Application Specification
HD-20 Precision 114-10000
LOC B
1
of 11
E
2009 Tyco Electronics Corporation, Harrisburg, PA
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.
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
Formed Contacts
09 FEB 09 Rev T
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and
inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2
_
.
Figures and illustrations are for identification only and are not drawn to scale.
1. INTRODUCTION
This specification covers the requirements for the application of HD–20 Precision Formed Contacts. These
contacts are available in three snap–in types: crimp, posted, and solder cup. The crimp snap–in contacts are
available with or without an insulation support barrel for strain relief. The contacts accept a wire size range of
28 through 18 AWG and may be terminated to either stranded or solid wire.
After termination, these contacts are inserted into the cavities in the BACK of the connector housing and snap
into place. Assembled connectors containing these contacts are available and designed to meet requirements
of Military Specification MIL–C–24308.
When corresponding with Tyco Electronics Personnel, use the terminology provided in this specification to
facilitate your inquiries for information. Basic terms and features of this product are provided in Figure 1.
Figure 1
Locator Slot Wire Barrel
Insulation
Barrel
Color Dot on Underside
of Wire Barrel
Typical Pin Contact
Snap-In Crimp Contacts
Typical Socket Contact
Crimp ContactPosted Contact Solder Cup Contact
Stabilizer
Pin Contact Without
Insulation Barrel
Transition
Flange
Solder Cup
2. REFERENCE MATERIAL
2.1. Revision Summary
Revisions to this application specification include:
S
Updated document to corporate requirements
S
Added wire size range 32–28 to tables in Figures 2, 3, and 7
NOTE
i
HD-20 Precision Formed Contacts 114-10000
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2.2. Customer Assistance
Reference Product Base Part Number 66504 and Product Code 5899 are representative numbers of HD–20
Precision Formed 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 Product Information at the
number at the bottom of page 1.
2.3. Drawings
Customer Drawings for each product part number are available from the service network. The information
contained in Customer Drawings takes priority if there is a conflict with this specification or with any technical
documentation supplied by Tyco Electronics.
2.4. Manuals
Manual 402–40 is available from the service network. This manual provides information on various flux types
and characteristics along with the commercial designation and flux removal procedures. A checklist is included
in the manual as a guide for information on soldering problems.
2.5. 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 provides setup, operation, and maintenance of machines.
Document Number Document Title
408–3295 Preparing Reel of Contacts for Application Tooling
408–7424 Checking Terminal Crimp Height Gaging Die Closure
408–7799 AMPLIMITE* Solder Pot Contacts (66569–3 and 66570–3)
408–8040 HD Quick–Change Applicators (Side–Feed Type) with Mechanical Feed System
408–8547 CERTI–CRIMP* II Straight Action Hand Tools
408–9404 Insertion/Extraction Tool 91285–1 and Replacement Tip Kits 543382–[ ]
408–9816 Handling of Reeled Products
409–5128 Basic AMP–O–LECTRIC* Model “K” Terminating Machine 565435–5
409–5842 AMP–O–LECTRIC Model “G” Terminating Machine 354500–[ ]
409–5852 AMPOMATOR* CLS Model III–G Lead–Making Machine 122500–[ ]
409–10012 AMP–O–MATIC* Side–Feed Stripper–Crimper III Machine No. 1320895–[ ]
3. REQUIREMENTS
3.1. Storage
A. Reeled Contacts
When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically.
B. 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 products should be used on a first in, first out basis to avoid
storage contamination that could adversely affect signal transmissions.
C. Chemical Exposure
Do not store contacts near any chemicals listed below, as they may cause stress corrosion cracking in the
components.
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfur Nitrites Tartrates
3.2. Wire Size and Preparation
The contacts will accept a wire size range of 28 to 18 AWG and may be terminated to either stranded or solid
wire.
Figure 2 lists insulation stripping lengths as determined by the contact wire size range used. Also listed are
acceptable wire insulation outside diameters for the contacts, and color codes used to easily identify
loose–piece contacts.
