Application Specification
AMPLIMITE* HDP-22
Connectors and 114-10001
LOC B
1
of 17
E
2008 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
High-Density 22DF Contacts
18 DEC 08 Rev G
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 AMPLIMITE HDP–22 Crimp Snap–In Contact
Connectors with all–plastic contact retention and the 22DF Contacts used in the connectors. These connectors
will mate with any size 22 Subminiature D connector that has dimensions complying with MIL–C–24308.
AMPLIMITE HDP–22 Connectors are available in shell sizes 1 through 5. These connectors are designed with
cavity identification and features for easy polarization and mating. See Figure 2.
The connectors have centerlines of 2.29 x 1.98 mm [.090 x .078 in.] for shell sizes 1, 2, and 3; 2.41 x 1.98 mm
[.095 x .078 in.] for shell size 4; and 2.41 x 2.08 mm [.095 x .082 in.] for shell size 5. The contacts will accept a
wire size range of 28 to 22 AWG with an insulation diameter range of 0.76–1.02 mm [.030–.040 in.]. The wire
strip length shall be 3.97 mm [5/32 in.] if hand stripped and 3.56 mm [.140 in.] if digital stripping equipment is
used. AMPLIMITE HDP–22 Connectors have a variety of shielded and unshielded cable clamps, covers,
mounting hardware, retainers, locking posts, screwlocks, slide and spring latches, and latching blocks to
choose from for your mounting requirements. Contacts, inner and outer ferrules can be applied by hand or
machine, depending on your termination requirements.
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.
Figure 1
Connector Shell
Pin Contact
Insulation
Barrel
Retention
Feature
Retention
Feature
Socket
Contact
Receptacle Housing
(Accepts Socket Contacts)
Plug Housing
(Accepts Pin Contacts)
Wire Barrel
NOTE
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2. REFERENCE MATERIAL
2.1. Revision Summary
This paragraph is reserved for a revision summary of the most recent additions and changes made to this
specification which include the following:
S
Updated specification to corporate requirements
S
Deleted obsolete documents and added new documents in Paragraphs 2.4.B and 2.5
S
New logo and format
2.2. Customer Assistance
Reference Part Number 748333 and Product Code 4868 are representative numbers of AMPLIMITE HDP–22
Connectors and High–Density 22DF 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
Tooling Assistance Center or Product Information number at the bottom of page 1.
2.3. Drawings
Customer Drawings for specific products 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 other technical
documentation supplied by Tyco Electronics.
2.4. Specifications
A. Product Specifications
Product Specification 108–1268 provides product performance requirements and test information. Product
Specification 108–1092 provides related AMPLIMITE Connector Printed Circuit (PC) Board requirements.
B. Application Specifications
The following Application Specifications provide design, inspection and assembly procedures for related
AMPLIMITE HD–22 Connectors:
Document Number Document Title
114–13198 AMPLIMITE HD–22 Right–Angle Front Metal Shell Connectors
114–13199 AMPLIMITE HD–22 Straight Front Metal Shell Connectors
C. Military Specifications
These assembled connectors conform to the requirements of MIL–C–24308.
