Application Specification 114-10014 Size VIII Power Contacts NOTE 21 JUN 06 Rev D 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 Size VIII Power Pin and Socket Contacts. These contacts have a wire range of 8 thru 18 AWG and are terminated with hand held tooling. Size VIII Power Contacts may be used in Military Certified 24308 Special Series 109 connectors, such as the AMPLIMITE*, Drawer, and Metrimate connectors which are designed with power/coax and signal mix cavities. 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. PIN Wire Barrel Inspection Hole Contact Body Retention Spring SOCKET Figure 1 2. REFERENCE MATERIAL 2.1. Revision Information 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 document to corporate requirements S Changed crimp height dimension for wire size 8 in table in Figure 3 2.2. Customer Service Reference Product Base Part Number 211159 and Product Code 5064 are representative numbers of Size VIII Power 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 the Product Information Center number at the bottom of this page. E 2006 Tyco Electronics Corporation, Harrisburg, PA All International Rights Reserved Tyco is a trademark. TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark Other products, logos, and company names used are the property of their respective owners. visit our website at www.tycoelectronics.com 1 of 6 LOC B Size VIII Power Contacts 114-10014 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 technical documentation supplied by Tyco Electronics. 2.4. Specifications Product Specification 108-10045 provides product performance requirements and test information. 2.5. Instructional Material The following list of available instruction sheets (408-series) provides assembly procedures for product, operation, maintenance and repair of tooling. Document Number 408-6827 408-7424 408-7516 408-9310 Document Title Extraction Tool 58095-1 for AMPLIMITE Connectors Measuring Crimp Height Or Gaging Die Closure Screw Machine Contacts and Application Tooling Extraction Tool 58095-2 For HDI Hybrid Connector Power and Coaxial Contacts 3. REQUIREMENTS 3.1. Storage The contacts should remain in the shipping containers until ready for use to prevent deformation to the contact. The contacts should be used on a first-in/first-out basis to avoid storage contamination that could adversely affect signal transmissions. These contacts have a shelf life of 2 years from date of manufacture. 3.2. Wire Selection and Preparation A. Wire Type The contacts will accept copper fused-stranded, or stranded conductor wire within the range of 18 through 8 AWG. B. Preparation The wire must be stripped to the dimension provided in Figure 2. NOTE Do not nick, scrape, or cut the wire conductor during the stripping operation. Locate the contact to be crimped in the appropriate tooling. Crimp the contact according to the instructions packaged with that tooling. 9.52 [.375] Strip Length Insulation Conductor Figure 2 2 of 6 Rev D Size VIII Power Contacts 114-10014 3.3. Crimped Contact Requirements A. Crimp Length For optimum crimp effectiveness, the crimp must be within the area shown in Figure 3 and must meet the crimp dimensions provided. Effective crimp length shall be 3.05 mm [.120 in.] nominal, 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. B. Conductor Location The wire shall be visible through the wire barrel sight hole after crimping. Care shall be taken not to allow insulation to be crimped in the wire barrel. See Figure 3. C. Contact Retention Spring Contact retention springs shall not be deformed. D. Crimp Height See Figure 3 for correct crimp height according to wire size. Insulation 12.19 + 2.54 Effective [.480 + .100] Crimp Wire Barrel Length Wire Barrel Contact Inspection Retention