Application Specification Economy Power II Contacts and Connectors NOTE i 114-- 13265 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. Wire Barrel Insulation Barrel Economy Power II Housing Economy Power II Contact Figure 1 2. REFERENCE MATERIAL 2.1. Revision Summary S Initial 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. 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 9 LOC B Economy Power II Contacts and Connectors 114- 13265 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 408--3295 408--7424 408--8040 408--8053 408--9816 408--10116 Document Title Preparing Reel of Contacts for Application Tooling Checking Terminal Crimp Height or Gaging Die Closure Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type) Conversion Guide for Miniature Quick--Change Applicators Handling of Reeled Products Extracting EP--II Contacts from Housing 1744125--[ ] 409--5128 409--5842 409--5852 409--5878 409--10027 409--10029 409--10047 409--10078 Basic AMP--O--LECTRIC* Model "K" Terminating Machines AMP--O--LECTRIC Model "G" Terminating Machine 354500--[ ] AMPOMATOR* CLS Model III--G Lead--Making Machine 122500--[ ] AMPOMATOR CLS IV Lead--Making Machine Stripping Module 1490502--[ ], 1490500--[ ], and 1725910--[ ] Stripping Module 1490503--[ ] and 1490501--[ ] 3K Terminating Machines 1725950--[ ] and 5K Terminating Machines 1725900--[ ] 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 Amines Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfides Nitrites Sulfur Compounds 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. NOTE i 2 of 9 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. Tyco Electronics Corporation Rev A Economy Power II Contacts and Connectors CAUTION 114- 13265 DO NOT nick, cut, or scrape the wire conductor during the stripping operation. ! Stranded Wire Solid Wire Strip Length Strip Length Conductor Conductor CONTACT TYPE Economy Power II Receptacle C t t Contact Insulation WIRE SIZE RANGE 22--188 20--16 0 6 Insulation WIRE SIZE (AWG) INSULATION DIAMETER RANGE STRIP LENGTH HEIGHT +0.05 WIDTH INSULATION BARREL CRIMP WIDTH 22 1.7--2.9 2.69--3.30 1.00 1.78 2.60 20 1.7--2.9 2.69--3.30 1.10 1.78 2.60 18 20 1.7--2.9 1.7--2.9 2.69--3.30 2.46--2.84 1.15 1.12 1.78 1.78 2.60 2.60 18 16 1.7--2.9 1.7--2.9 2.46--2.84 2.46--2.84 1.27 1.47 1.78 1.78 2.60 2.60 WIRE BARREL CRIMP 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. CAUTION ! NOTE 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. i 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. NOTE The effective crimp length is given for tooling design only, and should not be used for inspection criteria. i Rev A Tyco Electronics Corporation 3 of 9 Economy Power II Contacts and Connectors 114- 13265 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. 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 Section X- X View "A" Wire Barrel Crimp Width 0.13 Max Wire Barrel Flash 4 of 9 Wire Barrel Crimp Height Figure 3 Tyco Electronics Corporation 0.5 Max Cutoff Tab 0.13 Max Burr Rev A Economy Power II Contacts and Connectors 114- 13265 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. 2_ 30' Max. Side--to--Side Up and Down Datum Line 3_ Max. 4_ Max. NOTE: Angles are drawn for clarification only and are not to scale. Figure 4 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. Rev A Tyco Electronics Corporation 5 of 9 Economy Power II Contacts and Connectors Pull Gently 114- 13265 Contacts Locked In Place Avoid Damage to Housing--Locking Ramp Must Clear Contact Locking Tab Terminated Contact NO! Back of Economy Power II Housing Cut Side View of Locking Ramp Sheared Figure 5 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. 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. 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 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. NOTE i 6 of 9 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. Tyco Electronics Corporation Rev A Economy Power II Contacts and Connectors WIRE SIZE RANGE 114- 13265 TOOLING APPLICATOR DOCUMENT 1385286 1 1385286--1 408 8040 408--8040 1385286 2 1385286--2 408 8040 408--8040 22 18 22--18 1385286 3 1385286--3 408 8040 408--8040 1852347 1 --66 1852347--1, 408 8040 408--8040 1852347 2 1852347--2 408 8040 408--8040 20 16 20--16 1852347 3 1852347--3 408 8040 408--8040 Basic AMP-- O-- LECTRIC Model "K" Terminating Machine 565435-- 5 (409-- 5128) POWER UNIT 122500--2, --3 356500--1, --2 354500--1 565435--5 DOCUMENT 409--5852 409--5878 409--5842 409--5128 354500--1 1490501--1 1725900--[ ] 1725910--[ ] 409--5842 409--10029 409--10047 409--10027 1725950--[ ] 1901700--[ ] 122500--2, --3 356500--1, --2 409--10047 409--10078 409--5852 409--5878 354500--1 409--5842 565435--5 409--5128 354500--1 1490501--1 1725900--[ ] 409--5842 409--10029 409--10047 1725910--[ ] 1725950--[ ] 409--10027 409--10047 1901700--[ ] 409--10078 AMP-- O-- LECTRIC Model "G" Terminating Machine 354500-- [ ] (409-- 5842) HD Quick Change Applicators (408-- 8040) Figure 6 (cont'd) Rev A Tyco Electronics Corporation 7 of 9 Economy Power II Contacts and Connectors 114- 13265 Stripping Module 1725910-- [ ] (409-- 10027) 3K Terminating Machine 1725950-- [ ] (409-- 10047) 5K Terminating Machine 1725900-- [ ] (409-- 10047) AMPOMATOR CLS IV+ Lead-- Making Machine (409-- 5878) AMPOMATOR CLS Model III-- G Lead-- Making Machine 122500-- [ ] (409-- 5852) Stripping Module 1490501-- 1 (409-- 10029) Typical DT-- 3000/5000 Machine with Quality Crimp Monitor (409-- 10078) Figure 6 (end) 8 of 9 Tyco Electronics Corporation Rev A Economy Power II Contacts and Connectors 114- 13265 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. 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 CONTACTS MUST BE LOCKED IN CONNECTOR CAVITY HOUSING MUST NOT BE CRACKED OR DAMAGED IN ANY WAY FIGURE 7. Rev A VISUAL AID Tyco Electronics Corporation 9 of 9