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
408–2498 Crimping Head Cross Reference for Pneumatic Tools
408–3295 Preparing Reel of Contacts for Application Tooling
408–4007 PRO CRIMPER* II Hand Tool Assembly 90800–1 with Die Assembly 90800–2
408–4106 Straight Action Crimp Head Adapter
408–4190 C–Head Pneumatic Adapter 318161–1
408–4390 Applicator 2000 (For Side–Feed Applications)
408–6551 Slide Latch Kits and Locking Post Kits
408–6609 AMPLIMITE HD–20 Shielded Cable Clamp Kits
408–6769 AMPLIMITE HDP–20, HDP–22, and HDE–20 R/A, Metal Shielded Cable Clamp Kits
408–7424 Checking Terminal Crimp Height or Gaging Die Closure
408–7555 Cable Clamp Assemblies for AMPLIMITE HD–20 and HD–22 Connectors
408–7837 Female Screwlock Kits and Male Screw Retainer Kits
408–8040 Heavy Duty Miniature Quick–Change Applicators (Side–Feed Type)
408–8053 Conversion Guide for Miniature Quick–Change Applicators
408–8083 Ferrule Applicator Assembly No. 812407–1
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Document Number Document Title
408–9128 AMPLIMITE Latching Blocks
408–9130 Two–Piece Spring Latches for AMPLIMITE Connectors with Cable Clamps
408–9131 Two–Piece Spring Latches for AMPLIMITE Connectors w/Post Molded Strain Relief
408–9199 Shielding Enclosure Expansion Tool Kits 58241–1, –2, and –4
408–9238 Universal Cable Clamp Kits for AMPLIMITE Connectors
408–9315 Hand Crimping Tool 543344–1
408–9318 Die Assemblies 543013–[ ]
408–9375 Hand Crimping Tool 90430–1
408–9381 AMPLIMITE HDP–22 Connectors (Plugs and Receptacles) with Crimp–Type Contacts
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
409–5842 AMP–O–LECTRIC Model “G” Terminating Machine
409–5852 AMPOMATOR CLS III–G Lead Making Machine
409–5855 AMP–O–MATIC* Side Feed Stripper Crimper Model II Machine No. 854040–3 and –4
409–5862 626 Pneumatic Tool Assemblies 189721–[ ] and 189722–[ ]
409–5878 AMPOMATOR CLS IV+ Lead–Making Machine
3. REQUIREMENTS
3.1. Storage
Due to the design of the connector, some corrosion may occur on the metal shell near the crimp tabs and on the ends
of the shell. This condition does not affect the aesthetics, form, fit, or function of the connector or adjacent
components and is considered to be acceptable by Tyco Electronics.
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housing
material.
B. Reel Storage
When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically.
C. Shelf Life
The contacts and housings should remain in the shipping containers until ready for use to prevent
deformation to those components. The components 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, housings, or accessories 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 Sulfides Nitrites Tartrates
3.2. Special Characteristics
AMPLIMITE HDP–22 Connectors come in a variety of sizes for your production needs and are adaptable to a
variety of mounting and hardware requirements. See paragraph 3.4 for contact positions. Using a keystone
mating face configuration, these connectors incorporate multiple polarization and mating alignment features,
allowing flexibility in system design. The plug connector has an integral hood which protects the inserted pin
contacts. See Figure 2.
Crimped DF–22 Contacts, with retention shoulders, are inserted into the cavities in the BACK of the connector
housing and snap into place. The cavity rows are number–coded for your convenience. If your design does not
require the use of all cavities, the contacts should be distributed evenly throughout the connector.
NOTE
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AMPLIMITE HDP-22 Connectors and HD 22DF Contacts 114-10001
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After inserting a contact into the housing, pull back LIGHTLY on the wire to make sure the contact is fully seated.
Figure 2
High-Density 22DF Contacts
AMPLIMITE HDP-22 Connector Housings
Retention Feature
Pin Contact
Mating Socket
Contact
Keystone Mating Face
Receptacle Housing
(Accepts Socket Contacts)
Connector Shell
Plug Housing
(Accepts Pin Contacts)
Pin Hood
Back of Connector
Housing
Number Coded
Cavity Rows
3.3. Panel Mounting Requirements
HDP–22 Connectors are designed for rack and panel, free–hanging, or combination of free–hanging and panel
mounting applications. The plug should be mounted in the panel, and the receptacle in the rack. Refer to
Figure 3 for mating clearance requirements, dimensions, and layout for the mounting requirements.
Dimensions H and J apply when FRONT-MOUNTING the connector, or when using cable clamps or latching blocks.