HD-20 Precision Formed Contacts 114-10000
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Tyco Electronics Corporation
DO NOT nick, scrape, or cut the wire conductor during the stripping operation.
Outer Jacket Strip Length
A" + 1.27 [.050]
Discrete Wire
Strip Length Braid Ferrule
Cable
OUTER JACKET STRIP LENGTH
CONTACT POSITIONS A" LENGTH
9
15 33.02 [1.300]
25
37 43.18 [1.700]
50 40.64 [1.600]
DISCRETE WIRE
CONTACT
WIRE SIZE COLOR CODE
(ON WIRE BARREL INSULATION
DIAMETER
STRIP LENGTH
"
0.25 [.010]
RANGE
(AWG)
(
OF LOOSE PIECE
CONTACTS ONLY)
DIAMETER
ACCEPTED MILLIMETERS DECIMAL
INCHES FRACTIONAL
INCHES
OPEN BARREL CONTACTS (With or Without Insulation Support)
32-28 --- 0.76-1.02 [.030-.040] 2.39 .094 3/32
BLUE 1.73 [.068] Max 2.77 .109 7/64
28-24 BLACK 1.27-1.52 [.050-.060]
BLUE 0.76-1.02 [.030-.040] 2.39 .094 3/32
26-22 YELLOW 1.27 [.050] Max
24 20
RED
1.73 [.068] Max 2.77 .109 7/64
24
-
20
RED
1.27-1.52 [.050-.060] 2.39 .094 3/32
22-18 GREEN 1.73 [.068] Max 2.77 .109 7/64
SOLDER-CUP CONTACTS
18 and Smaller None None Specified 3.96 .156 9/64
Figure 2
3.3. Crimped Contact Requirements
Contact shall be located in desired tooling and crimped according to the instructions packaged with that tooling.
See Section 5, TOOLING of this document for details on tooling options and instructional materials.
Wire insulation shall NOT be cut or broken during the crimping operation, nor shall the insulation be crimped into the
contact wire barrel. Reasonable care should be taken by tooling operators to provide undamaged wire terminations.
A. Contact Crimp Barrel Configurations
The contact wire barrel shall be crimped to an F–crimp configuration as shown in Section X–X of Figure 3.
The insulation barrel (when present) shall be crimped to an O–crimp configuration. Refer to the table in
Figure 3 for crimp dimensions.
CAUTION
!
CAUTION
!
HD-20 Precision Formed Contacts 114-10000
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B. Contact Crimp Features
Figure 3 shows a typical contact as it should appear after crimping. Although a pin contact with insulation
barrel is shown, the requirements apply equally to socket contacts and to contacts not having an insulation
barrel.
1.
Crimp Location
For optimum crimp effectiveness, the crimp must be within the area shown and must meet the crimp
requirements provided in Figure 3. Effective crimp length shall be no less than the dimension given in
Figure 3 and is 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.
2.
Conductor Extension
The conductor may extend beyond the wire barrel to the maximum shown.
3.
Wire Barrel Seam
The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam.
4.
Conductor/Insulation
The conductor and insulation must both be visible in the area between the insulation barrel and the wire
barrel.
5.
Bellmouth
Front and rear bellmouths shall be formed and adhere to the dimensions given.
6.
Cutoff Tab
The cutoff tab shall be cut to the dimensions shown.
7.
Burrs
The cutoff burr shall not exceed the dimensions shown.
8.
Flash
The wire barrel flash shall not exceed the dimensions shown in Section X–X.
