Application Specification 114-- 10007 Type VI Insulation Grip Contacts NOTE i 23 NOV 09 Rev C All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2_. Figures and illustrations are for identification only and are not drawn to scale. 1. INTRODUCTION This specification covers requirements for the application of Type VI Insulation Grip Contacts. These requirements apply to hand or automatic machine crimping tools for the contacts. These insulation grip contacts are available in size 16 (1.57 mm [.062 in.]) pin diameter only, with a wire size range of 28--14 (AWG). When corresponding with Tyco Electronics Personnel, use the terminology provided on this specification to help facilitate your inquiry for information. Basic terms and features of components are provided in Figure 1. Socket Contact Pin Contact Locking Lance Wire Barrel Locking Lance Insulation Barrel Mating End Figure 1 2. REFERENCE MATERIAL 2.1. Revision Summary S Updated document to corporate requirements S New logo and format 2.2. Customer Assistance Reference Base Part Number 66577 and Product Code 5056 are representative numbers of the Type VI Insulation Grip Contacts. Use of these numbers will identify the product line and expedite your inquiries through a service network established to help you obtain product and tooling information. Such information can be obtained through a Tyco Electronics Representative or, after purchase, by calling the Product Information Center at the number at the bottom of this page. 2.3. Drawings Customer Drawings for product part numbers are available from the service network. If there is a conflict between the information contained in the Customer Drawings and this specification or with any other technical documentation supplied, call the Product Information Center at the number at the bottom of this page. 2.4. Specifications Product Specification 108--10038 provides performance test information and quality requirements for Type VI Contacts. TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111 E2009 Tyco Electronics Corporation, Harrisburg, PA PRODUCT INFORMATION 1-- 800-- 522-- 6752 All International Rights Reserved TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 13 LOC B Type VI Insulation Grip Contacts 114- 10007 2.5. Instructional Material The following list includes available instruction sheets (408--series) that provide assembly procedures for product, operation, maintenance and repair of tooling, as well as setup and operation procedures of applicators; and customer manuals (409--series) that provide setup, operation, and maintenance of machines. Document Number 408--1216 408--1379 408--2498 408--3295 408--4106 408--4190 408--4321 408--6610 408--6613 408--6614 408--7347 408--7424 408--7680 408--7716 408--8040 408--8059 408--8322 408--8547 408--8620 408--9640 408--9816 408--9819 409--5128 409--5842 409--5852 409--5862 409--5866 409--5878 409--10012 409--10016 409--10027 409--10029 Document Title Extraction Tools 305183--[ ] for Type VI Contacts Selection Charts for Multimate Pin and Socket Contacts Crimping Head Cross Reference for Pneumatic Tools Preparing Reel of Contacts for Application Tooling Straight Action Crimp Head Adapter 217201--1 C--Head Pneumatic Adapter 318161--1 Pneumatic CERTI--CRIMP* Tool Holder 356304--1 Hand Crimping Tool 90066--7 Hand Crimping Tool 90067--4 Hand Crimping Tool 90067--5 Insertion Tools 91002--[ ] Checking Terminal Crimp Height or Gaging Die Closure Hand Crimping Tool 90310--1 