standard Retention .590 [15.0] .276 [7.0] .180 [4.57] D Type B Lead Wire High Retention C AMPLIVAR Direct Connect High Retention Product D Lead Wire Oval Contact Magnet Wire Size mm / CMA F Crimp Width Insulation Dia Crimp Width mm / inch mm / inch mm / inch 0.30 - .75 [22 - 18] 2.03 0.080 1.30 - 2.40 .051 - .095 0.80 - 1.3 [18 - 16] 2.79 0.110 Lead Wire Size Material Part Number 3.05 0.120 Tin Plated Phos Bronze 1599105-1 1.50 - 2.50 .060 - .100 3.56 0.140 Tin Plated Phos Bronze 62131-3 2.79 0.110 2.30 - 4.30 .090 - .170 4.57 0.180 Tin Plated Phos Bronze 63448-1 2.54 0.100 2.00 - 3.80 .080 - .150 3.30 0.130 Tin Plated Phos Bronze 1217264-1 0.26-0.77 [400 - 1600] 2.270 0.090 1.50 - 2.55 0.06 - .100 3.560 0.140 Tin Plated Phos Bronze 1742981-1 0.77 - 2.43 [1600 - 4800] 2.79 0.110 1.90 - 3.20 .075 - .125 3.94 0.155 Tin Plated Phos Bronze 1742964-1 3 2,29 0.090 2.00 - 3.40 .080 - .134 3.81 0.150 Tin Plated Phos Bronze 170063-2 2 0.11 - 0.73 [225 - 1445] 1.78 0.070 0.90 - 2.00 .035 - .079 3.3 0.130 Tin Plated Phos Bronze 1123655-1 2, 4 0.77 - 2.13 [1600 - 4200] 2.79 0.110 2.00 - 2.90 .080 - .114 3.81 0.150 Tin Plated Phos Bronze 353937-1 2, 4 2,29 0.090 2.00 - 3.40 .080 - .134 3.81 0.150 Tin Plated Phos Bronze 2825083-1 5 0.30 - 2.08 [22 - 14] 0.50 - 1.25 [20 - 16] E AMPLIVAR Short Barrel Oval Contact F Lead Wire Oval Contact Economy Model Lead Wire Standard Retention Economy Model E mm / AWG A Lead Wire Standard Retention .083 [2.12] Lead Wire Standard Retention 0.50 - 1.25 [20 - 16] Cluster Blocks Lead Wire Standard Retention Notes Notes: 1.May contain an equivalent copper alloy. 2.Requires extra wide type D housing. 3.Connects up to 3 Copper or aluminum magnet wires without stripping insulation. 4.Connects up to 2 copper magnets without stripping insulation. 5.Requires extra wide type D, Economy Model housing. 59 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Cluster Blocks 3.18 [.125] Pin Size (Lead Wire and Direct Connect) Housings .229 [5.82] .815 Dia. [20.70] .687 Dia. [17.45] .530 Dia. [13.46] .125 .001 [3.18 0.03] Pin Dia. 3 Plcs. .125 .001 [3.18 0.03] Pin Dia. 3 Plcs. .297 [7.55] .459 [11.66] Pin Location A and B .125 .001 [3.18 .353 [8.96] .595 [15.12] 0.03] Pin Dia. 3 Plcs. .706 [17.92] Pin Location C and D Pin Location E W W K K H H L L B A W W W K K H H K H L L L C Type Header Pin Circle Dia. mm / inch A 3 Position Center Forward 13.46 [.530] mm / inch Material / Use' Accepts Receptacle Style Part Number 31.17 [1.227] PBT Interior A, B, C & D 360052-1 Dim L Dim W Dim H Dim K mm / inch mm / inch mm / inch 44.60 [1.755] 19.45 [0.765] 11.95 [0.470] 44.60 19.45 13.35 31.17 [1.755] [0.765] [.525] [1.227] PBT Interior A, B, C & D 1217181-1 44.60 [1.755] 19.45 [0.765] 11.95 [0.470] 31.10 [1.225] PBT Interior A, B, C & D 360051-1 47.25 [1.860] 19.45 [.765] 13.35 [.525] 31.10 [1.225] PBT Interior A, B, C & D 1217200-1 40.50 [1.595] 22.75 [.895] 9.65 [.380] 27.45 [1.080] PBT Interior A, B, C & D 520995-1 43.95 [1.730] 22.75 [.895] 15.60 [.615] 27.45 [1.080] PBT Interior A, B, C & D 1217186-1 17.45 [.687] 47.00 [1.850] 22.75 [.895] 15.60 [.615] 31.10 [1.225] PBT Interior A, B, C & D 1217187-1 20.70 [.815] 50.15 [1.975] 25.80 [1.015] 15.00 [.590] 26.65 PBT Interior A, B, C & D 1217261-1 B 3 Position Center Back 13.46 [.530] C 3 Position Center Forward 17.45 [.687] D 3 Position Center Back E 3 Position Center Forward E D 1.05 Notes: 1.Interior use designates that the material can be subjected to refrigerants and lubricants often found in a compressor. Consult TE Connectivity product specification for additional information. 60 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Cluster Blocks 3.18 [.125] Pin Size (Lead Wire and Direct Connect) (Continued) Pin Receptacles .805 [20.45] .805 [20.45] .400 [10.16] .400 [10.16] .240 [6.10] .240 [6.10] .160 [4.06] .160 [4.06] A B Lead Wire Lead Wire .870 [22.1] .870 [22.1] .400 [10.16] .400 [10.16] .240 [6.1] .240 [6.1] C D AMPLIVAR Direct Connect Contact Type Insulation Dia Crimp Width mm / inch mm / inch mm / inch 0.75 - 1.5 2.79 2.30 - 3.30 3.94 [18 - 16] 0.110 .090 - .130 0.155 mm / AWG A Lead Wire Standard Retention B Lead Wire High Retention C AMPLIVAR Direct Connect Standard Retention D AMPLIVAR Direct Connect High Retention Magnet Wire Size mm / CMA AMPLIVAR Direct Connect Contact Crimp Width Lead Wire Size Cluster Blocks .160 [4.06] .160 [4.06] Material Part Number Notes Tin Plated Phos Bronze 62244-3 2 Tin Plated Phos Bronze 62243-3 2 2.0 - 6.0 3.56 3.30 - 4.30 4.57 14 - 10 0.140 .130 - .170 0.180 0.32-0.82 or 2x0.32 2.29 2.79 or 2x2.29 Max 3.56 [22-18 or 2x22] 0.090 .110 or 2x.090 Max 0.140 Tin Plated Phos Bronze 1742657-1 2 0.75 - 1.5 [18 - 16] 2.79 0.110 2.30 - 3.30 .090 - .130 3.94 0.155 Tin Plated Phos Bronze 1217176-1 2 2.0 - 6.0 [14 - 10] 3.56 0.140 3.30 - 4.30 .130 - .170 4.57 0.180 Tin Plated Phos Bronze 1217175-1 2 0.20 - 0.81 400 - 1600 2.27 0.090 1.50 - 2.55 .060 - .100 3.56 0.140 Tin Plated Phos Bronze 63453-1 2, 4 0.76 - 2.13 1500 - 4200 2.79 0.110 1.90 - 3.20 .075 - .125 3.94 0.155 Tin Plated Phos Bronze 63454-1 2, 4 2.00 - 4.30 4000 - 8500 3.56 0.140 2.30 - 4.30 .090 - .170 4.32 0.170 Tin Plated Phos Bronze 63455-1 2, 4 0.20 - 0.81 400 - 1600 2.27 0.090 1.50 - 2.55 .060 - .100 3.56 0.140 Tin Plated Phos Bronze 1217172-1 2, 4 0.76 - 2.13 1500 - 4200 2.79 0.110 1.90 - 3.20 .075 - .125 3.94 0.155 Tin Plated Phos Bronze 1217174-1 2, 4 2.00 - 4.30 3.56 2.30 - 4.30 4.32 4000 - 8500 0.140 .090 - .170 0.170 Tin Plated Phos Bronze 1217173-1 2, 4 Notes: 1.Material shown is for reference only. May contain an equivalent copper alloy. 2.Receptacle must be contained in a housing listed on the previous page for proper performance. 3.Stand-alone receptacle can be used with or without a housing. 4.Connects up to 3 copper or aluminum magnet wires without removing the insulation. 61 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 This product line is not recommended for new designs, MTM Crimpband Splices as the application machines are no longer manufactured. Product Facts Made from a continuous coil of ribbon connector material Magnet wires MTM Crimpband splices have machine-piercing serrations designed for displacing magnet wire insulation. Available in brass, tinplated brass, and coppernickel alloy material Make parallel or pigtail connections on same machine 100% of Crimpband material is used in scrap free terminations Crimpband material coupled with appropriate toolsets accommodate specific CMA ranges Produced in TE equipment on your production floor Meets UL 486C crimp tensile requirements Applications 62 Motors windings and connections Coil connections Transformer windings and connections Lighting ballasts Power supplies Cut Formed Crimped TE features the MTM Crimpband system that is comprised of two key features: the semiautomatic termination machine and a reel of MTM Crimpband material. In a one-step crimping operation, the machine feeds, cuts, forms and crimps the material to provide a low-cost, high reliability crimp connection. The MTM Crimpband splices are formed during the crimping process from machined longitudinal grooved material that pierces magnet wire varnish film insulation during crimping. TE provides a wide range of toolset types and Crimpband splices to meet various production requirements. Three magnet wires maximum can be terminated together with stranded lead wire in one splice. When aluminum magnet wire is used, MTM Crimpband splices must be tin plated. MTM Crimpband splices are specifically designed to terminate magnet wire to itself or in combination with standard solid or stranded lead wire. Depending on your specific application, MTM Crimpband splices are available in 7, 9, 11 and 13 serration versions for terminations in the 400 to 13,000 CMA range. www.te.com/appliances Magnet Wire Terminals and Termination Systems This product line is not recommended for new designs, as the application machines are no longer manufactured. MTM Crimpband Splices (Continued) MTM Crimpband Interconnection System Catalog 82221 Notes: To insure that the proper Crimpband splice is chosen, TE recommends the following: 1. Submit 10 samples of wire combinations and/or components to be crimped with any special requirements to your TE sales representative. 2. Pull-out force and/or millivolt drop tests will be performed to insure that the proper Crimpband material, toolset and crimp heights are recommended. 3. Tooling and testing will be documented on a Material & Tooling Sheet (M & T sheet). 