2,8x0,8mm Flat Contact 1. INTRODUCTION 2

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1 APPLICATIN SPECIICATIN ,8x0,8mm lat Contact RevG EC: 2,8x0,8mm lat Contact CNTENT 1. INTRDUCTIN 2 2. REERENCED DCUMENTS 2.1 Customer Drawings Product Specifications Application Specification Instruction Material National / International Standards 2 3. DESCRIPTIN 3.1 Contacts for Wires Contacts for SingleWire Sealing 4 4. REQUIREMENTS Wires Cutff and Burr Wire Crimp Insulation Crimp or SingleWire Seal Crimp Contact Area and Position Tolerances 7 IGURES / TABLES ig. 1 lat Contacts with Wires 3 ig. 2 lat Contacts with Single Wire Seals 4 ig. 3 and Position Tolerances 7 ig. 4 and Position Tolerances 8 Table 1 Crimping Data for lat Contacts with Wires 9 Table 2 Crimping Data for lat Contacts with Single Wire Seals 10 Table 3 Crimping Data for lat Contacts Typ A with Wires 10 Table 4 Crimping Data for lat Contacts Typ A with Single Wire Seals 11 Table 5 Comparison AWG / IS Wires 12 Tyco Electronics Corporation, Harrisburg, PA * Trademark Indicates change This specification is a controlled document. Copyright 2000 by Tyco Electronics Corporation. All rights reserved 1 of 12 ECC EG00 LC: AI

2 INTRDUCTIN This specification covers the special guidelines for the application of the lat Contact System 2,8mm and the lat Contact System 2,8mm Type A. The instructions are intended primarily for automatic or semiautomatic application of all versions (for both wires and singlewire sealing), but may also be applied, if agreed, to hand tools. The various contact types are listed in Tables 1 and 2, sorted by their wire ranges and crimping data. The various lat Contact System 2,8mm Type A are listed in Tables 3 and 4, sorted by their wire ranges and crimping data. 2. REERENCED DCUMENTS 2.1 Customer Drawings There is a customer drawing showing the dimensions and materials for each part number. In the case of a conflict between this document and a customer drawing, the customer drawing takes precedence. 2.2 Product Specification The Product Specification describes the characteristics of these contacts, together with the electrical and mechanical requirements. 2.3 Application Specifications The general guidelines laid down in Application Specifications and also apply to the crimp quality. 2.4 Instructional Material CM 5128 AI 8025 IS 6764 IS 7424 Contains information about crimping machines for MQC crimping tools. Describes the MQC crimping tool. Instruction sheet for AMP CERTILK* hand tool. Explains how to measure the crimp height. 2.5 National / International Standards DIN T5/05.92 DIN T6/01.92 DIN IS 6722 T1/04.85 DIN IS 6722 T2/04.84 DIN IS 6722 T3/08.87 DIN IEC 352 T2/04.92 Unscreened low tension cables (LR) Unscreened low tension cables (LR) Unscreened low tension cables (LK) Unscreened low tension cables (LK) Unscreened low tension cables (LK) Solderless electrical connections, crimped connections Rev G 2 of 12

3 DESCRITIN The terms shown below are used in the specification. 3.1 Contacts for Wires Locking Lance Cantilever spring ront BellMouth Rear Wire Crimp Height Contact Body Insulation Crimp Hight Cutff and Burr Wire Crimp Wire Crimp Insulation Crimp Wire End of Conductor End of Insulation Insulation Crimp ig. 1 Rev G 3 of 12

4 Contacts for SingleWire Sealing Locking lance Cantilever spring ront Bell Mouth Rear Contact body Wire crimp height Single wire seal CrimpHeight Cutoff and burr Wire crimp lange End of conductor End of Insulation Collar diameter Wire Wire crimp width Crimp for singlewire seal Singlewire seal Single Wire Seal Sealing lip Crimp width ig. 2 Rev G 4 of 12