Hand Crimping Tool 90327--1 Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type) with Mechanical General Preventive Maintenance for Applicators Heavy Duty Industrial (HD--I) Side--Feed Type Applicator Certi--Crimp II Straight Action Hand Tools Service Hand Tool 696202--1 Crimp Quality Monitor Applicators for Side--Feed and End--Feed Applications Handling of Reeled Products PRO--CRIMPER* III Hand Tool Assembly 58495--1 with Die Assembly 58495--2 Basic AMP--O--LECTRIC* Model "K" Terminating Machine 565435--5 AMP--O--LECTRIC Model "G" Terminating Machines 354500--[ ] AMPOMATOR* CLS III--G Lead Making Machine 122500--[ ] 626 Pneumatic Tooling Assemblies 189721--[ ] and 189722--[ ] AMPOMATOR CLS IV Lead--Making Machine 217500--[ ] AMPOMATOR CLS IV+ Lead--making Machine 356500--[ ] AMP--O--MATIC* Side Feed Stripper--Crimper III Machine 1320895--[ ] Entry Level Terminator (ELT) Machine 1338600--[ ] Stripping Modules 1490500 and 1490502 Stripping Modules 1490501 and 1490503 3. REQUIREMENTS 3.1. Storage A. Ultraviolet Light Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the contacts. B. Reeled Contacts When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically. C. Shelf Life The contacts should remain in the shipping containers until ready for use to prevent deformation to the contacts and/or damage to the housings. The contacts should be used on a first in, first out basis to avoid storage contamination that could adversely affect signal transmissions. D. Chemical Exposure Do not store contacts near any chemicals listed below, as they may cause stress corrosion cracking in the contacts. Alkalies Amines NOTE i 2 of 13 Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Sulfur Compounds Tartrates Where the above environmental conditions exist, phosphor--bronze contacts are recommended instead of brass if available. Tyco Electronics Corporation Rev C Type VI Insulation Grip Contacts 114- 10007 3.2. Wire Size and Preparation The contacts will accept a wire size range of 28 to 14 AWG and may be terminated to either stranded or solid wire. See Figure 2. The applied crimp dimension (within the functional range of the product) is dependent on the termination tooling being used. Refer to the documentation (applicator logs and instruction sheets) supplied with the termination tooling for the applied crimp height. See Section 5, TOOLING. NOTE i CAUTION DO NOT nick, scrape, or cut the wire conductor during the stripping operation. ! Stranded Wire Solid Wire Strip Length Strip Length Insulation Conductor WIRE SIZE, AWG 28 26 24 24 22 20 INSULATION DIAMETER 18 16 14 WIRE BARREL CRIMP HEIGHT RANGE CRIMP HEIGHT RANGE (MACHINE) (HAND TOOL) 0 84 0 74 [.033--.029] 0.84--0.74 [ 033 029] 3.18 [.125] and 3.56--4.75} [.140--.187]} 0.89--0.79 [.035--.031] 0.96--0.86 [.038--.034] 0.89--0.79 [.035--.031] 0.96--0.86 [.038--.034] 1.02--0.02 [.040--.036] 1.12--1.02 [.044--.040] 1.02--0.02 [.040--.036] 1.12--1.02 [.044--.040] 11.4--2.79 4 2 79 [ 055-- 110] [.055--.110] 4.37 3 [.172] [ ] 1.19--1.09 [.047--.043] 1.27--1.17 [.050--.046] 0.99--0.89 [.039--.035] 1.17--1.07 [.046--.042] 1.40--1.30 [.055--.051] 1.17--1.07 [.046--.042] 2.03--2.54 2.03 2.54 [.080--.100] 3.18 [.125] and 3.56--4.75} [.140--.187]} 1 55 1 25 [.061--.049] 1.55--1.25 [ 061 049] 2 03 3 43 2.03--3.43 [[.080--.135] 080-- 135] 3 96 [.156] 3.96 [ 156] 4.75 [.187] 1 02 2 03 1.02--2.03 [[.040--.080] 040-- 080] 18 16 STRIP LENGTH 0 84 0 74 [.033--.029] 0.84--0.74 [ 033 029] 0 89 1 