4. Crimpband material quotes, tooling quotes and samples will be submitted to the customer. How the System Operates Feed (Magnet Wire Connector Material) Machine feeds strip until the strip hits the wire stop. Shear (Blank Length) The strip is cut by the cutter block former bar insert tooling. W Bend (Crimp Formed) The former bar drives the cut strip over the anvil, bending the cut strip into an upside down "U". T A Wire (Placement) In pigtail and parallel (Thru) splices magnet wires must be placed on top of the lead wire. Magnet Wires on top Legend L Leased L See Figure 1 and/or Legend below W Dim. T Dim. Connector Material Finish Width Thickness 6R 20 T 092 6R Machine Basis P G* Purchase General * Customer has their own Tooling 20 T Tooling Size Code 032 032/036 036 045 051 061 061/076 076 076/092 092 092/125 125 125/160 125/165 165 Material Code Lead Wire B Crimpband Splice No. Example: Blank Length W Connector Specification Code L D A The anvil retracts as the driver takes the formed strip down into the clincher. B.L. Dim. Tooling Size 092 Serrations Section A-A Crimp (Crimp Formed) Machine Basis Burrs B Blank Length B/L (Nom.) .167 .228 .224 .246 .267 .292 .324 .339 .361 .379 .413 .446 .485 .506 .546 Note: For B/L above, .546 consult TE for tooling size code. Connector Width Code 4R 5 Serrations 6R 7 Serrations 8R 9 Serrations 10R 11 Serrations Material Thickness Code 12 14 16 20 25 Material Code B A TB T.002 Dim. .012 .014 .016 .020 .025 W .138 .154 .194 .234 D Serration Depth .005 .005 .007 .007 .007 UL486C Pull Out Wire Size Force Requirements AWG Underwriters Laboratory (lbs.) 26 3 24 5 22 8 20 10 18 10 16 15 14 25 12 35 10 40 Material/Finish CDA 260 Brass CDA 725 Copper/ Nickel Alloy Pre-Tin over CDA 260 Brass 63 www.te.com/appliances Magnet Wire Terminals and Termination Systems MTM Crimpband Splices (Continued) Catalog 82221 This product line is not recommended for new designs, as the application machines are no longer manufactured. 11 Serrations T W AWG/ Wire Range mm2 Solid Dia. .059-.087 141 2-111 2 1.80-4.00 1.50-2.21 .059-.087 141 2-111 2 1.80-4.00 1.50-2.21 .071-.097 131 2-101 2 2.54-4.50 1.70-2.46 .071-.097 131 2-101 2 2.54-4.50 1.70-2.46 CMA Range 3500-7500 3500-7500 4500-9500 4500-9500 Stock Mat'l Thk. (T) Width (W) Material .025 .234 Brass 0.64 5.94 .025 .234 Tin Plated 0.64 5.94 Brass .025 .234 Brass 0.64 5.94 .025 .234 Tin Plated 0.64 5.94 Brass Toolset Part Number Descriptive X-ref P125/ 16510R25B L125/ 16510R25TB P165/ 20010R25B P165/ 20010R25TB 125/165 1601842-1 125/165 1601705-1 165/200 1601847-1 165/200 1601848-1 Toolset Part Number 032/036 1601794-1 Descriptive X-ref P032/ 0368R16TB 061 1601607-1 L0618R16TB 061 1601608-1 L0618R20B 9 Serrations T W AWG/ Wire Range mm2 Solid Dia. 24-20 .020-.033 0.20-0.50 0.51-0.84 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 16-12 .051-.078 1.30-3.46 1.29-1.98 16-12 .051-.078 1.30-3.46 1.29-1.98 16-12 .051-.078 1.30-3.46 1.29-1.98 16-12 .051-.078 1.30-3.46 1.29-1.98 .055-.082 151 2-12 1.54-3.46 1.40-2.10 .055-.082 151 2-12 1.54-3.46 1.40-2.10 .055-.082 151 2-12 1.54-3.46 1.40-2.10 151 2-12 .055-.082 1.54-3.46 1.40-2.10 .059-.087 141 2-111 2 1.80-4.00 1.50-2.21 .059-.087 141 2-111 2 1.80-4.00 1.50-2.21 14-11 .063-.092 2.00-4.20 1.60-2.34 .084-.114 111 2-9 4.00-6.50 2.13-2.90 CMA Range 400-1100 900-2600 900-2600 900-2600 1600-4000 1600-4000 1800-4600 1800-4600 2600-6100 2600-6100 2600-6100 2600-6100 3000-6750 3000-6750 3000-6750 3000-6750 3500-7500 3500-7500 4000-8500 7000-13000 Stock Mat'l Thk. (T) Width (W) .016 .194 0.41 4.93 .018 .194 0.46 4.93 .018 .194 0.46 4.93 .018 .194 0.46 4.93 .016 .194 0.41 4.93 .020 .194 0.51 4.93 .020 .194 0.51 4.93 .020 .194 0.51 4.93 .020 .194 0.51 4.93 .020 .194 0.51 4.93 .025 .194 0.64 4.93 .025 .194 0.64 4.93 .016 .194 0.41 4.93 .016 .194 0.41 4.93 .020 .194 0.51 4.93 .025 .194 0.64 4.93 .025 .194 0.64 4.93 .025 .194 0.64 4.93 .025 .194 0.64 4.93 .025 .194 0.64 4.93 Material Tin Plated Brass Tin Plated Brass Brass Tin Plated Brass Tin Plated Brass Tin Plated Brass 061 1601814-1 P0618R20TB 076 1601824-1 P0768R16TB 076 1601857-1 PO768R20TB Brass 076/092 1601823-1 Tin Plated Brass 076/092 1601639-1 Brass 092/125 1601678-1 Tin Plated Brass 092/125 1601835-1 P076/ 0928R20B L076/ 0928R20TB P092/ 1258R20B L092/ 1258R20TB L092/ 1258R25B P092/ 1258R25TB Brass 125 1601717-1 L1258R16B Tin Plated Brass 125 1601718-1 L1258R16TB Brass 125 1601846-1 P1258R20B Brass 125 1601719-1 L1258R25B Brass 125/165 1601706-1 125/165 1601707-1 L125/ 1658R25B L125/ 1658R25TB 165 1601750-1 L1658R25TB 200/202 1601761-1 L200/ 2028R25TB Brass 092/125 1601833-1 Tin Plated Brass 092/125 1601677-1 Tin Plated Brass Tin Plated Brass Tin Plated Brass These part numbers are available upon special request; contact TE engineering for details. 64 www.te.com/appliances Magnet Wire Terminals and Termination Systems MTM Crimpband Splices (Continued) Catalog 82221 This product line is not recommended for new designs, as the application machines are no longer manufactured. 7 Serrations T W CMA Range 170-800 400-1100 400-1100 400-1100 400-1100 600-1300 600-1300 900-2600 900-2600 1600-4000 1600-4000 1600-4000 1800-4600 2200-5200 2600-6100 2600-6100 3000-6750 3000-6750 3000-6750 Stock Mat'l Thk. (T) Width (W) .012 .154 0.30 3.91 .012 .154 0.30 3.91 .012 .154 0.30 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .020 .154 0.51 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .020 .154 0.51 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .020 .154 0.51 3.91 .012 .154 0.30 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 Part Number Material Toolset Brass 032 Brass 032/036 1601539-1 Cu Ni 032/036 1601538-1 Descriptive X-ref 1601800-1 P0326R12BUF1 L032/ 0366R12B L032/ 0366R12AUF1 L032/ 0366R16B P032/ 0366R16TB Brass 032/036 1601540-1 Tin Plated Brass 032/036 1601793-1 Brass 045 1601559-1 L0456R16B Brass 045 1601560-1 L0456R20B Brass 061 1601604-1 L0616R16B Tin Plated Brass 061 1601606-1 L0616R16TB Brass 076 1601644-1 L0766R16B Tin Plated Brass 076 1601646-1 L0766R16TB Brass 076 1601647-1 L0766R20B Brass 076/092 1601637-1 L076/ 0926R16BX L0926R16TB Tin Plated Brass Tin Plated Brass 092 1601683-1 092/125 1601675-1 Brass 092/125 1601832-1 Brass 125 1601844-1 P1256R12B Brass 125 1601845-1 P1256R16B Tin Plated Brass 125 1601716-1 L1256R16TB L092/ 1256R16TB P092/ 1256R20B Crimpband AWG/ Wire Range mm2 Solid Dia. .013-.028 271 2-21 0.09-0.40 0.33-0.71 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 22-19 .024-.036 0.38-0.60 0.70-0.91 22-19 .024-.036 0.38-0.60 0.70-0.91 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 .042-.068 171 2-131 2 0.95-2.54 1.07-1.80 .047-.072 161 2-13 1.10-2.60 1.19-1.83 16-12 .051-.078 1.30-3.46 1.29-1.98 16-12 .051-.078 1.30-3.46 1.29-1.98 .055-.082 151 2-12 1.54-3.46 1.40-2.10 .055-.082 151 2-12 1.54-3.46 1.40-2.10 .055-.082 151 2-12 1.54-3.46 1.40-2.10 UF designates Ultra-Fine serrations which are recommended for applications using wire size 28 AWG [0.32 mm] or smaller. These part numbers are available upon special request; contact TE engineering for details. 1 65 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 This product line is not recommended for new designs, RTM Crimpband Splices as the application machines are no longer manufactured. Product Facts Made from a continuous coil of "Ribbon Connector" material RTM Crimpband have grooved serrations for improved axial retention. Available in brass, tin-plate d brass and copper-nickel alloy (CA725) materia l Make parallel or pigtail connections on same machine Used for electrical and nonelectrical connections. 100% of RTM Crimpband material is used in scrap free terminations Crimpband material coupled with appropriate toolsets accommodate specific CMA ranges Produced in TE equipment on your production floor Meets UL 486C crimp tensile requirements Applications Stranded and solid wire-towire connections Light bulb LED assembly Switch lead assembly Resistor lead assembly Printed circuit board lead assembly Flex-film lead assembly Glass reed switch lead assembly Cut Formed Crimped Mod I TE features the RTM Crimpband system that is comprised of two key features: the semiautomatic termination machine and a reel of RTM Crimpband material. In a one-step crimping operation, the machine feeds, cuts, forms and crimps the material to provide a low-cost, high reliability crimp connection. The RTM Crimpband splices are formed during the crimping process from Mod III milled longitudinal groove material that produce rolled, rounded serrations. They are designed to terminate pre-stripped stranded and solid wire conductors together as well as wire conductors to switch tabs, resistors, printed circuit board, flex circuit and light bulb LED and glass reed switch assemblies, etc. The flexibility of the RTM Crimpband system provides opportunity for use in custom applications for either electrical and / or mechanical connections. TE provides a wide range of toolset types and crimpband splices to meet various production requirements. Depending on your specific application, RTM Crimpband splices are available in 3, 6, 7, 8, 9, 10 14 and 20 ridge serration versions for terminations in the 170 to 13,000 CMA range. 66 www.te.com/appliances Magnet Wire Terminals and Termination Systems RTM Crimpband Splices (Continued) RTM Crimpband Interconnection System Catalog 82221 This product line is not recommended for new designs, as the application machines are no longer manufactured. Notes: To insure that the proper Crimpband splice is chosen, TE recommends the following: 1. Submit 10 samples of wire combinations and/or components to be crimped with any special requirements to your TE sales representative. 2. Pull-out force and/or millivolt drop tests will be performed to insure that the proper Crimpband material, toolset and crimp heights are recommended. 3. Tooling and testing will be documented on a Material & Tooling Sheet (M & T sheet). 