RoHS. Standard Terminals & Splices. Pre-Insulated Euro-Crimp. Ready

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Dylan Dawson
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1 RoHS Ready Standard Terminals & Splices Pre-Insulated

2 Engineering Notes 2

Contents Page Introduction... 4 Performance Specifications.

.. 9 Product Facts...11 Products...12-25 Part Number Index...26 Global Contacts.

Blade Tongue Page 16 Wire Pin Page 17 Female Push-On Page 18 Female Push-On Fully Insulated Page 19 Male Push-On

3 Contents Page Introduction... 4 Performance Specifications...5 Table isting: Circular Mil Area (CMA) for Popular Wire Sizes Terminal Stud Hole Size... 8 Tooling... 9 Product Facts...11 Products Part Number Index...26 Global Contacts Products Ring Tongue Page 12 Ring Tongue DIN Page 13 Fork Tongue Page 14 Blade Tongue Page 15 Hooked Blade Tongue Page 16 Wire Pin Page 17 Female Push-On Page 18 Female Push-On Fully Insulated Page 19 Male Push-On Page 20 Piggy Back Page 21 Male Bullet Page 22 Female Bullet Page 22 Butt Page 23 Parallel Page 24 Closed End Page 25 Terminals available in other colour coded wire sizes. See product pages for more information. 3

Introduction This Tyco Electronics family of Terminals and Splices provides reliable, low cost terminations for wire sizes 0.5sqr 6.0sqr (22AWG 10AWG).

4 Introduction This Tyco Electronics family of Terminals and Splices provides reliable, low cost terminations for wire sizes 0.5sqr 6.0sqr (22AWG 10AWG). The terminals are ideally suited to meet the cost / performance needs of commercial applications. The terminals and splices consist of precision formed metal wire barrel insulated with PVC and have a continuous maximum operating temperature of 75 C. The terminals and splices accept solid or stranded wire for single applications. The insulation allows insertion of wires that meet maximum voltage rating of 600 V. Colour Coding: Terminal Insulation is colour-coded by wire size range to eliminate errors during installation Wide Entry: Assures rapid wire insertion during volume cable assembly Serrations: Serrations inside the barrel provide maximum contact and tensile strength after crimping Basic Terminal : The terminals are constructed of high conductivity tin plated copper Vinyl Insulation sleeve provides good dielectric strength and supports the wire insulation so that no bare wire is exposed The terminals and splices are colour coded to provide a visual reference applicable to the wire size range suitable for the terminal or splice. In addition, terminals are marked on the tongue with the wire size range. The serrations inside the wire barrel provide maximum contact and tensile strength after crimping. The terminals suitable for mounting accept stud sizes M3 through M12. The terminals and splices are available in loose-piece for terminating with manual hand held tools, packed either in bulk or re-sealable dispensing plastic containers for in-field installation. Insulation Colour Code Insulation Colour Wire Size Range AWG Comments 0.1/0.41 (26-22) 0.16/0.65 (24-20) 0.26/1.65 (22-16) 1.04/2.62 (16-14) 1.04/2.62 (16-14) Heavy Duty 2.62/6.64 (12-10) 6.64/10.5 (8) 10.5/16.8 (6) 16.8/26.7 (4) 26.7/42.4 (2) 42.4/60.6 (1/0) 60.6/76.3 (2/0) 76.3/96.3 (3/0) 96.3/117 (4/0) Packaging Quantities Wire Size Range Packaging Type mm 2 / AWG Small Pack Bulk Pack 0.26/1.65 (22-16) /2.62 (16-14) /6.64 (12-10)

Performance Specifications: Typical Results Tensile Test Results Crimped terminals or splices must hold

Figure 1. Wire Size (AWG) Wire Size Eqv (mm 2 ) Tensile Force (N Min) 22 0.33 35.6 20 0.52 57.9 18 0.

26 / 1.65 (22-16AWG) Report 38-2007 Red ring terminal Part No 1-1838145-0 0.

00 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Sample number Values shown are typical 22 AWG 16 AWG

40 Resistance stated in milli-ohms 0.35 0.30 0.25 0.20 0.15 0.10 0.05 0.

Values shown are typical Wire Size 2.62 / 6.