Figure 3 (cont’d)
X
X
Wire Conductors and Insulation
Must Both be Visible in this Area
Wire Barrel Seam Closed with
No Conductor Strands Showing
0.13-0.51 [.005-.020]
Conductor Location
Rear Bellmouth
0.30+0.13 [.012+.005] Contact with Insulation Barrel
0.33+0.13 [.013+.005] Contact Without Insulation Barrel
1.27 [.050] Effective Crimp Length
0.25 [.010] Max Front Bellmouth
0.25 [.010] Max
Rear Cutoff Tab with
0.08 [.003] Max Burr
Crimp Width
at Tangent
(See Table)
Crimp Height
(See Table)
0.25 [.010] Max
Wire Barrel Flash
Section X-X
No Damage or Distortion to
Contact or Retention Feature
HD-20 Precision Formed Contacts 114-10000
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Tyco Electronics Corporation
HAND TOOL
WIRE CRIMP DIMENSIONS
WIRE SIZE
RANGE
WIRE INSUL DIA SIZE OF
WIRE
WIRE BARREL CRIMP INSULATION BARREL CRIMP
RANGE
(AWG) ACCEPTED
WIRE
APPLIED HEIGHT RANGE WIDTH WIDTH (Ref) HEIGHT (Ref)
076 102
32 0.58-0.46 [.023-.018]
135 157
064 193
32-28 0.76-1.02
[.030-.040] 30 0.61-0.46 [.024-.018] 0.84 [.033] 1.35-1.57
[.053-.062]
0.64-1.93
[.025-.076]
[]
28 0.63-0.51 [.025-.020]
[]
[]
28
1.73 [.068]
Max 26 0.47-0.57 [.0185-.0225] 1.40 [.055] --- ---
24
28
28-24 1.27-1.52
[.050-.060] 26 1.40 [.055] 1.27 [.050]
24
0 67-0 77 [ 0265- 0305]
1 07 [ 042]
28
0
.
67
-
0
.
77 [
.
0265
-.
0305]
1
.
07 [
.
042]
0.76-1.02
[.030-.040] 26 1.40 [.055] 0.76 [.030]
24
26
0 71-0 81 [ 028- 032]
26-22 1.02-1.27
[.040-.050] 24
0
.
71
-
0
.
81 [
.
028
-.
032]
1.07 [.042] 1.40 [.055] 0.76 [.030]
22 0.81-0.91 [.032-.036]
24
1.73 [.068]
Max 22 --- ---
24-20
20
0 70-0 80 [ 0275- 0315]
1 40 [ 055]
24
-
20
24
0
.
70
-
0
.
80 [
.
0275
-.
0315]
1
.
40 [
.
055]
1.27-1.52
[.050-.060] 22 1.40 [.055] 1.27 [.050]
20
22
0 84-0 94 [ 033- 037]
22-18 1.73 [.068]
Max 20
0
.
84
-
0
.
94 [
.
033
-.
037]
1.57 [.062] --- ---
18 1.07-1.17 [.042-.046]
Figure 3 (cont’d)
HD-20 Precision Formed Contacts 114-10000
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AUTOMATIC MACHINE
WIRE CRIMP DIMENSIONS
WIRE
SIZE WIRE INSUL
DIA
SIZE OF
WIRE
WIRE BARREL CRIMP INSULATION BARREL
CRIMP
RANGE
(AWG)
DIA
ACCEPTED
WIRE
APPLIED HEIGHT RANGE TENSILE STRENGTH
N [LB] Min WIDTH WIDTH
(Ref) HEIGHT
(Ref)
076 102
32 0.58-0.46 [.023-.018] 8.01 [1.8]
135 157
064 193
32-28 0.76-1.02
[.030-.040] 30 0.61-0.46 [.024-.018] 10.01 [2.2] 0.84 [.033] 1.35-1.57
[.053-.062]
0.64-1.93
[.025-.076]
[]
28 0.63-0.51 [.025-.020] 11.12 [2.8]
[]
[]
28 0.66-0.76 [.026-.030] 12.01 [2.7]
1.73 [.068]
Max 26 0.71-0.81 [.028-.032] 20.02 [4.5] --- ---
24 0.76-0.86 [.030-.034] 35.91 [8.0]
28 0.64-0.69 [.025-.027] 12.01 [2.7]
28-24 1.27-1.52
[.050-.060] 26 0.71-0.76 [.028-.030] 20.02 [4.5] 1.07 [.042] 1.35-1.57
[.053-.062] 1.14-1.93
[.045-.076]
24 0.79-0.84 [.031-.033] 35.91 [8.0]
28 0.64-0.69 [.025-.027] 12.01 [2.7]
0.76-1.02