4. Crimpband material quotes, tooling quotes and samples will be submitted to the customer. How the System Operates Feed (Ribbon Connector Material) Machine feeds strip until the strip hits the wire stop. Shear (Blank Length) The strip is cut by the cutter block former bar insert tooling. W Bend (Crimp Formed) The former bar drives the cut strip over the anvil, bending the cut strip into an upside down "U". Ridges T Section A-A A Wire (Placement) Pigtail and parallel (Thru) splice terminations are made on the same machine. A Crimp (Crimp Formed) The anvil retracts as the driver takes the formed strip down into the clincher. W B.L. Dim. Tooling Size 092 L L See Figure 1 and/or Legend below W Dim. T Dim. Connector Material Material Width Thickness F 20 TCRS 092 F 20 Crimpband Splice No. Example: Lead Wires Connector Specification Code Machine Basis Blank Length TCRS Legend Machine Basis L P Leased Purchase Tooling Size Code 032 032/036 036 045 051 061 061/076 076 076/092 092 092/125 125 125/160 125/165 165 Blank Length B/L (Nom.) .167 .228 .224 .246 .267 .292 .324 .339 .361 .379 .413 .446 .485 .506 .546 Note: For B/L above, .546 consult factory for tooling size code Connector Width Code B C D E F G H L M N P W Dim. .076 .138 .154 .185 .216 .234 .247 .086 .330 .500 .114 N No. of Ridges 3 6 7 8 9 10 10 3 14 20 5 Material Thickness Code 12 16 18 20 22 24 25 Material Code B A TB TCRS SS ST T.002 Dim. .012 .016 .018 .020 .022 .024 .025 Material/Finish UL486C Pull Out Wire Size Force Requirements AWG Underwriters Laboratory (lbs.) 26 3 24 5 22 8 20 10 18 10 16 15 14 25 12 35 10 40 CDA 260 Brass CDA 725 Copper/ Nickel Alloy Pre-Tin over CDA 260 Brass 1010 Cold Rolled Steel, Tin Plated 301 or 302 Stainless Steel Stainless Steel, Tin Plated 67 www.te.com/appliances Magnet Wire Terminals and Termination Systems RTM Crimpband Splices (Continued) Catalog 82221 This product line is not recommended for new designs, as the application machines are no longer manufactured. 20 Ridges T W AWG/ Wire Range CMA Stock Mat'l mm2 Solid Dia. Range Thk. (T) Width (W) Material .084-.114 7000-13000 .020 .500 Tin Plated 111 2-9 4.00-6.50 2.13-2.90 0.51 12.70 Brass Toolset 200/202 Part Number Descriptive X-ref 1601771-1 L200/202N20TB 14 Ridges T W AWG/ Wire Range CMA mm2 Solid Dia. Range 22-19 .024-.036 600-1300 0.38-0.60 0.61-0.91 22-19 .024-.036 600-1300 0.38-0.60 0.61-0.91 Stock Mat'l Thk. (T) Width (W) .012 .330 0.30 8.38 .012 .330 0.30 8.38 Material Toolset Part Number Descriptive X-ref Cu Ni 045 1601577-1 L045M12A Brass 045 1601578-1 L045M12B These part numbers are available upon special request; contact TE engineering for details. 10 Ridges T W AWG/ Wire Range mm2 Solid Dia. 22-19 .024-.036 0.38-0.60 0.61-0.91 21-181 2 .028-.039 0.40-0.75 0.71-0.99 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .084-.114 111 2-9 4.00-6.50 2.13-2.90 .084-.114 111 2-9 4.00-6.50 2.13-2.90 CMA Range Stock Mat'l Thk. (T) Width (W) .012 .234 600-1300 0.30 5.94 .016 .234 800-1500 0.41 5.94 .012 .234 900-2600 0.30 5.94 .020 .234 900-2600 0.51 5.94 .020 .234 7000-13000 0 .51 5.94 .025 .234 7000-13000 0.64 5.94 Material Toolset Part Number Descriptive X-ref Brass 045 1601575-1 L045G12B Cu Ni 051 1601593-1 L051G16A Brass 061 1601632-1 L061G12B Brass 061 1601633-1 L061G20B Brass 200/202 1601853-1 Brass 200/202 1601769-1 P200/ 202G20B L200/ 202G25BX These part numbers are available upon special request; contact TE engineering for details. 68 www.te.com/appliances Magnet Wire Terminals and Termination Systems RTM Crimpband Splices (Continued) Catalog 82221 This product line is not recommended for new designs, as the application machines are no longer manufactured. 9 Ridges T W AWG/ Wire Range CMA mm2 Solid Dia. Range 22-19 .024-.036 600-1300 0.38-0.60 0.61-0.91 .030-.051 201 2-16 900-2600 0.45-1.30 0.76-1.29 Stock Mat'l Thk. (T) Width (W) .012 .216 0.30 5.49 .012 .216 0.30 5.49 Material Stainless Steel Stainless Steel Toolset Part Number Descriptive X-ref 045 1601807-1 P045F12SS 061 1601520-1 G061F12SS Toolset Part Number 032/036 1601553-1 Descriptive X-ref L032/ 036E12A 8 Ridges T W AWG/ Wire Range CMA Stock Mat'l mm2 Solid Dia. Range Thk. (T) Width (W) Material 24-20 .020-.033 .012 .185 400-1100 Cu Ni 0.20-0.50 0.51-0.84 0.30 4.70 18-14 .040-.063 1600-4000 .018 .185 Tin Plated 0.80-2.00 1.02-1.60 0.46 4.70 CRS 111 2-9 .084-.114 7000-13000 .024 .185 Brass 4.00-6.50 2.13-2.90 0.61 4.70 076 1601669-1 L076E18TCRS L200/ 202E24B 1601768-1 Toolset Part Number 032/036 1601550-1 032/036 1601551-1 032/036 1601797-1 032/036 1601798-1 Descriptive X-ref L032/ 036D12B L032/ 036D16A P032/ 036D16B P032/ 036D16TB 045 1601572-1 L045D12B 045 1601573-1 L045D16A Crimpband 200/202 7 Ridges T W AWG/ Wire Range mm2 Solid Dia. 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 22-19 .024-.036 0.38-0.60 0.61-0.91 22-19 .024-.036 0.38-0.60 0.61-0.91 CMA Range 400-1100 400-1100 400-1100 400-1100 600-1300 600-1300 Stock Mat'l Material Thk. (T) Width (W) .012 .154 Brass 0.30 3.91 .016 .154 Cu Ni 0.41 3.91 .016 .154 Brass 0.41 3.91 .016 .154 Tin Plated 0.41 3.91 Brass .012 .154 Brass 0.30 3.91 .016 .154 Cu Ni 0.41 3.91 69 www.te.com/appliances Magnet Wire Terminals and Termination Systems RTM Crimpband Splices (Continued) 7 Ridges Catalog 82221 This product line is not recommended for new designs, as the application machines are no longer manufactured. (Continued) T W AWG/ Wire Range mm2 Solid Dia. 22-19 .024-.036 0.38-0.60 0.61-0.91 .028-.039 21-181 2 0.40-0.75 0.71-0.99 .028-.039 21-181 2 0.40-0.75 0.71-0.99 .028-.039 21-181 2 0.40-0.75 0.71-0.99 .028-.039 21-181 2 0.40-0.75 0.71-0.99 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 20-15 .033-.057 0.60-1.60 0.84-1.45 .035-.061 191 2-141 2 0.60-1.80 0.89-1.54 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 CMA Range 600-1300 800-1500 800-1500 800-1500 800-1500 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 1100-3200 1200-3700 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 Stock Mat'l Part Toolset Thk. (T) Width (W) Material Number .016 .154 Brass 045 1601507-1 0.41 3.91 .012 .154 Brass 051 1601587-1 0.30 3.91 .016 .154 Brass 051 1601588-1 0.41 3.91 .020 .154 Nickel Plated 051 1601591-1 0.51 3.91 Steel .020 .154 Tin Plated 051 1601811-1 0.51 3.91 CRS .012 .154 Cu Ni 061 1601818-1 0.30 3.91 .012 .154 Brass 061 1601620-1 0.30 3.91 .012 .154 Tin Plated 061 1601514-1 0.30 3.91 Brass .016 .154 Cu Ni 061 1601819-1 0.41 3.91 .016 .154 Brass 061 1601820-1 0.41 3.91 .016 .154 Tin Plated 061 1601623-1 0.41 3.91 Brass .018 .154 Brass 061 1601625-1 0.46 3.91 .018 .154 Tin Plated 061 1601628-1 0.46 3.91 Brass .020 .154 Cu Ni 061 1601629-1 0.51 3.91 .020 .154 Brass 061 1601630-1 0.51 3.91 .020 .154 Tin Plated 061 1601631-1 0.51 3.91 Brass .016 .154 Brass 061/076 1601601-1 0.41 3.91 .016 .154 Brass 061/092 1601603-1 0.41 3.91 .012 .154 Cu Ni 076 1601828-1 0.30 3.91 .012 .154 Brass 076 1601655-1 0.30 3.91 .016 .154 Cu Ni 076 1601656-1 0.41 3.91 .016 .154 Brass 076 1601829-1 0.41 3.91 .016 .154 Tin Plated 076 1601658-1 0.41 3.91 Brass .018 .154 Cu Ni 076 1601660-1 0.46 3.91 .018 .154 Brass 076 1601661-1 0.46 3.91 .018 .154 Tin Plated 076 1601664-1 0.46 3.91 Brass .020 .154 Brass 076 1601665-1 0.51 3.91 .020 .154 076 1601667-1 0.51 3.91 .024 .154 Brass 076 1601668-1 0.61 3.91 Descriptive X-ref G045D16B L051D12B L051D16B L051D20NPS P051D20TCRS P061D12A L061D12B G061D12TB P061D16A P061D16B L061D16TB L061D18B L061D18TB L061D20A L061D20B L061D20TBX L061/076D16B L061/092D16B P076D12A L076D12B L076D16A P076D16B L076D16TB L076D18AX L076D18B L076D18TB L076D20B L076D20TCRS L076D24B These part numbers are available upon special request; contact TE engineering for details. 70 www.te.com/appliances Magnet Wire Terminals and Termination Systems RTM Crimpband Splices (Continued) 7 Ridges Catalog 82221 This product line is not recommended for new designs, as the application machines are no longer manufactured. (Continued) T W CMA Range 1800-4600 2200-5200 2200-5200 2200-5200 2200-5200 2200-5200 2200-5200 2200-5200 2600-6100 2600-6100 2600-6100 3000-6750 3000-6750 3000-6750 3000-6750 3000-6750 3000-6750 3000-6750 3500-7500 3500-7500 3500-7500 3500-7500 4000-8500 4000-8500 4500-9500 7000-13000 7000-13000 7000-13000 7000-13000 Stock Mat'l Thk. (T) Width (W) .016 .154 0.41 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .016 .154 0.41 3.91 .018 .154 0.46 3.91 .018 .154 0.46 3.91 .018 .154 0.46 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .016 .154 0.41 3.91 .018 .154 0.46 3.91 .018 .154 0.46 3.91 .018 .154 0.46 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .018 .154 0.46 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .016 .154 0.41 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 .020 .154 0.51 3.91 Material Toolset Part Number Brass 076/092 1601642-1 Descriptive X-ref L076/ 092D16BX Cu Ni 092 1601689-1 L092D16ASP Brass 092 1601691-1 L092D16B Tin Plated Brass 092 1601693-1 L092D16TB Cu Ni 092 1601694-1 L092D18A Brass 092 1601695-1 L092D18B Tin Plated Brass 092 1601841-1 P092D18TB Brass 092 1601528-1 G092D20B Cu Ni 092/125 1601680-1 Brass 092/125 1601681-1 Tin Plated CRS 092/125 1601682-1 L092/ 125D20A L092/ 125D20B 092/ 125D20TCRS Brass 125 1601529-1 G125D16B Cu Ni 125 1601531-1 G125D18A Brass 125 1601726-1 L125D18B Tin Plated Brass 125 1601729-1 L125D18TBX Brass 125 1601730-1 L125D20B Tin Plated Brass 125 1601731-1 L125D20TB 125 1601733-1 L125D20TCRS Tin Plated Brass 