NOTE
i
NOTE
i
AMPLIMITE HDP-22 Connectors and HD 22DF Contacts 114-10001
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A
C
D
F
EJ
H
B
G+0.05 [.002] Dia
(2 Places)
10
_
+ 2
_
(2 Places)
K Radius
(4 Places)
G Dia
(2 Holes
Per Cutout)
A
F
6.60 [.260] Min
Clearance
Between
Connectors
Plug
Receptacle
7.06
6.30 .278
.248
Mating
Clearance
1.02 [.040] Dia
(Typ) (2 Holes)
3.28 + 0.05
[.129 + .002]
Cutout for Rear
Mount and Short
Latching Blocks
CONNECTOR
POSITIONS PANEL
MTG
FLOATING DIMENSIONS +0.05 [.002]
AND
SHELL SIZE
MTG
POSN BUSHING A B C D E F G H
D
J
D
K
Front
Yes 23.01
[.906] 11.51
[.453] 13.84
[.545] 6.93
[.273] 2.24
[.088]
---
---
2.11
15 Position
Front
No 24.99 12.50
22.20
[.874] 11.10
[.437] 13.03
[.513] 6.53
[.257] 3.05
[.120]
--- --- [.083]
Size 1
Rear
Yes [.984] [.492] 21.29
[.838] 10.64
[.419] 12.22
[.481] 6.12
[.241] 2.24
[.088] --- --- 3.35
Rear
No 20.47
[.806] 10.24
[.403] 11.40
[.449] 5.72
[.225] 3.05
[.120] 13.97
[.550] 19.05
[.750]
[.132]
Front
Yes 31.34
[1.234] 15.67
[.617] 13.84
[.545] 6.93
[.273] 2.24
[.088]
---
---
2.11
26 Position
Front
No 33.32 16.66
30.53
[1.202] 15.27
[.601] 13.03
[.513] 6.53
[.257] 3.05
[.120]
--- --- [.083]
Size 2
Rear
Yes [1.312] [.656] 29.62
[1.166] 14.81
[.583] 12.22
[.481] 6.12
[.241] 2.24
[.088] --- --- 3.35
Rear
No 28.80
[1.134] 14.40
[.567] 11.40
[.449] 5.72
[.225] 3.05
[.120] 18.54
[.730] 19.05
[.750]
[.132]
Front
Yes 45.08
[1.775] 22.56
[.888] 13.84
[.545] 6.93
[.273] 2.24
[.088]
---
---
2.11
44 Position
Front
No 47.04 23.52
44.27
[1.743] 22.15
[.872] 13.03
[.513] 6.53
[.257] 3.05
[.120]
--- --- [.083]
Size 3
Rear
Yes [1.852] [.926] 43.33
[1.706] 21.67
[.853] 12.22
[.481] 6.12
[.241] 2.24
[.088] --- --- 3.35
Rear
No 42.52
[1.674] 21.26
[.837] 11.40
[.449] 5.72
[.225] 3.05
[.120] 32.28
[1.275] 19.05
[.750]
[.132]
D
Dimensions H and J apply when using cable clamps or latching blocks. Connectors with floating bushings are for
use in drawer applications, or other difficult alignment situations.
Figure 3 (cont’d)
AMPLIMITE HDP-22 Connectors and HD 22DF Contacts 114-10001
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CONNECTOR
POSITIONS PANEL
MTG
FLOATING
SG
DIMENSIONS +0.05 [.002]
AND
SHELL SIZE
MTG
POSN BUSHING A B C D E F G H
D
J
D
K
Front
Yes 61.54
[2.423] 30.78
[1.212] 13.84
[.545] 6.93
[.273] 2.24
[.088]
---
---
2.11
62 Position
Front
No 63.50 31.75
60.73
[2.391] 30.38
[1.196] 13.03
[.513] 6.53
[.257] 3.05
[.120]
--- --- [.083]
Size 4
Rear
Yes [2.500] [1.250] 59.79
[2.354] 29.90
[1.177] 12.22
[.481] 6.12
[.241] 2.24
[.088] --- --- 3.35
Rear
No 59.08
[2.326] 29.54
[1.163] 11.40
[.449] 5.72
[.225] 3.05
[.120] 48.77
[1.920] 19.05
[.750]
[.132]
Front
Yes 59.16
[2.329] 29.59
[1.165] 16.64
[.655] 8.33
[.328] 2.24
[.088]
---
---
2.11
78 Position
Front
No 61.11 30.56
58.34
[2.297] 29.18
[1.149] 15.82
[.623] 7.92
[.312] 3.05
[.120]
--- --- [.083]
Size 5
Rear
Yes [2.406] [1.203] 57.15
[2.250] 28.58
[1.125] 14.91
[.587] 7.47
[.587] 2.24
[.088] --- --- 3.35
Rear
No 56.34
[2.218] 28.17
[1.109] 14.10
[.555] 7.06
[.278] 3.05
[.120] 43.64
[1.718] 19.05
[.750]
[.132]
D
Dimensions H and J apply when using cable clamps or latching blocks. Connectors with floating bushings are for
use in drawer applications, or other difficult alignment situations.