[.030-.040] 26 0.74-0.79 [.029-.031] 20.02 [4.5] 1.35-1.57
[.053-.062] 0.64-1.93
[.025-.076]
24 0.79-0.84 [.031-.033] 35.91 [8.0]
26 0.71-0.81 [.028-.032] 20.02 [4.5]
26-22 1.02-1.27
[.040-.050] 24 0.76-0.86 [.030-.034] 35.91 [8.0] 1.07 [.042] 1.35-1.57
[.053-.062] 0.64-1.93
[.025-.076]
22 0.86-0.97 [.034-.038] 53.38 [12.0]
24 0.76-0.86 [.030-.034] 35.91 [8.0]
1.73 [.068]
Max 22 0.76-0.86 [.030-.034] 53.38 [12.0] --- ---
24-20
20 0.76-0.86 [.030-.034] 88.96 [20.0]
1 40 [ 055]
24
-
20
24 0.76-0.86 [.030-.034] 35.91 [8.0]
1
.
40 [
.
055]
1.27-1.52
[.050-.060] 22 0.76-0.86 [.030-.034] 53.38 [12.0] 1.35-1.57
[.053-.062] 1.14-1.93
[.045-.076]
20 0.76-0.86 [.030-.034] 88.96 [20.0]
22 0.84-0.94 [.033-.037] 53.38 [12.0]
22-18 1.73 [.068]
Max 20 0.89-0.99 [.035-.039]
88 96 [20 0]
1.57 [.062] --- ---
18 1.07-1.17 [.042-.046]
88
.
96 [20
.
0]
Figure 3 (end)
HD-20 Precision Formed Contacts 114-10000
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Tyco Electronics Corporation
3.4. Crimped Contact Straightness
A. Twist or Roll
The crimped wire and insulation barrels must be aligned with the un–crimped portion of the contact to
within the limit shown in Figure 4.
Figure 4
Wire Barrel
Front of Contact
(Pin or Socket) 15
_
(Max)
B. Straightness
Test questionable contacts using a straightness gage manufactured to the specifications of Figure 5. To be
considered acceptable for use, a contact must fully enter the gage without binding.
ÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉ
Figure 5
NOTES:
Material Tool Steel, AISI Type 01 or 02........
Hardness Rockwell B99 Maximum...........
Finish Black Oxide......................
1.77 + 0.03
[.0695 + .0010] DIA
-A-
1.07 + 0.03
[.042 + .001] DIA
-B-
2.16 + 0.01
[.0850 + .0005] DIA
0.10 [.004] B
12.7 + 0.51
[.500 + .020]
DIA
Pin End
7.11
[.280]
6.35
[.250] 7.37
[.590]
29.97 + 0.51
[1.180 + .020]
2.16 + 0.01
[.0850 + .0005] DIA
0.10 [.004] A
Socket
End
3.5. Solder Cup Contacts
Observe the guidelines and procedures described in Instruction Sheet 408–7799 when solder cup contacts are
required. Solder, clean, and dry all wire leads to contacts according to the following:
A. Flux Selection
Wire lead and contact wire barrel interior shall be fluxed prior to soldering using a mildly active rosin. Flux
must be compatible with manufacturing, safety, and health guidelines.
B. Cleaning
After cleaning, removal of fluxes, residues, and activators is mandatory. Cleaning procedures and solvents
depend on the type of flux used. See Figure 6.
HD-20 Precision Formed Contacts 114-10000
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Consideration must be given to toxicity and other safety and health requirements as recommended in the Material
Safety Data Sheet supplied by the solder cleaning solvent manufacturer.