Hole Spring Measuring Crimp Height of Contact NOTE: When checking crimp height, always measure the most compressed area of the crimp. WIRE SIZE SELECTOR POSITIONER OR TURRET HEAD (AWG) SETTING (TYCO ELECTRONICS PART NUMBER) 8 7 CRIMP HEIGHT SP689 (608651-2) SP858 D (608651-3) 3 18 +0.18/-0.10 3.18 +0 18/-0 10 [[.125 125 + +.007/-.004] 007/- 004] SP689 (608651-2) 10 3 SP858 D (608651-3) 2 44 +0.10 2.44 +0 10 [[.096 096 + +.004] 004] SP689 (608651-2) 12 1 SP867 D (---) 2 13 +0.10 2.13 +0 10 [[.084 084 + +.004] 004] SP689 (608651-2) 14 1 SP867 D (---) TP731 (608668-2) 16 7 SP867 D (---) 1 73 +0.10 +0 10 [[.068 068 + 004] 1.73 +.004] TP731 (608668-2) 18 6 SP867 D (---) 1 55 +0.10 1.55 +0 10 [[.061 061 + +.004] 004] DUse with long contact only. Figure 3 Rev D 3 of 6 Size VIII Power Contacts 114-10014 E. Straightness After crimping the wire to the contact, the contacts shall be chucked in the area shown in Figure 4 and rotated 360_ minimum. The point of Total Indicator Reading (TIR) measurement, shall be as shown in Figure 4. The TIR shall not exceed 0.76 [.030]. There shall be no twist, roll, deformation or other damage to the mating portion of the crimped contact that will prevent proper mating. Chucking Area Circle Diameter Contact Contact and Circle Diameter Dial Indicator Probe Centerlines Placed Here for Measurement of TIR 0.76 [.030] Max. Figure 4 3.4. Chemical Exposure Do not store contacts near any chemicals listed below as they may cause stress corrosion cracking in the contacts. Alkalies Amines NOTE Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Sulfur Compounds Tartrates Where the above environmental conditions exist, phosphor bronze contacts are recommended instead of brass if available. 3.5. Repair Contacts are not repairable once a termination has been made. Any defective contact should be removed and replaced with a new one. If a damaged contact has already been placed in a housing, refer to Section 5 (TOOLING). 4. QUALIFICATIONS While Size VIII Power Contacts are not UL Listed or CSA International Certified, they are designed to be used in Military Certified Connectors. 5. TOOLING Various tools are available for your production needs. The following Figure 5 and table provide tooling information related to wire size. NOTE The use of Extraction Tools are designed to remove contacts from the connector housings. Extraction tools 58095-1 or 58095-2 may provide your requirements for this process. For more information on extraction tooling or other tooling information, contact the Tooling Assistance Center number listed at the bottom of page 1. 4 of 6 Rev D Size VIII Power Contacts 114-10014 Hand Crimping Tool (Typ) Pneumatic Crimping Tool (Typ) Extraction Tool (Typ) DANIELS TOOLING CONTACT WIRE SIZE SELECTOR TYPE (AWG) SETTING POSITIONER OR TURRET HEAD 8 CRIMPING TOOLS POSITIONER HAND OR TURRET CRIMPING HEAD TOOL SP689 608651-2 SP858 608651-3 7 SP858 10 TYCO ELECTRONICS TOOLING 608651-3 M300-BT 3 SP689 (Hand Tool) 608651-2 or SP689 12 1 Size VIII Power Contacts 14 WA27-300-BT-EP (Pne matic Tool) (Pneumatic SP867 --- SP689 608651-2 SP867 --- 1 TP731 16 608651 1 608651-1 608651-2 608651-2 FT8 7 SP867 (Hand Tool) --- or TP731 18 6 WA27-309EP 608668-1 608668 1 608651-2 (Pne matic Tool) (Pneumatic SP867 --- Figure 5 Rev D 5 of 6 Size VIII Power Contacts 114-10014 6. VISUAL AID Figure 6 shows a typical application of Size VIII Power Pin and Socket 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. CRIMP SHALL BE FULLY FORMED AND CENTRALLY LOCATED WIRE VISIBLE IN WIRE INSPECTION HOLE SLIGHT GAP BETWEEN INSULATION AND WIRE BARREL IS PERMISSIBLE CRIMPED SIZE VIII POWER PIN INSULATION NOT CRIMPED IN WIRE BARREL CRIMPED SIZE VIII POWER SOCKET RETENTION SPRINGS NOT DEFORMED FIGURE 6. VISUAL AID 6 of 6 Rev D