5 Performance Specifications: Typical Results Tensile Test Results Crimped terminals or splices must hold the wire firmly and have a crimp pull-out test value meeting that is specified in Figure 1. Figure 1. Wire Size (AWG) Wire Size Eqv (mm 2 ) Tensile Force (N Min) Voltage Drop (Resistance) Results Wire Size 0.26 / 1.65 (22-16AWG) Report Red ring terminal Part No Resistance stated in milli-ohms Initial resistance Final resistance Sample number Values shown are typical 22 AWG 16 AWG Wire Size 1.04 / 2.62 (16-14AWG) Report Blue ring terminal Part No Resistance stated in milli-ohms Sample number Initial resistance Final resistance Values shown are typical Wire Size 2.62 / 6.64 (12-10AWG) 16 AWG 14 AWG Report Yellow ring terminal Part No Resistance stated in milli-ohms Initial resistance Final resistance Sample number Values shown are typical 12 AWG 10 AWG 5

6 Table isting: Circular Mil Area for common wire sizes Computing Circular Mil Area This table has been included into this publication to assist in selecting the appropriate terminal where multiple cables require to be terminated. For best results, the correct Tyco Electronics terminal or splice must be selected not by the "fit" of wire or wires in the terminal barrel, but by the total Circular Mil Area (CMA) in cross section of the wires used. For this purpose Tyco Electronics has prepared convenient tables to assist in the calculation of Circular Mil Area (CMA). When the totals are known, the correct Tyco Electronics terminal or splice can be determined quickly. Unusual combinations or special applications should be submitted to Tyco Electronics engineering department for size recommendation. In any application, the careful selection of terminals by the Circular Mil Area (CMA) method will insure the highest possible performance, both electrically and mechanically, in your Tyco Electronics terminations. Nominal Strands Approximate Wire Size Diameter Conductor Diameter CMA AWG mm 2 No. Inch mm Inch mm

7 Table isting: Circular Mil Area for common wire sizes Example of Multiple Wire Configurations Used In One Termination AWAYS SEECT TERMINAS BY THE CIRCUAR MI AREA METHOD. For example, a No. 18 AWG 16-strand conductor (1600 CMA) and a No. 16 AWG 19-strand conductor (2426 CMA) will have a combined total of 4026 CMA. This total CMA is equivalent to a No. 14 AWG conductor. Wire Sizes in AWG and mm 2 to CMA Note: The following tables are applicable to single and multiple strand, round, conductors only. Nominal Strands Approximate Wire Size Diameter Conductor Diameter CMA AWG mm 2 No. Inch mm Inch mm

8 Terminal Stud Hole Size Use to Select Proper Size Terminal This chart shows sizes and dimensions of various studs and the corresponding terminal stud hole sizes used with Tyco Electronics crimp devices. Terminal stud hole sizes may easily be checked by fitting sample terminal to black circle. Stud Size Stud Dia Minimum Terminal Metric U.S. mm Hole Diameter # # M2 # # # M3 # M3.5 # M4 # # # # M6 1/ M8 5/ / / M12 1/ All dimensions shown are typical. Please consult Tyco Electronics Customer Drawing for actual clearance dimensions 8

9 Tooling and Wire Preparation Wire Selection and Preparation The terminals and splices will accept solid or stranded copper wire sizes 0.5 Stranded Wire Solid Wire mm 2 to 6 mm 2 [22 to 10 AWG] with an insulation diameter range of 2.03 to 6.35 mm. Correct strip length is necessary to insert the wire into the terminal or splice properly. The strip length of the wire is shown in Figure 2. Figure 2 Terminal or Splice Wire Size mm 2 Insulation Insulation Wire Strip ength AWG Colour Diameter Terminal Butt Splice Parallel Splice (22-16] Red (16-14] Blue (12-10] Yellow For full Application Specification, use Tyco Electronics document For more information, go to Tooling Hand tools for manual application of loose piece terminals and splices are available to cover the full wire size range. Tooling part numbers and instructional material packaged with the tooling are shown in Figure 3. Hand crimping tools consist of a handle assembly with integral fixed jaws or fixed dies, or a head that accepts various die assemblies. The jaws or dies have one or more crimping chambers used to crimp terminals and splices onto pre-stripped wire. The hand tool assemblies have a ratchet, except the hydraulic hand crimping tool which uses hydraulic fluid, to ensure full crimping pressure is applied to the terminal or splice. Modified designs and additional tooling concepts may be available to meet other application requirements. Tool Engineers have designed machines for a variety of application requirements. For assistance in setting up prototype and production line equipment, contact your local Tyco Electronics Representative. * Tooling for Ring Tongue Terminals according to DIN 46237, use CERTI-CRIMP Hand Tool: - Red terminals: Blue terminals: Yellow terminals: Figure 3. TETRA-CRIMP Hand Crimping Tool Application Specification, see document