CLEANER TIME
(Mi )
TEMPERATURES (Maximum)
NAME TYPE (Minutes) CELSIUS FAHRENHEIT
Alpha 2110
H
Aqueous 1 132 270
Bioact EC-7
z
Solvent 5 100 212
Butyl Carbitol
D
Solvent 1 Room Ambient
Isopropyl Alcohol Solvent 5 100 212
Kester 5778
s
Aqueous 5 100 212
Kester 5779
s
Aqueous 5 100 212
Loncoterge 520
D
Aqueous 5 100 212
Loncoterge 530
D
Aqueous 5 100 212
Terpene Solvent Solvent 5 100 212
H
Product of Fry’s Metals, Inc.
z
Product of Petroferm, Inc.
D
Product of Union Carbide Corp.
s
Product of Litton Systems, Inc.
Figure 6
C. Drying
When drying cleaned assemblies, DO NOT exceed recommended temperature limitations. Excessive
temperatures may cause degradation of the connector used as a stabilizer during the soldering process.
D. Soldering Guideline
Manual 402–40 is available upon request and can be used as a guide in soldering. This manual gives
various flux types and characteristics, commercial designation, and flux removal procedures. A checklist is
included in the manual to aid in obtaining information pertaining to soldering problems.
3.6. Posted Contacts
Pin and socket contacts having 0.64 mm [.025 in.] square technology posted aft ends are available to fit
HD–20 connectors. Posts 3.18 mm [.125 in.], 4.78 mm [.188 in.], 10.80 mm [.425 in.], and 16.54 mm [.651 in.]
in length are offered, allowing a variety of mating or grounding options. When inserting posted contacts into
housings, be careful to hold the contact by the transition flange. See Figure 1.
3.7. Repair/Replace
Use Insertion/Extraction Tool 91285–1 (Instruction Sheet 408–9404) to remove individual contacts from
housings for replacement or for relocation to another housing cavity. Damaged or worn contacts may be
replaced provided there is sufficient slack, after restripping the wire, to insert the new contact.
DO NOT re-use damaged or worn contacts. Instead, replace them with new contacts and discard the old ones.
4. QUALIFICATION
No qualifications or approvals are required for HD–20 Precision Formed Contacts.
5. TOOLING
HD–20 Precision Formed Contacts can be terminated to wire using hand, semi–automatic, or automatic
crimping tools. Recommended tooling, and instructional material, is provided in Figure 7.
All hand tools and applicators include integral dies. The automatic machines that hold applicators are also
listed in the table along with related documentation.
The Model K" AMP-O-LECTRIC Terminating Machine 565435-5 has been superseded by the Model G" Terminating
Machine 354500-1 for new applications. For existing applications, the Model K" is still recommended because of the
large number of installed machines.
DANGER
CAUTION
!
NOTE
i
HD-20 Precision Formed Contacts 114-10000
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Tyco Electronics Corporation
WIRE SIZE RANGE
(AWG) WIRE INSULATION
DIAMETER ACCEPTED HAND TOOL
(408-8547) APPLICATOR
g
(408-8040) AUTOMATIC
MACHINE MACHINE
DOCUMENT
32-28
0 76-1 02 [ 030- 040]
---
680659-2
354500-1 409-5842
32
-
28
0
.
76
-
1
.
02 [
.
030
-.
040]
---
680659
-
2
565435-5 409-5128
1 73 [ 068] Max
91548-1
466506-2 565435-5 409-5128
1
.
73 [
.
068] Max
91548
-
1
466903-1 1320895-1 409-10012
127 152
466758-2
354500-1 409-5842
1
.
27
-
1
.