Figure 3 (end)
3.4. Hardware and Accessories (Placement and Assembly)
AMPLIMITE HDP–22 connectors are available with the mounting hardware and accessories shown in Figure 4.
For more information on these or other hardware and accessories, call the Product Information number at the
bottom of page 1.
Instruction material listed with each accessory provides details for product selection and assembly procedures.
Some of the instructions were written for the AMPLIMITE HDP–20 Connector product line, however, HDP–22
connectors use the same outer shell size, enabling the same accessories to be used with both product lines.
Figure 4 is a cross–reference by shell size to guide you in selecting the proper accessories for the size
connector you wish to use.
Refer to Paragraph 2.5, Instructional Material, for procedures on using the following assembly and mounting hardware.
Before securing cable clamp halves, make sure you have sufficient slack in the wire to prevent the wire from being
taut.
A. Plastic Cable Clamp
Cable clamp assembly kits are available in straight/45
_
and straight/90
_
versions. The clamp assemblies
can be mated using spring latches and latching blocks, or using screwlocks and retainers.
B. Metal Cable Clamp
Metal RFI/EMI Shielded Cable Clamp Assemblies come in two–piece kits, and are available in both
straight–exit and 90
_
–exit versions. The straight–exit shield is attached to the connector using saddle
screws. The 90
_
–exit shield is attached using slide latches and screws.
C. Universal Cable Clamp
Universal cable clamp kits are available for size 3 connectors ONLY. Each kit consists of two cable clamp
halves, a two–piece braid termination clamp set (shielded versions only), a cable clamp wedge set, and
screws.
NOTE
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NOTE
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Figure 4 (cont’d)
One-Piece Slide
Latch Assembly Kit
Y
Typical Slide
Latch Application
Locking Post
Assembly Kit
Two-Piece Slide
Latch Assembly Kit
Straight 90
_
Cable Clamp
Assembly Kit (Assembled)
4-40 Screw
(2)
One-Piece
Slide Latch
Flat Washer (2)
Lockwasher (2)
4-40 Hex
Nut (2)
4-40 Hex
Nut (2)
Lockwasher (2)
Shim (Between Connector
Flange and Panel When
Front-Mounted;
Not Supplied)
Flat Washer (2)
4-40 Locking
Post (2)
4-40 Hex
Nut (2)
Lockwasher (2)
Flat Washer
(2)
Slide
Latch (2)
4-40 Screw (2)
Screw (3)
Cable Clamp
Assembly
Latching
Block (2)
M3 Metric
Screw (2)
Plug
(Ref)
Receptacle
(Ref)
Spring
Latch (2)
Y
One-piece slide latches for shell sizes 1 and 4 cannot be used with cable clamps that extend
beyond the front of the connector flange.
AMPLIMITE HDP-22 Connectors and HD 22DF Contacts 114-10001
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Figure 4 (end)
Assembled
Screwlock
(Ref)
Retainer
(2)
Retainer
Screw (2) Hex Nut
(2)
Lockwasher (2)
Flat Washer
(4)
Female
Screwlock (2)
Cable Clamp Assembly with
Screwlocks and Retainers
Two-Piece
Shield
4-40 Saddle
Screw (2)
4-40 Fillister
Head Screws
and Hex Nuts
(2 Each)
Connector 4-40 Slide Latch
Screw (2)
One-Piece
Slide Latch
4-40 Pan Head
Screw (3)
Connector
Straight Exit RFI/EMI Shielded
Cable Clamp Assembly Kit 90
_
Exit RFI/EMI Shielded
Cable Clamp Assembly Kit
D. Slide Latch Assembly
One–piece slide latch assemblies and two–piece slide latch clips attach to the connector mating face. The
mating connector uses locking post assemblies onto which the slide latch assembly will latch.
