Application Specification
Economy Power II 114--13265
LOC B
1of 9
E2009 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
Contacts and Connectors 26 OCT 09 Rev A
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters. Unless
otherwise specified, dimensions have a tolerance of +0.13 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 application of Economy Power II Contacts and Connectors.
These connectors are available in 2 through 12 positions and the contacts will accept stranded or solid wire in
a 22--16 AWG wire size range. Contact Product Information at the bottom of this page for information on
housing sizes 13 thru 24. The Economy Power II Connectors will mate with the same headers as standard
Economy Power Connectors. The contacts may be ordered with or without internal tongues. The contacts with
internal tongues have a higher mating force and current rating and are typically used with smaller housing
sizes. Those without tongues have a lower mating force and current rating and are typically used with larger
housing sizes.
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
Economy Power II Housing
Economy Power II Contact
Insulation Barrel
Wire Barrel
2. REFERENCE MATERIAL
2.1. Revision Summary
SInitial release of application specification
2.2. Customer Assistance
Reference Part Numbers 1744125--[ ], 1744144--[ ], and Product Code K885 are representative numbers of
Economy Power II Contacts and Connectors. 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 local Tyco Electronics Representative or, after purchase, by calling the
Tooling Assistance Center or Product Information number at the bottom of this page.
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.
NOTE
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Economy Power II Contacts and Connectors 114- 13265
Rev A2 of 9 Tyco Electronics Corporation
2.4. Specifications
Design Objective 108--2297 provides expected product performance and test information.
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 or Gaging Die Closure
408--8040 Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type)
408--8053 Conversion Guide for Miniature Quick--Change Applicators
408--9816 Handling of Reeled Products
408--10116 Extracting EP--II Contacts from Housing 1744125--[ ]
409--5128 Basic AMP--O--LECTRIC* Model “K” Terminating Machines
409--5842 AMP--O--LECTRIC Model “G” Terminating Machine 354500--[ ]
409--5852 AMPOMATOR* CLS Model III--G Lead--Making Machine 122500--[ ]
409--5878 AMPOMATOR CLS IV Lead--Making Machine
409--10027 Stripping Module 1490502--[ ], 1490500--[ ], and 1725910--[ ]
409--10029 Stripping Module 1490503--[ ] and 1490501--[ ]
409--10047 3K Terminating Machines 1725950--[ ] and 5K Terminating Machines 1725900--[ ]
409--10078 DT--3000 and DT--5000 Machines with SLE Crimp Quality Monitors
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
3.2. Material
The contacts are made from phosphor bronze, pre--tinned over copper; and the housings are made from white
UL 94V--0 Rated Nylon.
3.3. Wire Selection and Preparation
Economy Power II 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.
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
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Economy Power II Contacts and Connectors 114- 13265
Rev A 3 of 9Tyco Electronics Corporation
DO NOT nick, cut, or scrape the wire conductor during the stripping operation.
Strip Length
Conductor Insulation
Solid Wire
Stranded Wire
Strip Length
Insulation
Conductor
CONTACT WIRE
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WIRE
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INSULATION
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STRIP WIRE BARREL CRIMP INSULATION
B
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TYPE
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RANGE
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(AWG)
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RANGE
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LENGTH HEIGHT +0.05 WIDTH
B
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WIDTH
22 1.7--2.9 2.69--3.30 1.00 1.78 2.60
E
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m
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22--18 20 1.7--2.9 2.69--3.30 1.10 1.78 2.60
E
conomy
Power II
8
18 1.7--2.9 2.69--3.30 1.15 1.78 2.60
P
o
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r
I
I
Receptacle
C
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20 1.7--2.9 2.46--2.84 1.12 1.78 2.60
Contact 20--16 18 1.7--2.9 2.46--2.84 1.27 1.78 2.60
0
6
16 1.7--2.9 2.46--2.84 1.47 1.78 2.60
Figure 2
3.4. 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.
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.
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 most 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 2.
B. Crimp Length
For optimum crimp effectiveness, the crimp 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.
The effective crimp length is given for tooling design only, and should not be used for inspection criteria.
CAUTION
!
CAUTION
!
NOTE
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NOTE
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Economy Power II Contacts and Connectors 114- 13265
Rev A4 of 9 Tyco Electronics Corporation
C. Bellmouths
Rear bellmouths shall be evident and conform to the dimensions given in Figure 3.
D. Cutoff Tab
The cutoff tab shall be cut to 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.
Figure 3
0.13 Max Wire
Barrel Flash
Section X- X
Wire Barrel
Crimp Height
Wire Barrel
Crimp Width
0.5 Max
Cutoff Tab
0.13 Max
Burr
View “A”
Conductor Location
0.1--1.2
Wire Barrel Closed at
Seam with No Strands
Protruding or Showing
No Insulation
in Seam
Wire Insulation and
Conductors Must
Both be Visible in
this Area
Rear Bellmouth
0.1--0.7
X
X
Economy Power II Contacts and Connectors 114- 13265
Rev A 5 of 9Tyco Electronics Corporation
H. Conductor Location
The conductor may extend beyond the wire barrel to the maximum shown in Figure 3.