10 Engineering Notes 10

Product Facts Product Facts Pre-Insulated EURO-CRIMP solderless terminals and splices Designed to meet the cost/ performance needs of insulated electrical terminations Wide and varied use for almost

11 Product Facts Product Facts Pre-Insulated EURO-CRIMP solderless terminals and splices Designed to meet the cost/ performance needs of insulated electrical terminations Wide and varied use for almost all commercial applications Re-sealable packaging for ease of infield termination Design Features Accommodates wire sizes 0.5sqr 6.0sqr (22AWG 10AWG) Colour coded vinyl insulation by wire size for easy identification Easy wire insertion for low cost termination Tyco Electronics F crimp termination provides long life performance Standard Tyco Electronics hand crimp tool and die set ensure uniform high quality crimp U isted under File E13288 CSA Certified* VDE Approved* Terminals Page Ring Tongue...12 Ring Tongue according to DIN Fork Tongue...14 Blade Tongue...15 Hooked Blade Tongue Wire Pin Female Push-On...18 Female Push-On Fully Insulated Male Push-On...20 Piggy Back...21 Male Bullet...22 Female Bullet...22 Splices Butt Parallel...24 Closed End * Approval Pending 11

12 Ring Tongue Terminal Vinyl, U94V-0 Application Tooling: pg 9 W E Wire Tongue Wire Insulation Size Thickness Stud Dimensions Terminal Diameter Part Numbers mm 2 Max Size W E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty 0.75 M , M , M , M , M , M , M , M , M , M , M , M , M , M , M , M , M M M MS M M M M

13 Ring Tongue Terminal according to DIN Vinyl, U94V-0 Application Tooling: pg 9* W Wire Tongue Wire Insulation Size Thickness Stud Dimensions Terminal Diameter Part Numbers mm 2 Max Size W Colour Max Small Pack Box Qty Bulk Pack Bag Qty 0.8 M M M M M M M M M M M M M M M M

14 Fork Tongue Terminal Vinyl, U94V-0 Application Tooling: pg 9 W E Wire Tongue Wire Insulation Size Thickness Stud Dimensions Terminal Diameter Part Numbers mm 2 Max Size W E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty 0.75 M , M , M , M , M , M , M , M , M , M , M , M , M M M M Visit our electronic catalogue for our complete range at 14

Blade Tongue Terminal Vinyl, U94V-0 Application Tooling: pg 9 C E Wire Tongue Wire Insulation Size Thickness Blade Dimensions Terminal Diameter Part Numbers mm 2 Max Width C Min E Max Max Colour Max

15 Blade Tongue Terminal Vinyl, U94V-0 Application Tooling: pg 9 C E Wire Tongue Wire Insulation Size Thickness Blade Dimensions Terminal Diameter Part Numbers mm 2 Max Width C Min E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty , , , , , Search for distributor inventory at 15

16 Hooked Blade Tongue Terminal Vinyl, U94V-0 Application Tooling: pg 9 H E Wire Tongue Wire Insulation Size Thickness Blade Dimensions Terminal Diameter Part Numbers mm 2 Max Width H E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty , , , , Visit our electronic catalogue for our complete range at 16

Wire Pin Terminal Vinyl, U94V-0 Application Tooling: pg 9 E Wire Tongue Wire Insulation Size Thickness Pin Dimensions Terminal Diameter Part Numbers mm 2 Max ength E Max Max Colour Max Small Pack Box

17 Wire Pin Terminal Vinyl, U94V-0 Application Tooling: pg 9 E Wire Tongue Wire Insulation Size Thickness Pin Dimensions Terminal Diameter Part Numbers mm 2 Max ength E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty , , , , Search for distributor inventory at 17

Female Push-On Terminal Vinyl, U94V-0 E Application Tooling: pg 9 B Wire Max Max Wire Insulation Size Tongue Tongue Dimensions Terminal Diameter Part Numbers mm 2 Width Thickness B E Max Max Colour