E. Ferrules
For applications using jacketed shielded cable with AMPLIMITE shields, three types of ferrules are
available. Split–ring ferrules are used with foil or braided shields and are not crimped. Inner and outer
crimped ferrules are for use on braid–shielded cable only. See Figure 5.
Figure 5
CABLE DIAMETER RANGE
SHELL
SIZE
INNER AND
OUTER
FERRULES
SPLIT-RING
FERRULES
14.83 - 9.40
[.190 - .370]
24.83 - 10.92
[.190 - .430]
34.83 - 13.46
[.190 - .530]
44.83 - 16.51
[.190 - .650]
54.83 - 19.05
[.190 - .750]
4.06 - 9.40
[.160 - .370]
4.70 - 10.92
[.185 - .430]
6.10 - 13.46
[.240 - .530]
7.87 - 16.51
[.310 - .650]
8.51 - 19.05
[.335 - .750]
Conductors
Inner
Ferrule
Flared
Braid Cable
Jacket
Outer
Ferrule
Cable
Jacket
Ground Wire
Split-Ring
Ferrule
Foil or Braid
(To be Folded Back Over
Ferrule and Ground
Wire)
Conductors
Crimp Ferrules for
Braided Cable Shield
Split-Ring Ferrules
for Foil or Braided
Cable Shield
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3.5. Wire Selection and Preparation
A. Types
The contact will accept discrete copper solid, fused–stranded, or stranded conductor wire within the range
of 28 through 22 AWG.
B. Preparation
Position the crimp ferrule over the cable jacket before stripping wire.
The wire must be stripped to the dimension provided in Figure 6.
Do not nick, scrape, or cut the wire conductor during the stripping operation.
Figure 6 provides information on insulation strip lengths as determined by the size contact used. Also
listed are acceptable wire insulation outside diameters for the contacts, crimp width, and crimp height.
Crimp the contact in the appropriate tooling according to the instructions packaged with that tooling.
Insulation
Strip
Length
NOTE:
Not to Scale
WIRE SIZE, INSULATION STRIP WIRE BARREL CRIMP INSULATION BARREL CRIMP
,
AWG DIAMETER LENGTH HEIGHT
D
WIDTH WIDTH HEIGHT (REF)
28 0.58-.074 [.023-.029]
26 0.76-1.02 3.56 [.140]
or
0.64-0.74 [.025-.029] 1.22-1.02 1.47-0.97 1.45
24 [.030-.040]
or
3.97
[
.156
]
[
0.71-0.84 [.028-.033] [.048-.040] [.058-.038] [.057]
22
3.97 [.156]
[
0.74-0.91 [.029-.036]
D
The crimp height range listed in each row represents the entire range for all available tooling. The crimp heights and tolerances specified in
specific tooling instruction material or applicator logs supercedes the values in this table.
[
Hand Stripping Only
Figure 6
3.6. Tensile Inspection
Crimped contacts should hold the wire firmly and have a crimp pull–out test value meeting that specified in the
chart in Figure 7.
Adjust tensile testing machine for head travel of 25.4 mm [1 inch] per minute. Directly and gradually apply force for 1
minute.
CRIMP PULL OUT TEST
WIRE SIZE, AWG MINIMUM FORCE NEWTONS (POUNDS)
28 12.01 [2.7]
26 20.02 [4.5]
24 35.56 [8.0]
22 53.38 [12.0]
Figure 7
NOTE
i
CAUTION
!
NOTE
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3.7. Crimped Contact Requirements
A. Axial Concentricity
The axial concentricity of a crimped contact shall 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. The contact, including the cutoff tab and burr, shall pass through a 15.88 mm [.625 in.] long, straight
tube with an inside diameter of 1.60 mm [.063 in.]. After inserting the mating end of the crimped contact
into the tube, the contact shall pass through the tube without interference between the inside diameter of
the tube and the contact insulation barrel or the cutoff tab. See Figure 8.