I. Wire Barrel Seam
The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam.
J. 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 mating.
K. Straightness
The force 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.
Figure 4
4_Max.
Datum Line
3_Max.
2_30’ Max.
NOTE: Angles are drawn for clarification only and are not to scale.
Up and Down
S i d e -- t o -- S i d e
3.5. Housings
Economy Power II Connector Housings are available in 2 through 24 positions. They are available in a white
color nylon and consist of a 94V--0 flame retardant material.
3.6. Contact Insertion
Orient the crimped contact as shown in Figure 5. Insert contact into housing until it bottoms, and audible click
is heard or felt. Pull back lightly on the wire to ensure retention of crimped contact in housing.
Economy Power II Contacts and Connectors 114- 13265
Rev A6 of 9 Tyco Electronics Corporation
Figure 5
NO!
Side View of
Locking Ramp
Cut
Sheared
Avoid Damage to
Housing—Locking
Ramp Must Clear
Contact Locking Tab
Pull Gently Contacts
Locked In
Place
Back of
Economy
Power II
Housing
Terminated
Contact
3.7. Repair/Contact Replacement
Refer to Instruction Sheet 408--10116 for information on Economy Power II extraction techniques.
4. QUALIFICATION
Economy Power II Connectors have not yet been sent for agency evaluation.
5. TOOLING
This section provides a selection of tools for various application requirements. They include 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 6.
SApplicators
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.
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.
SPower 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 (409--5128) has been superseded by the Model
“G” Terminating Machine PN 354500--1 (409--5842) for new applications. For existing applications, the Model “K” is still
recommended because of the large number of installed machines.
NOTE
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NOTE
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Economy Power II Contacts and Connectors 114- 13265
Rev A 7 of 9Tyco Electronics Corporation
W
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TOOLING
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APPLICATOR DOCUMENT POWER UNIT DOCUMENT
1
3
8
5
2
8
6
1
4
0
8
8
0
4
0
122500--2, --3 409--5852
1385286--1 408--8040 356500--1, --2 409--5878
1
3
8
5
2
8
6
2
4
0
8
8
0
4
0
354500--1 409--5842
1385286--2 408--8040 565435--5 409--5128
2
2
1
8
354500--1 409--5842
22--18 1490501--1 409--10029
1
3
8
5
2
8
6
3
4
0
8
8
0
4
0
1725900--[ ] 409--10047
1385286--3 408--8040 1725910--[ ] 409--10027
1725950--[ ] 409--10047
1901700--[ ] 409--10078
1
8
5
2
3
4
7
1
6
4
0
8
8
0
4
0
122500--2, --3 409--5852
1852347--1, --6 408--8040 356500--1, --2 409--5878
1
8
5
2
3
4
7
2
4
0
8
8
0
4
0
354500--1 409--5842
1852347--2 408--8040 565435--5 409--5128
2
0
1
6
354500--1 409--5842
20--16 1490501--1 409--10029
1
8
5
2
3
4
7
3
4
0
8
8
0
4
0
1725900--[ ] 409--10047
1852347--3 408--8040 1725910--[ ] 409--10027
1725950--[ ] 409--10047
1901700--[ ] 409--10078
Figure 6 (cont’d)
Basic AMP--O--LECTRIC Model “K”
Terminating Machine 565435--5
(409--5128)
HD Quick Change Applicators
(408--8040)
AMP--O--LECTRIC Model “G”
Terminating Machine
354500--[ ] (409--5842)
Economy Power II Contacts and Connectors 114- 13265
Rev A8 of 9 Tyco Electronics Corporation
Figure 6 (end)
AMPOMATOR CLS IV+ Lead--Making Machine (409--5878)
AMPOMATOR CLS Model III--G Lead--Making Machine
122500--[ ] (409--5852)
Stripping Module
1725910--[ ]
(409--10027)
Stripping Module 1490501--1
(409--10029)
3K Terminating
Machine
1725950--[ ]
(409--10047)
5K Terminating
Machine
1725900--[ ]
(409--10047)
Typical DT--3000/5000
Machine with Quality
Crimp Monitor
(409--10078)
Economy Power II Contacts and Connectors 114- 13265
Rev A 9 of 9Tyco Electronics Corporation
6. VISUAL AID
Figure 7 shows a typical application of Economy Power II Connector. 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 7. VISUAL AID
CONTACTS MUST BE
LOCKED IN CONNECTOR
CAVITY
HOUSING MUST NOT
BE CRACKED OR
DAMAGED IN ANY
WAY
NO DAMAGE OR
DISTORTION TO
CONTACT
INSULATION AND WIRE
CONDUCTORS MUST
BOTH BE VISIBLE
HOUSING LOCKING RAMP
MUST BE IN SAME POSITION
AFTER CONTACT INSERTION
AS IT WAS PRIOR TO
CONTACT INSERTION