125/165 1601709-1 Brass 125/165 1601711-1 Tin Plated Brass 125/165 1601712-1 L125/ 165D18TB L125/ 165D20A L125/ 165D20B L125/ 165D20TB Cu Ni 125/165 1601710-1 Cu Ni 165 1601754-1 L165D20A Brass 165 1601755-1 L165D20B Brass 165/200 1601532-1 Brass 200/202 1601764-1 Cu Ni 200/202 1601765-1 Brass 200/202 1601852-1 Tin Plated Brass 200/202 1601766-1 Crimpband AWG/ Wire Range mm2 Solid Dia. 171 2-13 .042-.068 0.95-2.54 1.07-1.80 .047-.072 161 2-13 1.10-2.60 1.19-1.83 .047-.072 161 2-13 1.10-2.60 1.19-1.83 .047-.072 161 2-13 1.10-2.60 1.19-1.83 161 2-13 .047-.072 1.10-2.60 1.19-1.83 .047-.072 161 2-13 1.10-2.60 1.19-1.83 .047-.072 161 2-13 1.10-2.60 1.19-1.83 .047-.072 161 2-13 1.10-2.60 1.19-1.83 16-12 .051-.078 1.30-3.46 1.29-1.98 16-12 .051-.078 1.30-3.46 1.29-1.98 16-12 .051-.078 1.30-3.46 1.29-1.98 .055-.082 151 2-12 1.54-3.46 1.40-2.10 .055-.082 151 2-12 1.54-3.46 1.40-2.10 .055-.082 151 2-12 1.54-3.46 1.40-2.10 .055-.082 151 2-12 1.54-3.46 1.40-2.10 .055-.082 151 2-12 1.54-3.46 1.40-2.10 .055-.082 151 2-12 1.54-3.46 1.40-2.10 .055-.082 151 2-12 1.54-3.46 1.40-2.10 .059-.087 141 2-111 2 1.80-4.00 1.50-2.21 .059-.087 141 2-111 2 1.80-4.00 1.50-2.21 .059-.087 141 2-111 2 1.80-4.00 1.50-2.21 .059-.087 141 2-111 2 1.80-4.00 1.50-2.21 14-11 .063-.092 2.00-4.20 1.60-2.34 14-11 .063-.092 2.00-4.20 1.60-2.34 131 2-101 2 .071-.097 2.54-4.50 1.70-2.46 .084-.114 111 2-9 4.00-6.50 2.13-2.90 .084-.114 111 2-9 4.00-6.50 2.13-2.90 .084-.114 111 2-9 4.00-6.50 2.13-2.90 .084-.114 111 2-9 4.00-6.50 2.13-2.90 G165/ 200D20B L200/ 202D16B L200/ 202D20A P200/ 202D20B L200/ 202D20TB These part numbers are available upon special request; contact TE engineering for details. 71 www.te.com/appliances Magnet Wire Terminals and Termination Systems RTM Crimpband Splices (Continued) Catalog 82221 This product line is not recommended for new designs, as the application machines are no longer manufactured. 6 Ridges T W AWG/ Wire Range mm2 Solid Dia. 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 22-19 .024-.036 0.38-0.60 0.61-0.91 22-19 .024-.036 0.38-0.60 0.61-0.91 22-19 .024-.036 0.38-0.60 0.61-0.91 .028-.039 21-181 2 0.40-0.75 0.71-0.99 .028-.039 21-181 2 0.40-0.75 0.71-0.99 .028-.039 21-181 2 0.40-0.75 0.71-0.99 .028-.039 21-181 2 0.40-0.75 0.71-0.99 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 20-15 .033-.057 0.60-1.60 0.84-1.45 20-15 .033-.057 0.60-1.60 0.84-1.45 20-15 .033-.057 0.60-1.60 0.84-1.45 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 .042-.068 171 2-13 0.95-2.54 1.07-1.80 .047-.072 161 2-13 1.10-2.60 1.19-1.83 161 2-13 .047-.072 1.10-2.60 1.19-1.83 .055-.082 151 2-12 1.54-3.46 1.40-2.10 .055-.082 151 2-12 1.54-3.46 1.40-2.10 .055-.082 151 2-12 1.54-3.46 1.40-2.10 CMA Range 400-1100 400-1100 600-1300 600-1300 600-1300 800-1500 800-1500 800-1500 800-1500 900-2600 900-2600 900-2600 900-2600 900-2600 900-2600 1100-3200 1100-3200 1100-3200 1600-4000 1600-4000 1600-4000 1600-4000 1600-4000 1800-4600 2200-5200 2200-5200 3000-6750 3000-6750 3000-6750 Stock Mat'l Thk. (T) Width (W) .012 .138 0.30 3.51 .016 .138 0.41 3.51 .012 .138 0.30 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .012 .138 0.30 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .018 .138 0.46 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .018 .138 0.46 3.51 .018 .138 0.46 3.51 .020 .138 0.51 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .018 .138 0.46 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .018 .138 0.46 3.51 .018 .138 0.46 3.51 .018 .138 0.46 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .016 .138 0.41 3.51 .018 .138 0.46 3.51 .018 .138 0.46 3.51 Material Toolset Part Number Tin Plated Brass 032/036 1601548-1 Brass 032/036 1601549-1 Descriptive X-ref L032/ 036C12TB L032/ 036C16B Brass 045 1601566-1 L045C12B Cu Ni 045 1601569-1 L045C16A Brass 045 1601571-1 L045C16B Brass 051 1601808-1 P051C12B Cu Ni 051 1601809-1 P051C16A Brass 051 1601810-1 P051C16B Brass 051 1601586-1 L051C18B Cu Ni 061 1601614-1 L061C16A Brass 061 1601511-1 G061C16B Tin Plated Brass 061 1601617-1 L061C16TB Cu Ni 061 1601618-1 L061C18AX Brass 061 1601619-1 L061C18B Brass 061 1601513-1 G061C20B Brass 061/076 1601597-1 Tin Plated Brass 061/076 1601599-1 Brass 061/076 1601600-1 L061/ 076C16B L061/ 076C16TB L061/ 076C18B Cu Ni 076 1601650-1 L076C16A Brass 076 1601651-1 L076C16B Cu Ni 076 1601652-1 L076C18A Brass 076 1601827-1 P076C18B 076 1601654-1 L076C18TCRS Brass 076/092 1601640-1 L076/ 092C16B Cu Ni 092 1601837-1 P092C16AX Brass 092 1601687-1 L092C16B Tin Plated Brass 125 1601721-1 L125C16TB Cu Ni 125 1601722-1 L125C18A Brass 125 1601723-1 L125C18B These part numbers are available upon special request; contact TE engineering for details. 72 www.te.com/appliances Magnet Wire Terminals and Termination Systems RTM Crimpband Splices (Continued) Catalog 82221 This product line is not recommended for new designs, as the application machines are no longer manufactured. 3 Ridges T W CMA Range Stock Mat'l Thk. (T) Width (W) .012 .076 170-800 0.30 1.93 .012 .076 400-1100 0.30 1.93 .012 .076 400-1100 0.30 1.93 .016 .076 400-1100 0.41 1.93 .016 .076 400-1100 0.41 1.93 .018 .076 400-1100 0.46 1.93 .016 .076 600-1300 0.41 1.93 .016 .076 600-1300 0.41 1.93 .016 .076 600-1300 0.41 1.93 .016 .076 600-1300 0.41 1.93 .016 .076 800-1500 0.41 1.93 .016 .076 800-1500 0.41 1.93 .016 .076 800-1500 0.41 1.93 .020 .076 800-1500 0.51 1.93 .016 .076 900-2600 0.41 1.93 .016 .076 900-2600 0.41 1.93 .016 .076 900-2600 0.41 1.93 .016 .076 900-2600 0.41 1.93 .016 .076 1100-3200 0.41 1.93 .016 .076 1600-4000 0.41 1.93 .020 .076 1600-4000 0.51 1.93 Material Toolset Part Number Descriptive X-ref Brass 032 1601555-1 L032B12B Cu Ni 032/036 1601542-1 Brass 032/036 1601795-1 Brass 032/036 1601545-1 Tin Plated Brass 032/036 1601546-1 Brass 032/036 1601547-1 L032/ 036B12A P032/ 036B12B L032/ 036B16B L032/ 036B16TB L032/ 036B18B Cu Ni 045 1601503-1 G045B16A Brass 045 1601562-1 L045B16B 045 1601504-1 G045B16TB 045 1601564-1 L045B16TBSP Cu Ni 051 1601580-1 L051B16A Brass 051 1601582-1 L051B16B Tin Plated Brass 045 1601583-1 L051B16TB Tin Plated Brass Tin Plated Brass Brass 051 1601584-1 L051B20B Tin Plated Brass 061 1601612-1 L061B16TB Cu Ni 061 1601610-1 L061B16A Brass 061 1601611-1 L061B16B Brass 061 1601635-1 L061L16B Tin Plated Brass 061/076 1601596-1 L061/ 076B16TBX Brass 076 1601825-1 P076B16B Brass 076 1601649-1 L076B20B Crimpband AWG/ Wire Range mm2 Solid Dia. .013-.028 271 2-21 0.09-0.40 0.33-0.71 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 24-20 .020-.033 0.20-0.50 0.51-0.84 22-19 .024-.036 0.38-0.60 0.61-0.91 22-19 .024-.036 0.38-0.60 0.61-0.91 22-19 .024-.036 0.38-0.60 0.61-0.91 22-19 .024-.036 0.38-0.60 0.61-0.91 .028-.039 21-181 2 0.40-0.75 0.71-0.99 .028-.039 21-181 2 0.40-0.75 0.71-0.99 .028-.039 21-181 2 0.40-0.75 0.71-0.99 .028-.039 21-181 2 0.40-0.75 0.71-0.99 .030-.051 201 2-16 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 201 2-16 .030-.051 0.45-1.30 0.76-1.29 .030-.051 201 2-16 0.45-1.30 0.76-1.29 20-15 .033-.057 0.60-1.60 0.84-1.45 18-14 .040-.063 0.80-2.00 1.02-1.60 18-14 .040-.063 0.80-2.00 1.02-1.60 These part numbers are available upon special request; contact TE engineering for details. 73 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Power Splice Product Facts Compression crimp eliminates cold solder points, weld burns and wire enbrittlement usually connected with thermal-type terminations Precisely controlled crimp termination helps eliminate human error, for maximum reliability Excellent tensile strength, up to 90 lbs axial retention, vibration resistant Provides a superior electrical connection that is free of many contaminates such as stripper residue and solder flux 8000 - 38,000 CMA nominal capacity Accepts up to six magnet wires and two standard solid or stranded lead wires Superior test results: low resistance, high stability High termination rates, low wire consumption and the elimination of rejects caused by solder flux or heat damage results in the lowest applied costs Applications Hermetic/Compressor motors Squirrel cage DC motors Capacitor start motors Gear & Traction motors Power supplies Liner, Torroid & RF transformers Circuit breakers & welders TE features the Power Splice terminal that is specifically designed to terminate a wide range of lead and magnet wire combinations. The splice contains two cavities that separate and cradle magnet wire and stripped lead wires prior to crimping. The outer saddle accepts up to six-magnet wire allowing for a CMA range of 15,000 to 30,000. The inner saddle accepts pre-stripped lead wires that total up to 10,900 CMA. In a one step automatic operation, the magnet wire film insulation is multiple ring-stripped as it is forced into the serrations while the lead wire is simultaneously terminated during the precisely controlled crimp. The outer saddle has machined, sharp edges made by a special production process that pierces the insulating layer of the magnet wire in a manner that provides a large contact area. The resulting termination produces a high tensile strength, air sealed connection that is as resistant to corrosion as the insulated conductor with up to 90 lbs axial retention. As many as six magnet wires can be terminated simultaneously in one splice in combination with up to two pre-stripped standard solid or stranded lead wire. A semi-automatic machine provides high output per hour terminations. 