Figure 8
Circle Diameter
Contact and
Circle Diameter
Centerlines
Contact
WIRE SIZE,
AWG CIRCLE
DIAMETER
28
26
24
22
1.69 [.0665]
B. Twist and Roll
There shall be no twist, roll, deformation, or other damage to the mating portion of the crimped contact
that will prevent proper insertion into the connector housing or that will prevent mating with its counterpart
contact. Test questionable contacts using a straightness gage manufactured to the specifications of
Figure 9. To be considered acceptable for use, a contact must fully enter the gage without binding.
Figure 9
-A-
-B-
.0.10 [004] B
Pin
End
Socket End
1.588 + 0.025 [.0625 + .0010]
0.813 + 0.025 [.032 + .001]
1.676 + 0.013 [.0660 + .0005]
12.7 + 0.5
[.500 +.020
Dia
.0.10 [004] A
1.676 + 0.013 [.0660 + .0005]
7.11
[.280]
6.35
[.250] 14.99
[.590] 29.97 + 0.51
[1.180 + .020]
NOTES:
Material: Tool Steel, AISI Type 01 or 02
Hardness: Rockwell B99 Maximum
Finish: Black Oxide
Figure 10 shows a typical contact as it should appear after crimping. Figure 6 lists proper crimp dimensions.
AMPLIMITE HDP-22 Connectors and HD 22DF Contacts 114-10001
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Periodic inspections must be made to ensure crimped contact formation is consistent as referenced in Figure 10.
C. Crimp Location
For optimum crimp effectiveness, the crimp must be within the area shown and must meet the crimp
requirements provided in Figure 6. Effective crimp length shall be 2.06 mm [.081 in.] minimum, 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.
D. Conductor Extension
The conductor may extend beyond the wire barrel to the maximum shown.
E. Wire Barrel Seam
The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam.
F. Conductor/Insulation
The conductor and insulation must both be visible in the area between the insulation barrel and the wire
barrel.
G. Bellmouths
Front and rear bellmouths shall be formed and adhere to the dimensions given.
H. Cutoff Tab
The cutoff tab shall not be longer than 0.25 mm [.010 in.].
I. Burrs
The burr on the cutoff tab shall not exceed 0.13 mm [.005 in.].
Figure 10
Conductor Extension
+0.51/-0 [+.020/-.000]
Wire Insulation and
Conductors Must Both
be Visible in This Area
Wire Barrel Closed at Seam with
No Strands Protruding or Showing
Front Bellmouth
0.18 [.007] Max
Effective Crimp Length
Rear Bellmouth
0.36 + 0.15
[.014 + .006] X
X
Wire
Barrel
Flash
No Damage or Distortion to the
Contact or the Retention Feature
Cutoff Tab Must be
Visible - See View A
0.25 [.010] Max
Cutoff Tab
Section X-X
0.25 [.010] Max
Wire Barrel Flash
Wire Barrel
Crimp Width
Wire Barrel
Crimp Height
0.13 [.005]
Max. Burr
View A
NOTE
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of 17 Tyco Electronics Corporation
J. Flash
The wire barrel flash shall not exceed the dimensions shown in Section X–X. See Figure 10.
K. Straightness
The contact, including the cutoff tab and burr, shall not be bent above or below the datum line more than
the amount shown. The side–to–side bending of the contact shall not exceed the limits specified. See
Figure 11.
Figure 11
Datum LIne
5
_
Max
5
_
Max
5
_
Max
5
_
Max
3.8. Precautions
Do not over-tighten, or use excessive force in mating connector housings or mounting hardware. Push testing is not
recommended as it could damage the locking tines in the housing.
3.9. Repair/Replacement
Do NOT re-use damaged contacts.
Contacts are not repairable once a termination has been made. Any defective contact should be removed and
replaced with a new one. Damaged contacts can be removed from the housing by using Insertion/Extraction
Tool 91285–1. Refer to Instruction Sheet 408–9404 for extraction procedures.