5 REQUIREMENTS 4.1 Wires A Selection The contacts and singlewire seals are designed for LR conductors to DIN Part 5 and Part 6 or LK conductors to DIN IS 6722 Parts 13 (formerly DIN Part 2), as well as LR and LU wires in accordance with LV1121. ther wires require the approval of the Engineering Department. Single termination is preferred. Double termination is possible within the wire range with LR conductors; with LK conductors, this is possible only with restrictions. B Preparation The wire must be stripped to the lengths shown in Tables 1 till 4. Take care that the individual strands of the wire are not be bent or cut off. or single wire sealing, care must be taken that the insulation of the wire in the sealing area is not damaged, compressed or deformed. The insulation must be clean and free of contamination. 4.2 Cutff and Burr The cutoff must be visible after crimping. The maximum length of the cutoff is 0.5 mm. Any burrs at the shearing point may not exceed 0.08 mm. 4.3 Wire Crimp A Wire position After crimping, the end of the wire must extend mm beyond the front end of the wire crimp. B Crimping data The shape, height and width of the crimp, and the wire range, are shown in Tables 1 till 4. C Extraction forces The crimp extraction forces must fulfill the requirements of DIN IEC 352 Part 2. D Crimp bellmouth The size of the rear bellmouth depends on the wire range: mm² : 0.25 ± 0.15 mm mm² : 0.40 ± 0.20 mm A front bellmouth is permissible. Rev G 5 of 12

6 Insulationcrimp or Crimp for SingleWire Seal A Position of the end of the insulation In the case of contacts for crimping on wire, the end of the insulation must be visible in the transition between the wire crimp and the insulation crimp. In no case may the insulation be crimped in the wire crimp; conversely, the insulation must extend at least to the front edge of the insulation crimp. In the case of contacts for singlewire sealing, the end of the insulation must be flush with the front edge of the singlewire seal or may project by up to 1.0 mm from this seal. B Crimping data for wires The shape and width of the crimp, and the insulation diameter, are shown in Table 1 and 3. The crimp height is adjusted either after the bending test to DIN Part 1 or after the wrapping test to DIN Part 66. C Crimping data for singlewire seals The shape and width of the crimp, and the part number of the singlewire seal, are shown in Table 2 and 4 The crimp height is correctly adjusted if the crimp encloses the seal in the shape of a circle. val enclosure as the result of differing insulation diameters is permissible. D Position of the singlewire seal Singlewire seals without a collar on the sleeve must be flush with the front edge of the crimp or may project up to 1 mm from the crimp. In the case of singlewire seals with a collar on the sleeve, this collar is positioned in front of the front edge of the crimp. The collar must be centered within the window on the bottom of the crimp. 4.5 Contact Area After crimping, neither the cantilever spring, the locking lances nor the contact body may be bent or deformed. Rev G 6 of 12

7 and Position Tolerances A Contacts for crimping on wire (see ig. 3) Parallelism The bottom of the wire crimp or of the insulation crimp must be parallel with the contact body, with a tolerance of 0,3 mm. Symmetry The width of the insulation crimp must be symmetrical with the contact body, with a tolerance of 0,3 mm. Bild 3 Rev G 7 of 12

8 B Contacts for singlewire seals (ig. 4) Parallelism The bottom of the wire crimp or of the insulation crimp must be parallel with the contact body, with a tolerance of 0.3 mm. Symmetry The crimp for the singlewire seal must lie within a symmetrical tolerance of 0,5 mm relative to the longitudinal axis of the contact. The singlewire seal must be symmetrical in both directions with the longitudinal axis of the contact, with a tolerance of 0,8 mm. ig. 4 Rev G 8 of 12

9 Table 1 Crimping Data for TAB 2,8mm with wires PartNo. Insulation Diameter ( mm ) Wire Crimp Insulationcrimp Strip Loose Piece Wire Size ( mm² ) LU LR LK Stripped length ±0,3 Height ±0,05 1) 2) ±0,2 Crimping Tool Die for handcrimping tool ,20 0,25 0,35 3) 1,151,6 3,5 1,60 0,98±0,03 1,00±0,03 1,05±0,03 1,12±0,03 2,30 x878549x ,75 1,00 3) 1,42,0 4,2 2,05 1,27 1,36 1,15 1,20 2,55 x878550x ,50 2,00 2,50 3) 2,12,9 5,0 2,55 1,58 1,73 1,88 3,30 x878551x ,50 2,00 2,50 3) 2,43,7 5,0 2,55 1,58 1,73 1,88 3,95 x878552x ,50 2,50 3) 2,43,7 5,0 2,55 1,58 1,88 3,95 x x ,00 3) 3,43,7 3,05 2,15 4,1 x541534x ,00 3) 3,43,7 3,05 2,15 4,1 x x 1) current standard 2) preferred standard to meet new LV2142 slow motion bending test 3) Contact, wire combination has not yet been considered Rev G 9 of 12

