Application Specification CST-100 Connectors 114-1 601 ) AMP for Crimp Snap Terminals 12 AUG 99 RevD NOTE All numerical values are in metric units [with U.S. customary units in brackets}. Dimensions are in millimeters [and inches]. Uniess 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 scate. 1. INTRODUCTION This specification covers the requirements for application of AMP* CST (CrimpSnap Terminals) for connectors on 2.64 [.100] centerline. These requirements are applicable to hand or automatic machine crimping tools. These connectors are available in 2 through 28 positions and are terminated to 22, 24, and 26 AWG conductors. The CST100 connectors provide an interconnection between wires and 0.64 [.025] square post headers mounted on printed circuit (pc) boards. When corresponding with AMP 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. Receptacle Insulation CST-100 Barrel Housi CST-100 ousing Contact Contact Insertion Cavity Wire Barrel Locking Lance Polarization Tab Figure 1 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: Per EC: 0990-0901-98 * Updated specification to corporate requirements * Added new or corrected artwork in Figures 1, 3,4, 5,6, 7,8, and9 * Added new crimping information in Figures 2, 3, and 8 Added qualification file numbers in Section 4 * Added new Paragraphs in Sections 2, 3, and5 * Added new tooling information in Section 5 * 1999 AMP Incorporated, Harrisburg, PA. This controlled document is subject to change. TOOLING ASSISTANCE CENTER 1-800-722-1111 1o0f9 All International Rights Reserved. For latest revision call the AMP FAX* number. AMP FAX/PRODUCT INFO 1-800-522-6752 Trademark LocBANP CST-100 Connectors 4114-16019 2.2. Customer Assistance Reference Part Number 770602 and Product Code 1443 are representative numbers of AMP CST-100 Connectors. Use of these numbers will identify the product line and expedite your inquiries through an AMP service network established to help you obtain product and tooling information. Such information can be obtained through a local AMP Representative (Field Sales Engineer, Field Applications Engineer, etc.) or, after purchase, by calling the Tooling Assistance Center or AMP FAX/Product Information number at the bottom of page 1. 2.3. Drawings AMP 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 AMP Incorporated. 2.4. Specifications AMP Product Specification 108-1328 covers test and performance requirements. 2.5. Instructional Material The following list includes available AMP instruction sheets (408series) that provide assembly procedures for product, operation, maintenance and repair of tooling, as well as setup and operation procedures of applicators; and customer manuals (409series) that provides setup, operation, and maintenance of AMP machines. Document Number Document Title 408-3295 Preparing Reel of Contacts for Application Tooling 408-4064 AMP PRO-CRIMPER* II Hand Tool Assembly 58517-1 with Die Assembly 5851 7-2 408-7424 Checking Terminal Crimp Height or Gaging Die Closure 408-8040 AMP Heavy Duty Miniature QuickChange Applicators (SideFeed Type) 408-8053 Conversion Guide for AMP Miniature Quick-Change Applicators 408-9816 Handling of Reeled AMP Products 408-9866 AMP Terminal Reel Flange Removal Tool 354030-1 408-9930 AMP PRO-GRIMPER II Hand Crimping Tool Frame Assembly 354940-1 409-5128 AMP-O-LECTRIC* Model K Terminating Machine 565435-5 409-5289 AMP Model T Terminating Unit 458000-4 409-5842 AMP-O-LECTRIC Model G Terminating Machine 354500-[ ] 409-5852 AMPOMATOR* CLS III-G Lead-Making Machine 122500-| ] 409-5878 AMPOMATOR CLS IV+ Lead-Making Machines 356500-1, -2 and 1213400-1, -2 409-6885 Model MM Terminator 904000-1 3. REQUIREMENTS 3.1. Storage 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 near any chemicals listed below as they may cause stress corrosion cracking in the contacts. Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds Amines Carbonates Nitrites Sulfides Nitrites Tartrates 2o0f9 Rev DANP CST-100 Connectors 4114-16019 NOTE Where the above environmental conditions exist, phosphorbronze contacts are recommended instead of brass if available. 