4. QUALIFICATIONS
AMPLIMITE HDP–22 Connectors are Listed by Underwriters Laboratories Inc. (UL) in File Number E81956
and Recognized with the Component Program in file No. E28476, and Certified by CSA International in File
Number LR 16455. These connectors are also Mil–Spec Qualified with MIL–C–24308.
5. TOOLING
A listing of tooling recommendations covering the full wire size range is provided in Figure 12. The listing
includes semi–automatic and automatic machines for power assisted application of strip form contacts.
Modified designs and additional tooling concepts may be available to meet other application requirements. For
additional information, contact one of the service groups at the bottom of page 1.
Tyco Electronics Tool Engineers have designed machines for a variety of application requirements. For assistance in
setting up prototype and production line equipment, contact Tool Engineering through your local Tyco Electronics
Representative or call the Tooling Assistance Center number at the bottom of page 1.
S
Applicators
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.
CAUTION
!
CAUTION
!
NOTE
i
AMPLIMITE HDP-22 Connectors and HD 22DF Contacts 114-10001
Rev
G 13
of 17
Tyco Electronics Corporation
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 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.
The Model K" AMP-O-LECTRIC Terminating Machine PN 565435-5 has been superseded by the Model G"
Terminating Machine PN 354500-1 for new applications. For existing applications, the Model K" is still recommended
because of the large number of installed machines.
S
Hand Tools
Hand crimping tools that accommodate the full wire range are designed for prototype and low–volume
applications such as repair of damaged contacts.
S
Crimping Die Assemblies
Crimping Die Assemblies for crimping the contacts or ferrules are available for the full wire or cable size
range. They are designed for easy installation and removal in hand crimping tool frame assemblies or
applicators.
S
Expansion Tools
Expansion tools are recommended for expanding the cable exit hole in the shielding enclosure to ease
insertion of the jacketed cable into the enclosure.
S
Insertion/Extraction Tools
Insertion/Extraction tools are designed for contacts crimped to small fragile wire. They are designed to
stabilize the contact during insertion. The extraction tip is used to release the contacts inside the
connector housings without damaging the housing or contacts.
WIRE SIZE,
AWG INSULATION
DIAMETER HAND TOOL
(DOCUMENT)
CRIMPING
DIES
(DOCUMENT)
HEAD
(DOCUMENT)
PNEUMATIC
HOLDER
(DOCUMENT)
APPLICATOR
(DOCUMENT) POWER UNIT
(DOCUMENT)
28 0.76-1.02
[.030-.040] --- --- --- --- 567906-1 854040-3
(409-5855)
90430-1
(408-9375)
or
90800-1
(408-4007)
--- --- --- --- ---
189721-1
(409-5862) 90430-2 217201-1
(408-4106)
189928-1
(408-2498)
(408-4190) --- ---
28-22 0.76-1.02
[.030-.040] 466975-1, -5
]
854040-3
(409-5855)
--- --- --- --- 567243-1
(408-8040)
122500-2, -3
(409-5852)
356500-1, -2
(409-5878)
662700-[ ]
(409-5884)
1213400-1, -2
(409-5878)
]
Designed to meet IBM crimp specification, only 28-24 wire size range.
Figure 12 (cont’d)
NOTE
i
NOTE
i
AMPLIMITE HDP-22 Connectors and HD 22DF Contacts 114-10001
Rev
G14
of 17 Tyco Electronics Corporation
WIRE SIZE,
AWG INSULATION
DIAMETER HAND TOOL
(DOCUMENT)
CRIMPING
DIES
(DOCUMENT)
HEAD
(DOCUMENT)
PNEUMATIC
HOLDER
(DOCUMENT)
APPLICATOR
(DOCUMENT) POWER UNIT
(DOCUMENT)
567243-2
(408-8040)
354500-1
(409-5842)
565435-5
(409-5128)
0.76-1.02
[.030-.040] --- --- --- --- 567243-3
(408-8040) 354500-[ ]
(409-5842)
[]
567809-1 854040-4
(409-5855)
28 22
1016013-[ ]
G
(408-4390) See Note
G
28
-
22
1.90-2.16
[.075-.085] --- --- --- ---
567429-1
(408-8040)
122500-2, -3
(409-5852)
356500-1, -2
(409-5878)
662700-[ ]
(409-5884)
1213400-1, -2
(409-5878)
567429-2
(408-8040)
354500-1
(409-5842)
565435-5
(409-5128)
Ferrule Crimp Tooling
Die 543013-[ ]
Hand Tool
543344-1
Applicator
s
812407-1
NOTE:
G
Applicator 2000 will fit most available power units. Contact the Tooling Assistance Center number at the bottom of page 1 for specific
machines, documentation, and conversion information.