74 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Power Splice (Continued) .425 [10.80] .375 [9.53] .408 [10.36] Type A 1 Magnet Wire Range CMA 15,000-30,000 Lead Wire Range CMA 4200-10,900 Part Number Reeled 1601953-11 Total combined CMA not to exceed 38000. Magnet wire insulation piercing serrations Inner saddle for lead wire (CMA 4,200-10,900) Magnet wires smaller than #18 AWG (1.0 mm) are placed here Outer saddle accepts up to 6 magnet wires (CMA 15,000-30,000) #20 AWG minimum .118 [3.00] .430 .010 [10.92 0.25] Power Splice R .060 [1.52] .430 Max. [10.92] Cut-off .408 [10.36] Direction of Feed .385 [9.78] .296 [7.52] R .024 [0.61] Part Number 111-000-001 75 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Application Tooling Worldwide Leadership in Wire and PCB Manufacturing Products Leadership demands commitment and TE is committed to meeting manufacturing needs worldwide with technology, products and systems, and service. Application Tooling of TE Connectivity TE has long been recognized as a leader in providing the tools for wire harness and printed circuit manufacturing. There's a good reason. Our products are designed to meet and anticipate our customers' ever-changing requirements and built to the highest quality standards, for longest, most productive performance lifetimes. Whatever your production volume and job mix, we can the tools to get it done. With a full range of tooling from hand tools to high volume, fully automated systems, TE is able to meet most manufacturing demands worldwide. It's an ability that comes from our experience with manufacturers large and small, giving us a unique view of the trends and challenges in wire harness and PCB manufacturing. It all derives from our commitment to your manufacturing challenges, giving you the advantage in your marketplace. This catalog is just a sampling of the types of solutions that will make your job easier, faster, more productive and more profitable. Make tooling, assembly equipment, and service from TE part of your thinking, now and as you grow into the future. TE Connectivity Service and Support Few suppliers can match TE customer service and support. From helping you select the tooling for your requirements to maintenance and repair and analyzing your operation for maximum productivity, our worldwide capabilities in your production and bottom line. and experience will make a real For more information regarding the products and services shown in this brochure, visit our website at www.tooling.te.com ProductionChek Service -- In a consultative role, our field engineer will meet with you to determine your objectives and known production issues, then observe and record in detail each step in your operation. Based on this information, the engineer will be able to make recommendations for improvement, typically in people, process or equipment. Tool Repair and Certification -- Our field engineers will set up, certify, and repair application tooling on site or recommend our factory-level service. Flexible plans, including options for premium access to parts and service, will keep your PCB assembly automation equipment running at peak performance. For additional maintenance services, the TE Technical Support Center is dedicated to providing the answers you need, toll-free at 1-800-522-6752. Support contracts are available for preventive maintenance, training, emergency situations and other specific requirements. 76 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Application Tooling Magnet Wire Crimp Application Equipment MAG-MATE and AMPLIVAR splices and terminals are available in a wide range of configurations to meet most magnet-wire termination needs. All provide high reliability with minimal wire preparation. TE Connectivity a wide variety of magnet-wire termination solutions for thru splicing, pigtail splicing and coil termination. AMPLIVAR Product Terminator (APT) Machines The new APT 5A magnet wire pigtail splice machine a fast, system, with no need to strip mag-wire insulation. Simply place the wires in the target area and depress the foot switch. The machine automatically shears the splice or Direct Connect contact from the strip, crimps it, shears excess wire, and advances the next splice or contact into position. APT bench machines are available in two versions: the 5A with automatic precision adjustment controlled by the crimp quality monitor (CQM) and the 5E with manual precision adjustment. Using CQM, the APT 5A provides 100% inspection and automatic adjustment of crimp height. If a questionable crimp is detected, visual and audible alarms alert the operator. The lower cost, manual adjust APT 5E is a simpler version with the advantage of faster set-up times but without CQM capability. Power Splice Machine Not CE approved, contact engineering for quotation. The Power Splice Machine and applicator from TE provides reliable pigtail splice termination of magnet wire and solid or stranded lead wire. This machine can terminate pigtail splices consisting of up to two solid or stranded copper lead wires in wire size from 10-14 AWG and having a Circular Mil Area (CMA) of 4,100 - 11,000. The splice will simultaneously accept combinations of multiple copper magnet wires in a range of 11-20 AWG. The total CMA range for lead wire and magnet wire is 4,000 to 40,000. Application Tooling 77 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Application Tooling Magnet Wire Crimp Application Equipment AMPLIVAR Terminator for Parallel and End Connections Primarily sold in Europe. The machine was developed for processing magnet wire connections. versions for end-feed and side-feed contacts are available. The design takes into account that the motor windings and coils can be supplied directly to the connectors. The exposed crimp position permits precise handling. In case of end connections the projecting magnet wires are cut AMPLIVAR splices and terminals are specifically designed to terminate magnet wires or in combination with standard solid or stranded wire. In a one-step operation the magnet wire is automatically multiple ring stripped of its insulation as it is forced into the serrations during the precisely controlled crimping operation. As many as three magnet wires can be terminated, simultaneously in one splice. Nearly the entire AMPLIVAR splice program can be applied with this machine in combination with suitable applicators. The comprehensive range of manufacturing possibilities demands a specific machine and applicator combination. AMP-O-LECTRIC Model G Terminator with Thru-Splice Applicator Not CE Approved. Applying thru-splices is fast and when you have access to both sides of the applicator for placing and holding the wires. The AMP-O-LECTRIC model G splice terminator with a standard G splice applicator provides front and rear access to maximize production cy. It provides full guarding for operator safety and is available with or without a Crimp Quality Monitor. Request catalog 889021 for more information. 78 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Application Tooling Magnet Wire Crimp Application Equipment Crimpband application machines have been discontinued and are no longer offered by TE. Crimpband Application Tooling Not CE approved, contact engineering for quotation. solderless crimping systems to handle a wide range of wire TE connections including solid and stranded lead wire, insulated magnet wire, and component leads. Each system is comprised of continuous, serrated Crimpband material and a crimping machine. The TE solution allows the flexibility to create a shape and size, which optimizes the crimp's electrical and mechanical performance. The TE crimping system produces a very economical and reliable interconnection. Utilizing a continuous crimpband material the machine will feed, cut form, and crimp your application resulting in a very strong and uniform interconnect crimp. Whether your application required a wire-to-wire, wire to components leads, wire to terminals, or magnet wire splice termination, the very flexible and dependable crimping machine will provide high-speed scrap free interconnects. Substantial increase in production interconnection rates can be realized versus traditional soldering. Not to mention it completely eliminates the noxious fumes. The mod I crimping system is used when running standard RTM and MTM crimpband product. In addition, left and right horn termination machines are available when your application requires additional working envelope. Application Tooling www.te.com/appliances 79 Magnet Wire Terminals and Termination Systems Catalog 82221 Application Tooling Magnet Wire MAG-MATE Terminal Application Equipment MPT-5 MAG-MATE Product Terminator Not CE approved, refer to Mark I, Mark II pages 83, 84. The MPT-5 is an air-operated machine with microprocessor control that inserts MAG-MATE terminals into customer-designed cavities in the coil bobbin or similar magnet-wire housing, terminating the wire for connectivity. Please note: The customer designed cavities must follow TE specification guidelines. Termination of single, dual, triple and up to quadruple termination possible