3.2. Wire Selection CST-100 Contacts will accept stranded copper wire sizes and insulation diameters as listed in Figure 2. The crimp heights and insulation barrel crimp widths are also provided. NOTE The applied crimp dimension (within the functional range of the product) is dependent on the termination tooling being used. Refer to the AMP documentation (applicator fogs and instruction sheets) supplied with the termination footing for the applied crimp height See Section 6, TOOLING. NOTE Other contact crimp dimensions are provided on the documentation supplied with the termination tooling. ens DO NOT nick, cut, or scrape the wire conductor during the stripping operation. INSULATION WIRE BARREL CRIMP INSULATION antes We DIAMETER | STRIP LENGTH BARREL CRIMP RANGE WIDTH HEIGHT WIDTH 0.89-1.65 254-3,18 081-071 26 [.035~.065] [100-.125] 1.07 [.042] [.032-.028] 1.78 [.070] 0.89-1.65 2.54-3.18 0.86-0.76 Strip 24 (088-.685] 100. 125) 1.07 [,042] (034000) 1.78 [.070] 0.89-1.65 2.54-3,18 091-081 22 [.035~065] [100-125] 1.07 [042] [,036-.032] 1.78 [070] 0.89-1.65 254-3,18 0840.74 Loose Piece 26-22 [.035-065] [100-125] 1.07 [.042] [,033-029] 1.78 [.070] Figure 2 3.3. Crimped Contact Requirements Locate the contact to be crimped in the appropriate tooling according to the instructions packaged with that tooling. Detailed instructions covering the placement of contacts in the tooling and the use of such tooling is packaged with each tool. Terminate the contact according to the directions shipped with the appropriate tooling. See Section 5, TOOLING. hie = Wire insulation shal! NOT be cut or broken during the crimping operation, nor shail the insulation be crimped into the contact wire barrel. Reasonable care should be taken by tooling operators fo provide undamaged wire terminations. ens Periodic inspections must be made to ensure crimped contact formation is consistent as shown in Figure 3. A. Crimp Height The crimp applied to the wire portion of the contact is the mest compressed area and is most critical in ensuring optimum electrical and mechanical performance of the crimped contact. The crimp height must be within the dimensions provided in Figure 3. B. Crimp Length For optimum crimp effectiveness, the crimp must be within the area shown 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 Figure 8. NOTE The effective crimp length is given for tooling design only, and should not be used for inspection criteria. Rev D 3o0f9ANP CST-100 Connectors 4114-16019 No Wire Strands Wire and Insulation Showing In This Area -~ Must Both Be Visible In This Area | Flush to / r 0.51 [.020] Max Front Bellmouth No Insulation 0.25 [.010] Max Crimped In Insulation Barrel Seam Crimp Length Rear Bellmouth 0.13-0.46 [.005-.018] pe KX |X SU i X See View A | 0.71-0.51 [.028-.020] Wire Barral Locking Lance Height Wire Barrel Crimp Height Crimp Width 0.06 [.003] Max. Burr View A 0.13 [,005] Max. Wire Barrel XQ a Flash 0.00-0.25 Pe [000 - .010] Cutoff Tab | Section X-X Figure 3 C. Bellmouths Front and rear bellmouths shall be evident and conform to the dimensions given in Figure 3. D. Cutoff Tab The cutoff tab shall be cutto the dimensions shown in Figure 3 in View A. E. Burrs The cutoff burr shall not exceed the dimensions shown in Figure 3 in View A. F. Wire Barrel Flash The wire barrel flash shall not exceed the dimensions shown in Figure 3 in Section X-X. G. Wire Location After crimping, the wire conductor and insulation must be visible in the transition area between the wire and insulation barrels. H. Conductor Location The conductor may extend beyond the wire barrel to the maximum shown in Figure 3. I. Locking Lance Locking lance height must net change during termination. Refer to specific product customer drawing for exact dimensional requirements. 4o0f9 Rev DANP CST-100 Connectors 4114-16019 J. Wire Barrel Seam The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam. K. Twist and Roll There shall be no twiat, roll, deformation, or other damage to the mating portion of the crimped contact that will prevent proper mating. L. Straightness The foree applied during crimping may cause some bending between the crimped wire barrel and the mating portion of the contact. Such deformation is acceptable within the following limits. 1. Up and Down The crimped contact, including cutoff tab and burr, shall not be bent above or below the datum line more than the amount shown in Figure 4. 