4 0.89--1.4 [[.035--.055] 035-- 055] 22 20 18 Insulation WIDTH (REF) INSUL BARREL CRIMP WIDTH (MAX) 14 1.4 [[.055] 055] 1.788 [.070] [ 0 0] 1 58 1.58 [[.062] 062] 2.299 [.090] [ 090] 1 78 1.78 [[.070] 070] 2.54 5 [.100] [ 00] 1 55 1 25 [.061--.049] 1.55--1.25 [ 061 049] 2.03 [.080] 3 05 [.120] 3.05 [ 120] 1 55 1 25 [.061--.049] 1.55--1.25 [ 061 049] 1 55 1 25 [.061--.049] 1.55--1.25 [ 061 049] 33.56 56 [.140] [ 0] 1.78--1.68 [.070--.066] 1.78--1.68 [.070--.066] 2 29 2.29 [[.090] 090] }Hand Tools Only. Figure 2 3.3. Crimped Contact Requirements The contact must be crimped onto the wire according to instructions packaged with applicable tooling. After crimping, the contact should appear as shown in Figure 3. A typical pin contact is shown as it should appear after crimping; these requirements apply equally to the socket contact. CAUTION The wire insulation must not be damaged during the crimping process. ! Rev C Tyco Electronics Corporation 3 of 13 Type VI Insulation Grip Contacts 114- 10007 A. Wire Barrel Crimp The crimp applied to the wire portion of the contact is the most compressed area and is most critical in ensuring optimum electrical and mechanical performance of the crimped contact. The contact wire barrel crimp height must be within the dimension provided in Figure 2. B. Effective Crimp Length For optimum crimp effectiveness, the crimp must be within the area shown in Figure 3 and must meet the crimp dimensions provided in Figure 2. Effective crimp length shall be defined as that portion of the wire barrel, excluding bellmouth(s), fully formed by the crimping tool. Instructions for adjusting, repairing, and inspecting tools are packaged with the tools. See Section 5, TOOLING. C. Bellmouths Front and rear bellmouths shall be evident and conform to the dimensions given in Figure 3. D. Cutoff Tabs The cutoff tab shall be cut to the dimensions shown in Figure 3. E. Burrs The cutoff burr shall not exceed the dimensions shown in Figure 3. F. Wire Barrel Flash The wire barrel flash shall not exceed the dimensions shown in Figure 3, Section X--X. G. Insulation Barrel Crimp The insulation barrel shall grip the insulation firmly. A slight cut in the insulation by the insulation barrel is permissible as this causes no problems in actual use. Insulation crimp shall comply to width and height provided in Figure 3. NOTE i Comparing a crimped contact to an uncrimped contact should reveal any fault that may have occurred to front shoulder or locking lances during crimping. Wire Conductors and Insulation Must Both be Visible in This Area Wire Barrel Seam Closed with No Conductor Strands Showing Insulation Barrel Crimp Width 0.81 [.032] Max Conductor Location Locking Lance Undamaged 0.25 [.010] Max Front Bellmouth 0.20-- 0.46 [.008-- .018] Rear Bellmouth X X See View A VIEW A 0.08 [.003] Max Burr SECTION X- X 0.25 [.010] Max Wire Barrel Flash 0.13-- 0.38 [.005-- .015] Cutoff Tab Figure 3 4 of 13 Tyco Electronics Corporation Wire Barrel Crimp Height Wire Barrel Crimp Width Rev C Type VI Insulation Grip Contacts 114- 10007 H. Wire Location The wire conductor and insulation must be visible in the transition area between the wire and insulation barrels. I. Conductor Extension The conductor may extend beyond the wire barrel to the maximum shown. J. Wire Barrel Seam The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam. 3.4. Axial Concentricity The axial concentricity of a crimped contact must be within an area defined by the diameter