depending on the application details. The machine is available in either vertical or horizontal configuration to match the customer's application. The dual reel capability of the MPT-5 machine allows inserMAG-MATE terminals, with the capability to tion of two alternate between inserting one and two terminals at a time. The MPT-5 is also capable of trimming excess magnet wire. The MPT-5 Terminator also has the capability to alternate between inserting 2 bridged (or commoned) terminals and 2 separated terminals. Request catalog 1308387 for more information. MAG-MATE Terminal Cavity and Fixture Design MAG-MATE terminals insert into a molded-in cavity in the coil bobbin. The bobbin is generally secured in a fixture during the insertion/termination process. TE engineers work with our customers to support cavity and fixture design, at any level. We can provide complete design of cavities and fixtures for customer's applications, work with our customer's engineers, or simply provide CAD models and other engineering data as needed. Consultation early in the design process allows customers maximum benefit from our decades of magnet-wire experience. Product Line Integration The MPT-5 and APT IIIA Machines have the production capacity and the electronics for easy integration into automated production lines. TE Engineers work with your system integrators to assure the of TE equipment into the line's design and assembly. 80 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Application Tooling Magnet Wire MAG-MATE Terminal Application Equipment MPT-5 S/L Machine (for SIAMEZE and Lead Lok Terminals) Not CE approved, refer to Mark I, Mark II pages 83, 84. For quick, easy and reliable termination of magnet wire, TE the MPT-5 S/L MAG-MATE product terminator -- an air-operated insertion machine with microprocessor control. The MPT-5 S/L machine inserts a SIAMEZE terminal into a customer-designed cavity in the coil bobbin or similar mag-wire housing, terminating the wire for connectivity. Please note: The customer designed cavities must follow TE specification guidelines. It can insert both the SIAMEZE terminal and the Lead Lok terminal to assure your lead wire connection. The MPT-5 S/L dual reel capability and is also capable of trimming excess magnet wire. The dual reel capability of the MPT-5 S/L allows insertion of SIAMEZE terminals, with the capability to alternate between inserting one two and two terminals at a time. The MPT-5 S/L machine is available as a horizontal or vertical bench machine or as a discrete module for integration into automated lines. MPT-5 S/L EMT -- Entry Level Magnet Wire Terminator (for loose piece SIAMEZE, Lead Lok, or MAG-MATE Terminals) Not CE approved, contact engineering for quotation. The Entry Level Magnet Wire Terminator tube design is based on the proven MPT-5 system and incorporates a fine adjust mechanism for easy set-up. The floating tube bottoms on the top of the terminal cavity to create the datum for the insertion depth of the terminal. The insertion depth can be adjusted in .002" [.05 mm] increments quickly and easily. An unobstructed view of the tube bottom permits the operator to easily load loose piece terminals. A two-handed actuation system protects the operators during the insertion process and the open architecture design allows operators to easily load and unload the stators on and o the fixture. Entry Level Terminator Application Tooling 81 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Application Tooling Magnet Wire MAG-MATE Terminal Application Equipment Manual Hand Tool (for loose piece SIAMEZE, Lead Lok, or MAG-MATE Terminals) * Inserts loose piece terminals into molded cavities * Insertion depth is repeatable due to the hand tools design which requires the operator to fully compress the handle before it is allowed to retract * Since tooling captures the cavities during insertion, no fixturing is needed * Hand tools are available quickly for prototyping, repair, and/or low volume applications ** The manual hand tool is not compatible with every application. Please contact TE Connectivity for more information. Manual Hand Tool Manual Arbor Press (for loose piece SIAMEZE, Lead Lok, or MAG-MATE Terminals) * Inserts loose piece terminals into molded cavities * One tip is capable of inserting the SIAMEZE wire-to-wire terminal, the lead wire and the Lead Lok terminal * Insertion tip bottoms on the top of the cavity to provide repeatable insertion depth capability * Customers often supply their own fixtures for prototyping or low volume requirements * Tips, arbor presses, and CERTI-LOK hand tools are available quickly for prototyping applications requirements Manual Arbor Press Hand Insertion Tools * Inserts loose piece terminals into molded cavities * Available quickly for prototyping application requirements * Available for each type of MAG-MATE terminal Full Line of Crimp Tooling Insertion Tools * TE a full line of hand tools, bench equipment, and automatic machines to perform the wire crimps for the mating end of these MAG-MATE connections. CERTI-LOK Tools 82 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Application Tooling Magnet Wire MAG-MATE Terminal Application Equipment MAG-MATE Inserter MK I with Pneumatic Control, Primarily sold in Europe. * Single, dual, triple and quadruple insertion * Module easily integrated into production lines using simple handshake signals * Holding fixture for bobbin can be designed and built by TE * Can apply standard MAG-MATE and SIAMEZE terminals * Load-while-running feature increases productivity * Cycle time: 0.9 - 1.3 s depending on terminal type * Mechanical insertion force limiter optional MK I Inserter MAG-MATE Inserter MK I with Electro Pneumatic Control (PLC), Primarily sold in Europe. * * * * Single contact Double contacts with or without bridge 2 single contacts alternately with 2 bridged contacts Module is easily integrated into customer's production line using simple handshake signals * Terminations up to 4 terminals at a time as single or linked type * Mechanical insertion force limiter optional MAG-MATE and SIAMEZE Inserter Mark II with PLC, Primarily sold in Europe. TE magnet wire terminations are a perfect connecting alternative to all soldering techniques used in a lead-free environment. Special knowledge is required to design a mass manufacturing line for insulation displacement crimps on thin lacquerd insulated wires with high yield. Design aspects of the terminal, the cavity and the machine all need to be harmonized. With the Inserter Mark II, TE an economic solution especially for the application of can MAG-MATE and SIAMEZE terminals. Mark II Inserter with PLC Application Tooling 83 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Application Tooling Magnet Wire MAG-MATE Terminal Application Equipment MAG-MATE and SIAMEZE Inserter Mark II with PLC and Insertion Force Control, Primarily sold in Europe. This advanced insertion machine provides the features of the MAG-MATE inserter Mark II with an additional force distance control system. The machine is designed to apply multiple contacts and will be customized according to the customer or product specific requirement. The contacts can be used as single contacts or in strip form (bridge function adjusted "on-the-fly"). A gauge is available to check the adjusted insertion force and to recalibrate the insertion force control sensor. Request catalog 7-1773440-4 for more information. Mark II Inserter with PLC and Insertion Force Control Pneumatic Insertion Tool for MAG-MATE Terminals, Primarily sold in Europe. The pneumatic tool for MAG-MATE terminals features a rotary insertion angles. insertion finger to faciliate This tool is designed for use in TE standard insertion machines such as P200 and P300 but can also be integrated into customized production lines or assembly cells. Pneumatic Insertion Tool 84 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Application Tooling Magnet Wire MAG-MATE Terminal Application Equipment Customer Specific Machines This unique machine was developed to process all IDC terminals regardless of shape and configuration. The insertion head module is capable of inserting individual or multiple terminals and can be configured for dual feed, left and right hand supply reels. The servo-driven NC-Axis facilitates precisely controlled insertion with programmable ramp profile. If required, a servo driven torque motor will locate the stator/bobbin to programmable positions. during the insertion cycle Excess magnet wire and wrap post are and removed via a ventury. The cutting punches are cam actuated via our patented linear slide module. The machine is designed and built for easy maintenance. Spare parts (punches, insertion blades, trim blades, die plate inset) are easy to access and replace. Custom Built IDC Terminal Insertion Head The insertion head module is designed to be integrated into a rotary index or linear transfer line. The IDC terminal insertion can be in vertical or horizontal plane. The terminal strip feeds from the right and/or from the left, if necessary with 2 terminal configurations. Wrap posts and excess magnet wire can be removed via a trim blade. Insertion force monitoring is available as an option. Cam driven linear slide module for punch actuation. The insertion head module is custom built according to your requirements. Request catalog 7-1773440-4 for more information. Application Tooling Horizontal Design Vertical Design 85 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Technical Information Tensile Strength of Magnet Wire1 Wire Size 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 1 Nominal Nominal Dia. Dia. Copper Aluminum (lbs.) (lbs.) 438 142 340 113 269 89 213 71 189 56 134 44 106 35 84 28 66 22 53 17 42 14 33 11 6 8 21 7 16 5 13 4 10 3 8 2.7 6 2.1 5 1.7 4 1.3 3 1.1 2 .86 2 .68 1 .55 1 .43 1 .34 .81 .27 .65 .21 .65 .21 .42 .13 .32 .10 .25 .083 .20 .067 .16 .054 .12 .041 .10 .034 .08 .027 .06 .022 .05 .017 .04 .013 .03 .010 .02 .009 .02 .007 .01 .005 C. -80 -70 -60 -50 -45 -40 -35 -30 -25 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -09 -08 -07 -06 -05 -04 -03 -02 -01 0 1 2 4 5 6 7 8 F. -112.0 -94.0 -76.0 -58.0 -49.1 -40.0 -31.0 -22.0 -13.0 -04.0 -02.2 -00.