18 Female Push-On Terminal Vinyl, U94V-0 E Application Tooling: pg 9 B Wire Max Max Wire Insulation Size Tongue Tongue Dimensions Terminal Diameter Part Numbers mm 2 Width Thickness B E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty , , , , , , , , Search for distributor inventory at 18

Female Push-On Terminal Fully Insulated Vinyl, U94V-0 E Application Tooling: pg 9 B Wire Max Max Wire Insulation Size Tongue Tongue Dimensions Terminal Diameter Part Numbers mm 2 Width Thickness B E

19 Female Push-On Terminal Fully Insulated Vinyl, U94V-0 E Application Tooling: pg 9 B Wire Max Max Wire Insulation Size Tongue Tongue Dimensions Terminal Diameter Part Numbers mm 2 Width Thickness B E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty , , , , Visit our electronic catalogue for our complete range at 19

Male Push-On Terminal Vinyl, U94V-0 E Application Tooling: pg 9 W Wire Max Max Wire Insulation Size Tongue Tongue Dimensions Terminal Diameter Part Numbers mm 2 Width Thickness W E Max Max Colour Max

20 Male Push-On Terminal Vinyl, U94V-0 E Application Tooling: pg 9 W Wire Max Max Wire Insulation Size Tongue Tongue Dimensions Terminal Diameter Part Numbers mm 2 Width Thickness W E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty , , Search for distributor inventory at 20

Piggy Back Terminal Vinyl, U94V-0 W Application Tooling: pg 9 C E Wire Max Max Wire Insulation Size Tongue Tongue Dimensions Terminal Diameter Part Numbers mm 2 Width Thickness W C Min E Max Max

21 Piggy Back Terminal Vinyl, U94V-0 W Application Tooling: pg 9 C E Wire Max Max Wire Insulation Size Tongue Tongue Dimensions Terminal Diameter Part Numbers mm 2 Width Thickness W C Min E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty Visit our electronic catalogue for our complete range at 21

Male Bullet Terminal Vinyl, U94V-0 E Application Tooling: pg 9 Wire Wire Insulation Size Contact Dimensions Terminal Diameter Part Numbers mm 2 Diameter E Max Max Colour Max

22 Male Bullet Terminal Vinyl, U94V-0 E Application Tooling: pg 9 Wire Wire Insulation Size Contact Dimensions Terminal Diameter Part Numbers mm 2 Diameter E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty , ,000 Female Bullet Terminal Vinyl, U94V-0 Application Tooling: pg 9 Wire Wire Insulation Size Contact Dimensions Terminal Diameter Part Numbers mm 2 Diameter Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty , ,000 22

Butt Splice Terminal Vinyl, U94V-0 E Application Tooling: pg 9 Wire Wire Insulation Size Dimensions Terminal Diameter Part Numbers mm 2 E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty 22-16

23 Butt Splice Terminal Vinyl, U94V-0 E Application Tooling: pg 9 Wire Wire Insulation Size Dimensions Terminal Diameter Part Numbers mm 2 E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty , , Visit our electronic catalogue for our complete range at 23

Parallel Splice Terminal Vinyl, U94V-0 E F Application Tooling: pg 9 Wire Wire Insulation Size Dimensions Terminal Diameter Part Numbers mm 2 F E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag

24 Parallel Splice Terminal Vinyl, U94V-0 E F Application Tooling: pg 9 Wire Wire Insulation Size Dimensions Terminal Diameter Part Numbers mm 2 F E Max Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty , , Search for distributor inventory at 24

Closed End Connector Terminal Vinyl, U94V-0 W Application Tooling: pg 9 Wire Size Wire Insulation mm 2 Dimensions Terminal Diameter Part Numbers Circular Mils W Max Colour Max Small Pack Box Qty Bulk

25 Closed End Connector Terminal Vinyl, U94V-0 W Application Tooling: pg 9 Wire Size Wire Insulation mm 2 Dimensions Terminal Diameter Part Numbers Circular Mils W Max Colour Max Small Pack Box Qty Bulk Pack Bag Qty , , Visit our electronic catalogue for our complete range at 25

26 Part Number Index Part No. Page No. Part No. Page No. Part No. Page No. Part No. Page No

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Product Facts. Need more information? Product Facts Wire-to-board and wire-towire connector system Free hanging or panel mount plug housings Vertical header with or without mounting pegs and with or without drain holes Selective loading available