2. Side to Side The side-to-side bending of the contact may not exceed the limits provided in Figure 4. Datum Line 5 Max. NOTE: Angles are drawn for clarification only and are not to scale. 5 Max. Figure 4 3.4. Housings CST-100 Housings are available in 2 through 28 positions. They are available in a natural coler nylon and consist of a 94V0 flame retardant material. See Figure 5. Contact Mating Lecking Lance Polarization Window Tab CST-100 Housing Figure 5 Rev D 50f9ANP CST-100 Connectors 4114-16019 3.5. Contact Insertion Orient crimped contact so that the locking lance aligns with the housing slots as shown in Figure 6. Insert contact into housing until it bottoms, and audible click is heard or felt. Pull back lightly on wire to ensure retention of crimped contact in housing. CST-100 Contacts Housing Locked In Place Contact Terminated Insertion Contact Cavity Figure 6 3.6. Repair/Contact Replacement Use AMP Extraction Tool 91302-1 to remove individual contacts from housings for replacement or for relocation to another housing cavity. See Figure 7. Damaged or worn contacts may be replaced provided there is sufficient slack, after restripping the wire, to insert the new contact. Damaged connectors must also be replaced. NOTE DO NOT re-use damaged or worn contacts. instead, replace them with new contacts and discard the ofd ones. Locking Lance Window Extraction Tool CST-100 Housing Figure 7 4. QUALIFICATION AMP CST-100 Connectors are listed by Underwriters Laboratories Inc. (UL) under File Number E28476, and certified by Canadian Standards Association (CSA), under File Number LR7189. 5. TOOLING This section provides a selection of tools for various application requirements. They include hand tools for manual application of loose piece contacts, and 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. A listing of tooling recommendations covering the full wire size range is provided in Figure 8. 6of9 Rev DANP CST-100 Connectors 4114-16019 Hand Crimping Tools Hand crimping tools that accommodate the full wire size range are designed for prototype and low-volume applications such as repair of damaged contacts. * Extraction Tools Extraction tools are designed to release the contacts inside the connector without damaging the housing or contacts. Refer to Paragraph 3.6. * Applicators Applicators are designed for the full wire size range of stripfed, precision formed contacts, and provide for high volume, heavy duty production requirements. The applicators can be used in bench or floor model power units. 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 te 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. * 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. NOTE The Model K AMP-O-LECTRIC Terminating Machine PN 5654355 (409-5728) has been superseded by the Model G Terminating Machine PN 354500-1 (409-6842) for new applications. For existing applications, the Model Kk is still recommended because of the large number of installed machines. Extraction Tool 91302-1 Hand Tool Assembly 5857-1 (408-4064) WIRE SIZE, INSULATION APPLICATOR POWER UNIT HAND TOOL AWG DIA (DOC) (DOC) ASSY (DOC) 122500-2, -3 (408-5852) 567373-1 (408-8040) 356500-1, -2 (409-5878) 1213400-1, -2 (409-5878) 25-22 0,89-1.65 [.035-.065] 354500-1 (409-5842 58517-1 (408-4064) ) 567373-2 (408-8040) 565435-5 (409-5128) ) ) 354500-[ ] (409-5842 567373-3 (408-8040) 904000-1 (409-5885 Figure 8 (cont'd) Rev D Togy-N ', | xe CST-100 Connectors AMP-O-LECTRIC Model G Terminating Machine 354500-1 (409-5842) Applicator (Typ . VX nae AMPOMATOR CLS [V+ LeadMaking Machines 356500-f | and 1243400 { | (409-5878) AMPOMATOR CLS HFG LeadMaking Machine 122500-{ | (409-5852) Figure 8 (end) 8of9 Heavy Duty Miniature Quick-Change Side Feed oS Model M Terminator 904000-1 {409-5885} 114-16019 AMP-O-LECTRIC Mode! K" Terminating Machine 565435-5 (409-5128) Rev DANP CST-100 Connectors 4114-16019 6. VISUAL AID Figure 9 shows a typical application of AMP CST-100 Connectors. 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 tocling. NO DAMAGE OR DISTORTION TO CONTACT NO CONDUCTOR WIRES SHOWING IN WIRE BARREL SEAM INSULATION AND WIRE CONDUCTORS MUST BOTH BE VISIBLE IN THIS AREA NO CRACKED OR DAMAGED HOUSING CONTACTS MUST BE LOCKED IN CONNECTOR CAVITY FIGURE 9. VISUAL AID Rev D Sof9