52
[
.050-.060
]
91549-1
466758
-
2
565435-5 409-5128
28-24
[ 050 060]
466963-1 1320895-1 409-10012
466423-1
122500-2, -3 409-5852
0.76-1.02 91503-1
or
466423
-
1
356500-1, -2 409-5878
[.030-.040]
or
91549-1
466423-2
354500-1 409-5842
466423
-
2
565435-5 409-5128
466901-1 1320895-1 409-10012
122500-2, -3 409-5852
26-24
567036-1
356500-1, -2 409-5878
26
-
24
1.02-1.27
91525-1
567036
-
1
662700-[ ] 409-5884
[.040-.050]
91525
-
1
1213400-1, -2 409-5878
22
567036-2
354500-1 409-5842
22
567036
-
2
565435-5 409-5128
466505-1
122500-2, -3 409-5852
466505
-
1
356500-1, -2 409-5878
1.73 [.068] Max 91548-1
466505-2
354500-1 409-5842
466505
-
2
565435-5 409-5128
24-20
466902-1 1320895-1 409-10012
24
-
20
466422-1
122500-2, -3 409-5852
127 152
466422
-
1
356500-1, -2 409-5878
1
.
27
-
1
.
52
[
.050-.060
]
91503-1
466422-2
354500-1 409-5842
[ 050 060]
466422
-
2
565435-5 409-5128
466900-1 1320895-1 409-10012
122500-2, -3 409-5852
22-20
356500-1, -2 409-5878
22
-
20
1 73 [ 068] Max
91513-1
567033-1
or
662700-[ ] 409-5884
1
.
73 [
.
068] Max
91513
-
1
or
567033-2 1213400-1, -2 409-5878
18
354500-1 409-5842
18
565435-5 409-5128
g
In order to use the same applicator in the AMPOMATOR CLS IV Lead-Making Machine and the AMP-O-LECTRIC Terminating Machine,
the feed cam and wire stripper must be changed. See the Customer Manuals supplied with these machines.
Figure 7 (cont’d)
HD-20 Precision Formed Contacts 114-10000
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Figure 7 (end)
AMP-O-MATIC Side Feed
Stripper-Crimper Model III
Machine 1320895-[ ]
(409-10012)
AMPOMATOR CLS IV+ Lead-Making Machine (409-5878)
AMPOMATOR CLS Model III-G Lead-Making Machine
122500-[ ] (409-5852)
AMP-O-LECTRIC Model G"
Terminating Machine
354500-[ ] (409-5842)
HD Quick Change Applicators
(408-8040)
Typical Hand Tool
(408-8547)
Insertion/Extraction Tool
91285-1 and Replacement Tip
Kits 543382-[ ] (408-9404)
Basic AMP-O-LECTRIC Model K"
Terminating Machine 565435-5
(409-5128)
HD-20 Precision Formed Contacts 114-10000
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Tyco Electronics Corporation
6. VISUAL AID
Figure 8 shows a typical application of HD–20 Precision Formed Contacts. This illustration should be used by
production personnel to ensure a correctly applied product. Applications which DO NOT appear correct should
be inspected using the information in the preceding pages of this specification and in the instructional material
shipped with the product or tooling.
FIGURE 8. VISUAL AID
NOTE: CRIMPED CONTACT WITH INSULATION BARREL SHOWN; SAME REQUIREMENTS
ALSO APPLY TO CONTACTS WITHOUT INSULATION BARREL
WIRE BARREL SEAM CLOSED WITH
NO CONDUCTOR STRANDS SHOWING
CONDUCTOR ENDS MUST BE
VISIBLE IN THIS AREA
WIRE CONDUCTORS AND
INSULATION MUST BE
UNDAMAGED
WIRE CONDUCTORS AND INSULATION MUST BOTH BE
VISIBLE IN THIS AREA (NO WIRE INSULATION MAY BE
IN THE WIRE BARREL)
REAR BELLMOUTH
MUST BE VISIBLE FRONT BELLMOUTH MAY
SHOW SLIGHTLY
CUTOFF TAB MUST
BE VISIBLE
THERE MUST BE NO
TWIST, ROLL, OR BEND
HERE
THERE MUST BE NO DAMAGE OR
DISTORTION TO CONTACT OR
RETENTION FEATURE