s
Use with die set 813809 and machine 565435-5 or 354500-1.
Figure 12 (cont’d)
AMPLIMITE HDP-22 Connectors and HD 22DF Contacts 114-10001
Rev
G 15
of 17
Tyco Electronics Corporation
Figure 12 (cont’d)
HD22 Contact Crimp Tooling
Hand Tool
90430-1
Typical Heavy Duty
Quick-Change
Mini-Applicator
Applicator 2000
1016013-[ ]
SAHT Head
Assembly
90430-2
Straight Action
Pneumatic Holder
189928-1
Pneumatic SAHT
Adapter 217201-1
Hand Power Unit
189721-1
Miscellaneous Tooling
Shielding Enclosure
Expansion Tool
58241-[ ]
Insertion/Extraction
Tool 91285-1
ADUZI Lead-Making
Machine 662700
PRO CRIMPER
Hand Tool
90800-1
AMPLIMITE HDP-22 Connectors and HD 22DF Contacts 114-10001
Rev
G16
of 17 Tyco Electronics Corporation
Figure 12 (end)
AMPOMATOR
CLS III-G 122500-[ ]
AMP-O-MATIC
Side Feed
Stripper-Crimper II
Machine 854040-[ ]
AMP-O-LECTRIC
Model K"
Terminating Machine
565435-5
AMPOMATOR CLS IV+
Lead-Making Machines
356500-[ ], 1213400-1, -2
AMP-O-LECTIRC
Model G" Terminating
Machine 354500-[ ]
HD22 Contact Crimp Tooling
AMPLIMITE HDP-22 Connectors and HD 22DF Contacts 114-10001
Rev
G 17
of 17
Tyco Electronics Corporation
6. VISUAL AID
Figure 13 shows a typical application of AMPLIMITE HDP–22 Connectors and High–Density 22DF 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 13. VISUAL AID
PULL LIGHTLY ON EACH INDIVIDUAL
WIRE TO BE SURE THE CONTACTS
ARE FULLY SEATED
ASSEMBLY ACCESSORIES SHOULD
BE PROPERLY MATCHED AND
SECURELY HELD IN PLACE
BY THE HARDWARE
MAKE SURE
HARDWARE
IS SECURE
MATING CONNECTOR
(Same Shell Size and
Number of Positions)
PLUG OR RECEPTACLE
CONNECTOR MUST BE
UNDAMAGED
NOTE: TYPICAL APPLICATION SHOWS FREE-HANGING CONNECTORS WITH LOCKING POSTS AND SLIDE LATCH
CONDUCTOR ENDS MUST
BE VISIBLE IN THIS AREA WIRE BARREL MUST
BE CLOSED AT SEAM
WITH NO STRANDS
PROTRUDING OR
SHOWING
CONDUCTORS AND
INSULATION SHOULD
NOT BE CUT, NICKED,
OR SCRAPED
WIRE INSULATION AND
CONDUCTORS MUST BOTH
BE VISIBLE IN THIS AREA
(No Wire Insulation May be
in The Wire Barrel)
FRONT BELLMOUTH
MAY SHOW SLIGHTLY
REAR BELLMOUTH
MUST BE VISIBLE
CUTOFF
TAB MUST
BE VISIBLE
NO DAMAGE OR DISTORTION
TO THE CONTACT OR THE
RETENTION FEATURE
NO LARGE BENT, TWIST OR
ROLL MAY BE PRESENT