10 Table 2 Crimping Data for TAB 2.8mm with single wire seals PartNo. Insulation Diameter ( mm ) Wire Crimp Insulationcrimp Single wire seal Strip Loose Piece Wire Size ( mm² ) LU LR Stripped length ±0,3 Height ±0,05 1) 2) ±0,2 Crimping Tool Die for handcrim ping tool LU LR ,20 0,25 0,35 3) Max.2,1 4,0 1,60 0,98±0,03 1,00±0,03 1,05±0,03 1,12±0,03 3,95 x878558x ,75 1,00 1,50 2,00 2,50 3) Max.2,1 4,5 2, Max.3,0 5,0 2,55 1,27 1,36 1,58 1,73 1,88 1,15 1,20 4,05 4,30 x878559x x878560x * ,00 3) Max.3,7 3,05 2,15 5,10 x541537x ) current standard 2) preferred standard to meet new LV2142 slow motion bending test 3) Contact, wire combination has not yet been considered *Attention: Construction of the Contact Cavity in the area of the single wire seal is 6,4 mm +0,1/0,05. Table 3 Crimping Data for TAB 2,8mm Type A with wire PartNo. Insulation Diameter ( mm ) Wire Crimp Insulationcrimp Strip Loose Piece Wire Size ( mm² ) LU LU Stripped length ±0,3 Height ±0,05 1) 2) ±0,2 Crimping Tool Die for handcrimping tool ,20 0,25 0,35 3) 1,151,6 3,5 1,60 0,98±0,03 1,00±0,03 1,05±0,03 1,12±0,03 2,30 x878950x ,35 3) 1,151,6 3,5 1,6 1,08±0,03 2,30 x878950x ,75 1,00 3) 1,42,1 4,0 2,05 1,27 1,36 1,15 1,20 2,55 x878937x ,25 1,50 2,00 2,50 3) 2,23,0 4,3 2,55 1,48 1,55 1,70 1,86 1,47 1,76 1) current standard 2) preferred standard to meet new LV2142 slow motion bending test 3) Contact, wire combination has not yet been considered 3,60 x878704x Rev G 10 of 12

11 Table 4 Crimping Data for TAB 2.8mm Type A with single wire seals PartNo. Insulation Diameter ( mm ) Wire Crimp Insulation crimp Strip Loose Piece Wire Size (mm²) LU LR AWG Stripped length ±0,3 Height ±0,05 1) 2) ±0,2 Crimping Tool Die for handcrimping tool Single wire seal ,20 0,25 0,35 3) 1,151,6 3,5 1,60 0,98±0,03 1,00±0,03 1,05±0,03 1,12±0,03 3,95 x878952x ,35 3) 1,151,6 3,5 1,60 1,08±0,03 3,95 x878952x ,75 1,00 3) 1,42,1 4,5 2,05 1,27 1,36 1,15 1,20 4,10 x878953x ,50 2,00 2,50 3) 2,23,0 4,9 2,55 1,55 1,70 1,86 1,47 1,76 4,20 x878954x ,3 (TXL) 3,8 (GXL) 5,6 CB CB , x x x 1) current standard 2) preferred standard to meet new LV2142 slow motion bending test 3) Contact, wire combination has not yet been considered Rev G 11 of 12

12 Table 5 AWG / IS Comparison in addition to Appl. Spec mm tab Basic part number Wire size IS 6722 Cross section Type USA SAE J1128 uter diameter (Insulation) Single Wire Seal Applicator Applicator Applicator AWG Cable type 0,35mm² LR 1,301,40mm TXL 1,501,75mm ,5mm² LR 1,581,70mm TXL 1,681,93mm ,75mm² LR 1,781,90mm TXL 1,882,13mm ,0mm² LR 1,982,10mm ,5mm² LK 2,062,30mm GXL 2,062,41mm ,75mm² LK 2,262,50mm GXL 2,182,54mm ,0mm² LK 2,462,70mm TXL 2,162,41mm ,5mm² LR 2,282,40mm ,0mm² LR 2,662,80mm TXL 2,512,77mm ,5mm² LR 2,863,00mm GXL 2,572,92mm ,5mm² LK 2,863,00mm GXL 2,823,18mm ,5mm² LK 3,323,60mm G LU wires added M. Merz S. Raab LTR REVISIN RECRD DWN APP DATE Rev G 12 of 12