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 8.4 30.2 32.0 33.8 35.6 39.2 41.0 42.8 44.6 46.4 C. 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 42 43 44 45 46 F. 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 107.6 109.4 111.2 113.0 114.8 C. 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 80 81 82 83 84 F. 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 176.0 177.8 179.6 181.4 183.2 C. 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 110 120 130 140 150 160 170 180 190 200 220 240 260 280 300 400 600 700 800 900 1000 F. 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 230.0 248.0 266.0 284.0 302.0 320.0 338.0 356.0 374.0 392.0 428.0 464.0 500.0 536.0 572.0 752.0 1112.0 1292.0 1472.0 1652.0 1832.0 C = 5/9 (F - 32) F = 9/5 C + 32 Magnet wire tensile will change as the psi of magnet wire changes. Note: Copper magnet wire is calculated at 33,000 psi. Aluminum magnet wire is calculated at 11,000 psi (EC grade). Magnet wire should be tensiled on each coil. After termination of the AMPLIVAR splice, the tensile strength will be 70% (min.) of the original magnet wire tensile values. 86 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Technical Information (Continued) Circular Mil Area (CMA) and diameter for magnet wires (AWG wire size range 52-25 1/2) AWG Bare Wire 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 35 34 33 32 31 301/2 30 291/2 29 281/2 28 271/2 27 261/2 26 251/2 Bare Wire Dia. in. mm .0008 .020 .0009 .023 .0010 .025 .0011 .028 .0012 .031 .0014 .035 .0016 .040 .0018 .045 .0020 .050 .0022 .056 .0025 0.06 .0028 0.07 .0031 0.08 .0035 0.09 .0040 0.10 .0045 0.11 .0050 0.13 .0056 0.14 .0056 0.14 .0063 0.16 .0071 0.18 .0080 0.20 .0089 0.23 .0095 0.24 .0100 0.25 .0107 0.27 .0113 0.29 .0120 0.30 .0126 0.32 .0134 0.34 .0142 0.36 .0151 0.38 .0159 0.40 .0169 0.43 CMA Bare 0.6 0.8 1.0 1.2 1.5 2.0 2.5 3.1 4.0 4.8 6.3 7.8 9.6 12.0 16.0 20.0 25.0 31.0 31.0 40.0 50.0 64.0 79.0 90.0 100.0 115.0 128.0 144.0 159.0 180.0 202.0 225.0 258.0 289.0 Single Film Coated Dia. in. mm .0010 .025 .0011 .028 .0012 .031 .0013 .033 .0014 .035 .0016 .040 .0017 .043 .0019 .048 .0022 .056 .0025 .063 .0028 0.07 .0031 0.08 .0035 0.09 .0039 0.10 .0045 0.11 .0050 0.13 .0056 0.14 .0062 0.16 .0062 0.16 .0069 0.18 .0077 0.20 .0084 0.21 .0092 0.23 .0099 0.25 .0106 0.27 .0114 0.29 .0120 0.30 .0126 0.32 .0136 0.35 .0144 0.37 .0152 0.39 .0160 0.41 .0170 0.43 .0180 0.46 CMA Single Film Coated 1.0 1.2 1.5 1.7 2.0 2.5 2.9 3.6 4.8 6.2 8.0 10.0 12.0 15.0 20.0 25.0 31.0 38.0 38.0 48.0 59.0 71.0 85.0 98.0 112.0 130.0 144.0 159.0 185.0 207.0 231.0 256.0 289.0 324.0 Heavy Film Coated Dia. in. mm .0011 .028 .0012 .031 .0013 .033 .0014 .035 .0015 .038 .0018 .045 .0019 .048 .0021 .053 .0025 .063 .0027 .069 .0030 0.08 .0034 0.09 .0038 0.10 .0043 0.11 .0049 0.12 .0055 0.14 .0060 0.15 .0067 0.17 .0067 0.17 .0075 0.19 .0085 0.22 .0095 0.24 .0105 0.27 .0111 0.28 .0116 0.29 .0123 0.31 .0130 0.33 .0137 0.35 .0144 0.37 .0153 0.39 .0161 0.41 .0170 0.43 .0179 0.45 .0190 0.48 CMA Heavy Film Coated 1.2 1.5 1.7 2.0 2.2 3.1 3.6 4.4 6.2 7.3 9.0 12.0 14.0 18.0 24.0 30.0 36.0 45.0 45.0 56.0 72.0 90.0 110.0 123.0 135.0 151.0 169.0 187.0 207.0 234.0 259.0 289.0 320.0 361.0 Technical Information 87 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Technical Information (Continued) Circular Mil Area (CMA) and diameter for magnet wires (AWG wire size range 25-8) AWG Bare Wire 25 241/2 24 231/2 23 221/2 22 211/2 21 201/2 20 191/2 19 181/2 18 171/2 17 161/2 16 151/2 15 141/2 14 131/2 13 121/2 12 111/2 11 101/2 10 9 8 Bare Wire Dia. in. mm .0179 0.45 .0190 0.48 .0201 0.51 .0214 0.54 .0226 0.57 .0240 0.61 .0253 0.64 .0269 0.68 .0285 0.72 .0303 0.77 .0320 0.81 .0340 0.86 .0359 0.91 .0381 0.97 .0403 1.02 .0428 1.09 .0453 1.15 .0481 1.22 .0508 1.29 .0540 1.37 .0571 1.45 .0606 1.54 .0641 1.63 .0681 1.73 .0720 1.83 .0764 1.94 .0808 2.05 .0858 2.18 .0907 2.30 .0963 2.35 .1019 2.59 .1144 2.91 .1285 3.26 CMA Bare 320 361 404 458 511 576 640 724 812 918 1,024 1,156 1,289 1,452 1,624 1,832 2,052 2,314 2,581 2,916 3,260 3,672 4,109 4,638 5,184 5,837 6,529 7,362 8,226 9,274 10,384 13,087 16,512 Single Film Coated Dia. in. mm .0190 0.48 .0200 0.51 .0213 0.54 .0226 0.57 .0238 0.60 .0252 0.64 .0266 0.68 .0282 0.72 .0298 0.76 .0315 0.80 .0334 0.85 .0353 0.90 .0373 0.95 .0395 1.00 .0418 1.06 .0443 1.13 .0468 1.19 .0496 1.26 .0524 1.33 .0560 1.42 .0587 1.49 .0622 1.58 .0658 1.67 .0698 1.77 .0738 1.87 .0783 1.99 .0827 2.10 .0877 2.23 .0927 2.35 .0983 2.50 .1040 2.64 .1166 2.96 .1307 3.32 CMA Single Film Coated 361 400 455 511 566 635 708 795 888 992 1,116 1,246 1,391 1,560 1,747 1,962 2,190 2,460 2,746 3,136 3,446 3,869 4,330 4,872 5,446 6,131 6,839 7,691 8,593 9,663 10,820 13,600 17,080 Heavy Film Coated Dia. in. mm .0200 0.51 .0212 0.54 .0223 0.57 .0236 0.60 .0249 0.63 .0263 0.67 .0277 0.70 .0293 0.74 .0310 0.79 .0328 0.83 .0346 0.88 .0365 0.93 .0386 0.98 .0409 1.04 .0431 1.09 .0456 1.16 .0482 1.22 .0510 1.30 .0583 1.37 .0570 1.45 .0602 1.53 .0639 1.62 .0675 1.71 .0711 1.81 .0749 1.90 .0793 2.01 .0838 2.13 .0888 2.26 .0938 2.38 .0994 2.52 .1050 2.67 .1177 2.99 .1318 3.35 CMA Heavy Film Coated 400 449 497 557 620 692 767 858 961 1,076 1,197 1,340 1,490 1,673 1,858 2,079 2,323 2,601 2,894 3,249 3,624 4,082 4,556 5,055 5,670 6,188 7,090 7,885 8,892 9,880 11,151 13,971 17,530 88 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Technical Information (Continued) Circular Mil Area (CMA) and diameter for lead wires (AWG wire size range 30-8) Wire Size Dia. (Mils) 7 1 7 19 1 7 1 6 10 16 8 1 26 7 3 12 10 8 1 10 8 16 4 1 26 13 7 56 19 10 8 1 21 6 8 16 10 1 7 19 10 1 26 7 19 19 16 1 7 65 7 4.0 10.0 5.0 3.1 12.6 5.6 14.2 6.3 5.0 4.0 5.6 15.9 3.1 6.3 10.0 5.0 5.6 6.3 17.9 6.3 7.1 5.0 10.0 20.1 4.0 5.6 8.0 2.8 5.0 7.1 8.0 22.6 5.0 10.0 8.9 6.3 8.0 25.3 10.0 6.3 10.0 10.0 6.3 12.6 7.9 9.2 10.0 40.3 15.2 5.0 15.3 Wire Area in Circ. Mils 112 100 175 181 159 219 202 238 250 256 251 253 250 278 300 300 314 318 320 397 403 400 400 404 416 408 448 439 475 504 512 511 525 600 634 635 640 640 700 754 1,000 1,024 1,032 1,111 1,186 1,608 1,600 1,624 1,617 1,625 1,639 Wire Size -- -- 18 AN 18 AN 16 16 16 16 16 -- 16 14 AN 14 14 14 14 -- 14 14 14 -- 12 12 AN 12 12 12 12 12 12 12 10 -- 10 10 10 10 10 -- 10 9 9 9 8 8 8 8 8 8 8 8 AN Strands No. 41 7 19 19 7 1 65 19 105 26 7 19 37 7 19 1 41 105 168 84 7 19 19 259 19 7 37 1 165 84 7 37 414 37 1 7 19 41 105 7 1 525 7 133 37 1 7 19 49 133 Dia. (Mils) 6.3 16.0 10.0 11.3 19.2 50.8 6.3 11.7 5.0 10.0 20.0 14.2 10.5 24.2 14.7 64.4 10.0 6.3 5.0 71 25.3 17.9 17.9 5.0 18.5 30.5 13.3 80.8 6.3 8.9 36.0 16.0 5.0 16.7 101.9 38.5 23.4 15.9 10.0 43.0 114.4 5.0 45.0 11.1 21.1 128.5 48.6 29.5 18.4 11.3 Wire Area in Circ. Mils 1,627 1,792 1,900 2,426 2,580 2,581 2,580 2,601 2,625 2,600 2,800 3,831 4,079 4,099 4,106 4,109 4,100 4,167 4,200 4,234 4,481 6,088 6,088 6,475 6,503 6,512 6,545 6,529 6,549 6,654 9,072 9,472 10,350 10,319 10,384 10,376 10,404 10,365 10,500 12,943 13,087 13,125 14,175 16,386 16,472 16,512 16,533 16,534 16,589 16,982 Technical Information 30 30 28 28 28 27 27 26 26 26 26 26 26 26 26 26 AN 25 25 25 24 24 24 24 24 24 24 24 24 24 AN 23 23 23 -- 22 22 22 22 22 22 22 AN 20 20 20 20 20 AN 18 -- 18 18 18 18 Strands No. 89 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Terminal Stud Hole Size The chart shows sizes and dimensions of various studs and the corresponding terminal stud hole sizes used with devices. Use to Select Proper Size Terminal Stud Size U.S. Cust. Metric Stud Dia. Minimum Terminal Hole Diameter #0 .060 .064 #1 .073 .077 .086 .090 #3 .099 .103 #4 .112 .116 #2 M2 #5 M3 .125 .129 #6 M3.5 .138 .142 #8 M4 .164 .168 #10 .190 .194 #12 .216 .220 #14 .242 .247 1/4" M6 .250 .260 5/16" M8 .312 .323 3/8" .375 .385 7/16" .437 .448 1/2" M12 .500 For example, with stud #5 (.125 [3.18] Diameter), use device listed for #5 stud (.129 [3.28] Hole Diameter). Stud Size U.S. Cust. Metric Terminal stud hole sizes may easily be checked by fitting sample terminal to black circle. Stud Dia. Minimum Terminal Hole Diameter .625 .651 .750 .776 .875 .901 1" 1.000 1.026 1-1/8" 1.125 1.151 1-1/4" 1.250 1.276 5/8" M16 3/4" 7/8" M22 .510 90 www.te.com/appliances Catalog 82221 Magnet Wire Terminals and Termination Systems Part Number Index Note: This index lists all cataloged parts by base no. only. Complete