of a circle that has the same center as the centerline of the contact. The diameter of the circle will depend on the wire size. There shall be no twist, roll, deformation or other damage to the mating portion of the crimped contact that will impair usage of the contact. See Figure 4. WIRE SIZE RANGE (AWG) Circle Diameter CIRCLE DIAMETER 28 -- 20 3.4 [.134] 18 -- 14 4.16 [.164] Contact Contact and Circle Diameter Centerlines Figure 4 3.5. Repair and Replacement Contacts are not repairable once a termination has been made. Any defective contact should be removed and replaced with a new one. 4. QUALIFICATIONS Type VI Insulation Grip Contacts are not required to be agency evaluated. 5. TOOLING Figure 5 provides tool part numbers and instructional material related to wire size. NOTE i Tyco Electronics Tooling Engineers have designed machines for a variety of application requirements. For assistance in setting up prototype and production line equipment, contact Tyco Electronics Tool Engineering through your local Tyco Electronics Representative or call the Tooling Assistance Center number at the bottom of page 1. S Hand Crimping Tool Hand crimping tools that accommodate the full wire size range are designed for prototype and low--volume applications such as repair of damaged contacts. S Applicator Applicators are designed for the full wire size range of strip--fed, precision formed contacts, and provide for high volume, heavy duty, production requirements. The applicators can be used in bench or floor model power units. NOTE i Each applicator is shipped with a metal identification tag attached. DO NOT remove this tag or disregard the information on it. Also, a packet of associated paperwork is included in each applicator shipment. This information should be read before using the applicator; then it should be stored in a clean, dry area near the applicator for future reference. Some changes may have to be made to the applicators to run in all related power units. Contact the Tooling Assistance Center number located at the bottom of page 1 for specific changes. S Power Units A power unit is an automatic or semi--automatic device used to assist in the application of a product. Power unit includes the power source used to supply the force or power to an applicator. Rev C Tyco Electronics Corporation 5 of 13 Type VI Insulation Grip Contacts NOTE i 114- 10007 The Model "K" AMP--O--LECTRIC Terminating Machine PN 565435--5 has been superseded by the Model "G" Terminating Machine PN 354500--1 (Customer Manual 409--5842) for new applications. For existing applications, the Model "K" is still recommended because of the large number of installed machines. S Insertion/Extraction Tooling Insertion Tools are designed for contacts crimped to small fragile wire. They are designed to stabilize the contact during insertion. For use of Insertion Tool 91002 which may be used with these contacts, refer to Instruction Sheet 408--7347. Extraction Tools are designed to release the locking lance inside the connector housing without damaging the housing or contacts. For use of Extraction Tool 305183 which may be used with these contacts, refer to Instruction Sheet 408--1216. WIRE SIZE RANGE (AWG) INSULATION DIAMETER RANGE TOOLING (DOCUMENT) APPLICATOR ------ POWER UNIT ------ HAND TOOL HEAD DIES TOOL HOLDER 58495--1 (408--9819) 90066--7 (408--6610) 91515--1 (N/A) 696202--1 (408--8620) ------ ------ ------ 217201--11 217201 (408--4106) 90066 9 90066--9 (N/A) 189928--1 (408--2498) (408 4190) (408--4190) 356304--1 (408--4321) ------ ------ ------ 189721--1 (408--2498) (409--5862) 189722--1 (408--2498) (409--5862) 28--24 0.89--1.4 [.035--.055] 466321--3 (408--8040) 122500--[ ] (409--5852) 217500--[ ] (409--5866) 356500--[ ] (409--5878) 466321--4D (408--8040) 354500--1 (409--5842) 565435--5 (409--5128) 466321--6 (408--8040) 354500--[ ] (409--5842) 1338600--[ ] (409--10016) 466908--2 (408--8040) 567753--1 (408--8040) 567753--2 (408--8040) 567753--3 (408--8040) 1320895--[ ] (409--10012) 122500--[ ] (409--5852) 217500--[ ] (409--5866) 356500--[ ] (409--5878) ------ 354500--1 (409--5842) 354500--[ ] (409--5842) 1338600--[ ] (409--10016) DThis applicator will terminate wire size 28--26 only. Figure 5 (cont'd) 6 of 13 Tyco Electronics Corporation Rev C Type VI Insulation Grip Contacts WIRE SIZE RANGE (AWG) INSULATION DIAMETER RANGE 114- 10007 TOOLING (DOCUMENT) APPLICATOR ------ POWER UNIT HAND TOOL HEAD DIES TOOL HOLDER ------ ------ ------ ------ 58495--1 (408--9819) 90066--7 (408--6610) 91515--1 (N/A) 696202--1 (408--8620) 217201--11 217201 (408--4106) 90066 9 90066--9 (N/A) 189928--1 (408--2498) (408 4190) (408--4190) 356304--1 (408--4321) ------ ------ ------ 189721--1 (408--2498) (409--5862) 189722--1 (408--2498) (409--5862) 24--20 24 20 1.02--2.03 [[.040--.080] 040-- 080] 466323--3 (408--8040) 122500--[ ] (409--5852) 217500--[ ] (409--5866) 356500--[ ] (409--5878) 466323--4 (408--8040) 354500--1 (409--5842) 565435--5 (409--5128) 466323--5 (408--8040) 354500--1 (409--5842) 565435--5 (409--5128) 466323--6 (408--8040) 354500--[ ] (409--5842) 1338600--[ ] (409--10016) 466907--2 (408--8040) 1320895--[ ] (409--10012) 567634--1 (408--8040) 122500--[ ] (409--5852) 217500--[ ] (409--5866) 356500--[ ] (409--5878) 567634--3 (408--8040) 354500--[ ] (409--5842) 1338600--[ ] (409--10016) 567807--1 (N/A) 1320895--[ ] (409--10012) ------ Figure 5 (cont'd) Rev C Tyco Electronics Corporation 7 of 13 Type VI Insulation Grip Contacts WIRE SIZE RANGE (AWG) 24--20 22--18 18--16 INSULATION DIAMETER RANGE 1.02--2.03 [.040--.080] 1.27--2.79 [.050--.110] 2.03--2.54 [.080--.100] 114- 10007 TOOLING (DOCUMENT) APPLICATOR POWER UNIT 1385125--1 (N/A) 122500--[ ] (409--5852) 217500--[ ] (409--5866) 356500--[ ] (409--5878) 1385125--2 (N/A) 354500--1 (409--5842) 565435--5 (409--5128) 1385125--3 (N/A) 354500--[ ] (409--5842) 1338600--[ ] (409--10016) 466384--4 (408--8040) 354500--1 (409--5842) 565435--5 (409--5128) 466384--5 (408--8040) 354500--[ ] (409--5842) 1338600--[ ] (409--10016) 466914--1 (N/A) 1320895--[ ] (409--10012) ------ ------ HAND TOOL HEAD DIES TOOL HOLDER ------ ------ ------ ------ 90327--1 (408--7716) ------ ------ ------ 58495--1 (408--9819) 90067--4 (408--6613) 90067--5 (408--6614) 91505--1 (408--8547) 91523--1 (N/A) 696202--1 (408--8620) ------ ------ ------ 217201--11 217201 (408--4106) 90067--7 (N/A) 90067--6 (N/A) 189928--1 (408--2498) (408 4190) (408--4190) 356304--1 (408--4321) 189721--1 (408--2498) (409--5862) 189722--1 (408--2498) (409--5862) Figure 5 (cont'd) 8 of 13 Tyco Electronics Corporation Rev C Type VI Insulation Grip Contacts WIRE SIZE RANGE (AWG) 18--16 INSULATION DIAMETER RANGE 2.03--2.54 [.080--.100] 114- 10007 TOOLING (DOCUMENT) APPLICATOR POWER UNIT 466325--1 (408--8040) 122500--[ ] (409--5852) 217500--[ ] (409--5866) 356500--[ ] (409--5878) 466325--2 (408--8040) 354500--1 (409--5842) 565435--5 (409--5128) 466325--4Y (408--8040) 354500--1 (409--5842) 565435--5 (409--5128) 466325--5 (408--8040) 354500--[ ] (409--5842) 1338600--[ ] (409--10016) 466906--1 (408--8040) 1320895--[ ] (409--10012) 466906--2 (408--8040) 1320895--[ ] (409--10012) 567638--1 (408--8040) 122500--[ ] (409--5852) 217500--[ ] (409--5866) 356500--[ ] (409--5878) 567638--3 (408--8040) 354500--[ ] (409--5842) 1338600--[ ] (409--10016) 1426020--1 (408--8322) 122500--[ ] (409--5852) 217500--[ ] (409--5866) 356500--[ ] (409--5878) 1426020--2 (408--8322) 354500--[ ] (409--5842) 1338600--[ ] (409--10016) 1426020--6 (408--8322) 122500--[ ] (409--5852) 217500--[ ] (409--5866) 356500--[ ] (409--5878) HAND TOOL HEAD DIES TOOL HOLDER ------ ------ ------ ------ YThis applicator is specifically made for IBM. Figure 5 (cont'd) Rev C Tyco Electronics Corporation 9 of 13 Type VI Insulation Grip Contacts WIRE SIZE RANGE (AWG) 18--16 18--14 INSULATION DIAMETER RANGE 2.03--2.54 [.080--.100] 2.03--3.43 [.080--.135] 114- 10007 TOOLING (DOCUMENT) APPLICATOR POWER UNIT 7--1426020--1 (408--8322) 122500--[ ] (409--5852) 217500--[ ] (409--5866) 356500--[ ] (409--5878) 7--1426020--2 (408--8322) 354500--[ ] (409--5842) 1338600--[ ] (409--10016) 7--1426020--6 (408--8322) 122500--[ ] (409--5852) 217500--[ ] (409--5866) 356500--[ ] (409--5878) 687997--2 (408--8040) 354500--1 (409--5842) 565435--5 (409--5128) 687997--3 (408--8040) 122500--[ ] (409--5852) 217500--[ ] (409--5866) 356500--[ ] (409--5878) 687997--4 (408--8040) 354500--1 (409--5842) 565435--5 (409--5128) HAND TOOL HEAD DIES TOOL HOLDER ------ ------ ------ ------ 90310--1 (408--7680) ------ ------ ------ Extraction Tool 305183--[ ] Insertion Tool 91002--[ ] Typical Single Action Hand Tool with Certi--Crimp Typical PRO--CRIMPER Hand Tool with Die Assembly Certi--Crimp II Single Action Hand Tool Figure 5 (cont'd) 10 of 13 Tyco Electronics Corporation Rev C Type VI Insulation Grip Contacts 114- 10007 Typical Heavy Duty Industrial (HDI) Applicator (408--8322) Service Hand Tool 696202--1 AMP--O--LECTRIC Model "G" Terminating Machine 354500--[ ] with Optional Stripping Module Typical Heavy Duty Mini (HDM) Applicator (408--8040) AMP--O--MATIC Side Feed Stripper--Crimper II Machine 1320895--[ ] ELT Machine 1338600--[ ] with Optional Stripping Module AMPOMATOR CLS Lead--Making Machines 122500--[ ]; 217500--[ ]; 356500--[ ] AMP--O--LECTRIC Model "K" Terminating Machine 565435--5 Figure 5 (cont'd) Rev C Tyco Electronics Corporation 11 of 13 Type VI Insulation Grip Contacts 114- 10007 Tool Holder Assembly 189928--1 Straight Action Crimping Head Adapter 217201--1 Typical Crimping Head Hand Non--Logic Power Unit 189721--1 Foot Non--Logic Power Unit 189722--1 Pneumatic CERTI--CRIMP Tool Holder 356304--1 Figure 5 (end) 12 of 13 Tyco Electronics Corporation Rev C Type VI Insulation Grip Contacts 114- 10007 6. VISUAL AID Figure 6 shows a typical application of a Type VI Insulation Grip Contact. This illustration should be used by production personnel to ensure a correctly applied product. Applications which DO NOT appear correct should be inspected using the information in the preceding pages of this specification and in the instructional material shipped with the product. REAR BELLMOUTH MUST BE VISIBLE WIRE BARREL SEAM MUST BE CLOSED, WITH NO CONDUCTOR STRANDS SHOWING LOCKING LANCE MAY NOT BE DEFORMED WIRE AND INSULATION MUST BE VISIBLE IN THIS AREA WIRE MUST BE FLUSH WITH END OF WIRE BARREL, OR PROTRUDE SLIGHTLY CONTACT MUST BE STRAIGHT FIGURE 6. Rev C VISUAL AID Tyco Electronics Corporation 13 of 13