part nos. (with prefixes and/or suffixes) are shown on the page(s) indicated. Part No. Page 48 48 48 48 48 48 48 48 48 48 48 48 48 55 51 51 51 51 51 51 51 54 54 52 48 52 49 53 53 52 47 47 47 47 49 54 54 59 47 49 47 47 61 61 47 47 47 47 47 47 47 47 47 47 49 56 4 4 13 4 13 13 Part No. 62445 62447 62458 62459 62511 62512 62513 62514 62600 62606 62609 62610 62651 62652 62670 62678 62702 62743 62755 62780 62781 62833 62835 62888 62891 62896 62897 62898 62904 62922 62923 62928 62935 62938 62958 62992 63018 63026 63027 63036 63039 63062 63063 63064 63107 63108 63109 63128 63132 63136 63140 63145 63147 63155 63160 63165 63199 63216 63218 63235 63236 63237 Page 53 53 10 10 18 18 18 18 21 30 10 10 21 21 49 18 13 19 51 30 30 4 51 19 7 7 7 7 18 53 22 11 4 13 11 10 18 21 21 10 10 17 17 22 19 19 19 21 21 54 54 17 51 22 13 54 31 14 7 10 10 10 Part No. 63240 63253 63273 63277 63278 63309 63340 63353 63364 63397 63399 63403 63410 63425 63427 63429 63431 63443 63444 63446 63448 63453 63454 63455 63458 63459 63460 63461 63463 63464 63465 63480 63484 63486 63489 63495 63499 63504 63506 63561 63562 63564 63565 63569 63570 63571 63584 63585 63591 63601 63607 63612 63613 63614 63621 63622 63623 63632 63641 63649 63658 63659 Page 10 11 18 16 16 21 19 20 7 7 51 21 7 22 20 19 49 16 16 51 59 61 61 61 8 22 22 18 14 22 22 56 53 17 14 22 21 10 55 48 48 48 13 16 16 21 18 18 4 21 21 51 30 21 49 54 54 6 10 51 4 11 Part Number Index 41765 41766 41770 41899 41900 41904 42076 42119 42192 42776 42778 42779 42780 60177 60318 60319 60320 60321 60322 60323 60325 60384 60385 60752 61074 61151 61166 61440 61442 61710 62000 62001 62002 62040 62044 62069 62080 62131 62157 62194 62200 62201 62243 62244 62295 62303 62304 62305 62306 62307 62308 62309 62310 62311 62341 62381 62420 62429 62430 62431 62438 62439 91 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Part Number Index Part No. 63660 63661 63662 63663 63664 63665 63666 63667 63670 63675 63690 63710 63711 63712 63713 63714 63716 63717 63718 63719 63720 63734 63735 63736 63737 63738 63740 63741 63742 63743 63744 63746 63762 63772 63775 63776 63777 63778 63782 63786 63788 63789 63795 63806 63807 63808 63810 63816 63818 63819 63827 63844 63856 63864 63870 63871 63888 63889 63899 63903 63940 63941 Page 11 11 4 18 18 18 20 20 18 31 10 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 17 20 16 7 18 17 31 19 4 16 4 30 14 14 14 14 22 13 13 17 30 10 52 53 53 27 53 14 27 55 55 Part No. 63942 63964 63965 63972 63973 63974 63975 63983 63995 63996 160809 160810 160897 170063 171370 235080 281006 281622 281633 284937 293029 293214 316300 350571 353937 356462 360033 360050 360051 360052 466010 466510 466816 485044 485079 505036 505044 505071 505072 505075 505079 520995 521078 565435 566410 566411 567343 567451 640212 680353 880631 926850 926851 926852 928770 928771 928854 964101 964106 964108 964110 964111 Page Part No. Page Part No. Page 55 56 14 14 14 14 6 20 20 20 13 13 13 59 58 58 58 7 7 41 40 38 18 52 59 55 58 58 60 60 54 53 54 51 51 52 52 51 51 51 52 60 58 53 55 55 54 54 52 55 58 5 5 5 5 5 5 7 5 5 5 5 964114 964156 964252 964290 964337 964338 964339 964340 964341 969082 969125 1123655 1217004 1217011 1217013 1217029 1217041 1217042 1217065 1217067 1217068 1217069 1217072 1217073 1217075 1217090 1217128 1217146 1217152 1217172 1217173 1217174 1217175 1217176 1217181 1217186 1217187 1217196 1217200 1217209 1217221 1217234 1217261 1217262 1217264 1217302 1217324 1217339 1217355 1217356 1217357 1217358 1217368 1217384 1217405 1217406 1217417 1217457 1217458 1217493 1217497 1217516 5 47 5 7 5 5 5 5 5 5 8 59 19 4 13 53 8 20 18 6 6 6 53 53 20 20 18 10 21 61 61 61 61 61 60 60 60 13 60 9 6 4 60 58 59 11 8 20 6 6 6 6 4 48 13 8 55 9 9 19 26 26 1217529 1217533 1217538 1217579 1217592 1217593 1217595 1217596 1217613 1217624 1217666 1217688 1217689 1217690 1217691 1217745 1217746 1217783 1217835 1217853 1217858 1217860 1217870 1217902 1217924 1217973 1247000 1247001 1247002 1247003 1247004 1380145 1394403 1394429 1394430 1394431 1394432 1394433 1394475 1394476 1394638 1394639 1418686 1534110 1534234 1534684 1534685 1534686 1534687 1599105 1601000 1601002 1601005 1601006 1601009 1601011 1601013 1601018 1601020 1601021 1601028 1601033 31 6 9 6 19 14 14 14 9 55 26 6 6 6 6 14 14 17 54 9 9 21 21 20 21 9 11 11 11 11 11 58 15 12 12 12 12 12 15 15 15 15 8 8 5 26 26 26 26 59 36 41 39 40 38 40 40 40 40 40 41 40 92 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Part Number Index Page Part No. Page Part No. Page Part No. Page 1601035 1601037 1601039 1601041 1601045 1601046 1601049 1601052 1601056 1601058 1601059 1601061 1601063 1601064 1601066 1601068 1601072 1601073 1601074 1601075 1601077 1601095 1601097 1601099 1601104 1601110 1601112 1601115 1601117 1601118 1601119 1601120 1601128 1601133 1601136 1601137 1601138 1601139 1601140 1601142 1601155 1601159 1601161 1601174 1601194 1601196 1601204 1601214 1601226 1601232 1601237 1601243 1601421 1601424 1601425 1601426 1601427 1601431 1601432 1601433 1601434 1601435 40 38 39 38 39 36 40 41 36 40 39 41 38 39 38 40 40 39 36 37 37 38 39 38 38 38 39 41 36 41 38 38 38 39 36 37 38 41 36 40 38 41 41 40 39 37 39 38 40 37 36 38 42 42 42 42 42 42 42 42 42 42 1601436 1601437 1601438 1601440 1601447 1601475 1601503 1601504 1601507 1601511 1601513 1601514 1601520 1601528 1601529 1601531 1601532 1601538 1601539 1601540 1601542 1601545 1601546 1601547 1601548 1601549 1601550 1601551 1601553 1601555 1601559 1601560 1601562 1601564 1601566 1601569 1601571 1601572 1601573 1601575 1601577 1601578 1601580 1601582 1601583 1601584 1601586 1601587 1601588 1601591 1601593 1601596 1601597 1601599 1601600 1601601 1601603 1601604 1601606 1601607 1601608 1601610 42 42 42 42 42 42 73 73 70 72 72 70 69 71 71 71 71 65 65 65 73 73 73 73 72 72 69 69 69 73 65 65 73 73 72 72 72 69 69 68 68 68 73 73 73 73 72 70 70 70 68 73 72 72 72 70 70 65 65 64 64 73 1601611 1601612 1601614 1601617 1601618 1601619 1601620 1601623 1601625 1601628 1601629 1601630 1601631 1601632 1601633 1601635 1601637 1601639 1601640 1601642 1601644 1601646 1601647 1601649 1601650 1601651 1601652 1601654 1601655 1601656 1601658 1601660 1601661 1601664 1601665 1601667 1601668 1601669 1601675 1601677 1601678 1601680 1601681 1601682 1601683 1601687 1601689 1601691 1601693 1601694 1601695 1601705 1601706 1601707 1601709 1601710 1601711 1601712 1601716 1601717 1601718 1601719 73 73 72 72 72 72 70 70 70 70 70 70 70 68 68 73 65 64 72 71 65 65 65 73 72 72 72 72 70 70 70 70 70 70 70 70 70 69 65 64 64 71 71 71 65 72 71 71 71 71 71 64 64 64 71 71 71 71 65 64 64 64 1601721 1601722 1601723 1601726 1601729 1601730 1601731 1601733 1601750 1601754 1601755 1601761 1601764 1601765 1601766 1601768 1601769 1601771 1601793 1601794 1601795 1601797 1601798 1601800 1601807 1601808 1601809 1601810 1601811 1601814 1601818 1601819 1601820 1601823 1601824 1601825 1601827 1601828 1601829 1601832 1601833 1601835 1601837 1601841 1601842 1601844 1601845 1601846 1601847 1601848 1601852 1601853 1601857 1601953 1718165 1740417 1740418 1740419 1740574 1740603 1740698 1740829 72 72 72 71 71 71 71 71 64 71 71 64 71 71 71 69 68 68 65 64 73 69 69 65 69 72 72 72 70 64 70 70 70 64 64 73 72 70 70 65 64 64 72 71 64 65 65 64 64 64 71 68 64 75 30 15 15 15 5 8 8 26 Part Number Index Part No. 93 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Part Number Index Part No. Page Part No. Page Part No. Page Part No. Page 1742125 1742159 1742160 1742167 1742203 1742211 1742347 1742398 1742410 1742605 1742614 1742657 7 9 18 14 6 8 6 21 8 13 10 61 1742708 1742781 1742819 1742820 1742828 1742881 1742882 1742898 1742964 1742977 1742979 1742981 11 9 20 20 7 55 55 47 59 55 55 59 1855633 1855634 1855680 1855681 1955415 1969357 1987143 1987199 1987222 1987223 1987224 1987225 55 55 55 55 58 58 12 8 28 28 28 28 1987226 2120743 2120744 2120745 2120746 2120747 2232326 2232327 2825082 2825083 28 27 27 27 27 27 58 58 58 59 94 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Engineering Notes 95 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Engineering Notes 96 www.te.com/appliances Magnet Wire Terminals and Termination Systems Catalog 82221 Engineering Notes 97 www.te.com/appliances LET'S CONNECT We make it easy to connect with our experts and are ready to provide all the support you need. 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All other logos, products and/or company names referred to herein might be trademarks of their respective owners. The information given herein, including drawings, illustrations and schematics which are intended for illustration purposes only, is believed to be reliable. However, TE Connectivity makes no warranties as to its accuracy or completeness and disclaims any liability in connection with its use. TE Connectivity`s obligations shall only be as set forth in TE Connectivity`s Standard Terms and Conditions of Sale for this product and in no case will TE Connectivity be liable for any incidental, indirect or consequential damages arising out of the sale, resale, use or misuse of the product. Users of TE Connectivity products should make their own evaluation to determine the suitability of each such product for the specific application. (c) 2016 82221 TE Connectivity Ltd. family of companies 06/2016 All Rights Reserved. APP APPLIANCES /// MAGNET WIRE TERMINATION