Applcaton Specfcaton 114-10004 Type III+ (Sze 16) Contacts 15 MAR 11 Rev L NOTE All numercal values are n metrc unts [wth U.S. customary unts n brackets]. Dmensons are n mllmeters [and nches]. Unless otherwse specfed, dmensons have a tolerance of +0.13 [+.005] and angles have a tolerance of +2_. Fgures and llustratons are fordentfcaton only and are not drawn to scale. 1. INTRODUCTION Ths specfcaton covers the requrements for the applcaton of Type III+ (Sze 16) Contacts. These contacts have a pn dameter of 1.57 mm [.062 n.]. A color dot appears on the loose pece or (loose pece only) contact sprng whch desgnates the applcable wre sze and matches the color dot above the hand tool crmpng secton. These requrements apply to hand or automatc machne crmpng tools for the nsulated grp contacts. When correspondng wth TE Connectvty (TE) Personnel, use the termnology provded on ths specfcaton to help facltate your nqury for nformaton. Basc terms and features of components are provded n Fgure 1. Insulaton Grp Contacts Insulaton Barrel Wre Barrel Color Dot (Loose Pece Only) Socket Wre Barrel Pn Lockng Lance Insulaton Barrel Posted Socket Solder Tab Pn Solder Type Socket Fgure 1 2. REFERENCE MATERIAL 2.1. Revson Summary S Updated document to corporate requrements S New logo 2.2. Customer Assstance Reference Base Part Number 66098 and Product Code 5022 are representatve numbers of the Type III+ (Sze 16) Contacts. Use of these numbers wll dentfy the product lne and expedte your nqures through a servce network establshed to help you obtan product and toolng nformaton. Such nformaton can be obtaned through a TE Representatve or, after purchase, by callng the Product Informaton Center at the number at the bottom of ths page. E2011 Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company TOOLING ASSISTANCE CENTER 1-800 -722-1111 All Rghts Reserved PRODUCT INFORMATION 1-800 -522-6752 TE logo s a trademark. *Trademark. Other product names, logos, or company names mght be trademarks of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.te.com 1 of 10 LOC B
2.3. Drawngs Customer Drawngs for product part numbers are avalable from the servce network. The nformaton contaned n the Customer Drawngs takes prorty f there s a conflct wth ths specfcaton or wth any other techncal documentaton suppled by TE. 2.4. Manuals Manual 402--40 s avalable upon request and can be used as a gude n solderng. Ths manual provdes nformaton on varous flux types and characterstcs along wth the commercal desgnaton and flux removal procedures. A checklst s ncluded n the manual as a gude for nformaton on solderng problems. 2.5. Specfcatons Product Specfcaton 108--10042 provdes product performance requrements and test nformaton. 2.6. Instructonal Materal The followng lst ncludes avalable nstructon sheets (408--seres) that provde assembly procedures for product, operaton, mantenance and repar of toolng, as well as setup and operaton procedures of applcators; and customer manuals (409--seres) that provde setup, operaton, and mantenance of machnes. Document Number Document Ttle 408--1216 Extracton Tools 305183--[ ] 408--1379 Selecton Charts for Multmate Pn and Socket Contacts 408--3295 Preparng Reel of Contacts for Applcaton Toolng 408--7347 Inserton Tools 91002--[ ] 408--7414 Hand Crmpng Tool 90225--2 408--7424 Checkng Termnal Crmp Heght or Gagng De Closure 408--7773 Hand Crmpng Tool 90331--1 408--8039 Heavy Duty Mnature Quck--Change Applcators (End--Feed Type) 408--8040 Heavy Duty Mnature Quck--Change Applcators (Sde--Feed Type) 408--8059 General Preventve Mantenance for Applcators 408--8547 CERTI--CRIMP* II Straght acton Hand Tools 408--9640 Crmp Qualty Montor Applcators for Sde--Feed and End--Feed Applcatons 408--9816 Handlng of Reeled Products 409--5128 Basc AMP--O--LECTRIC* Model K Termnatng Machne 565435--5 409--5842 AMP--O--LECTRIC Model G Termnatng Machnes 354500--[ ] 409--5852 AMPOMATOR* CLS III--G Lead--Makng Machne 122500--[ ] 409--5866 AMPOMATOR CLS IV Lead--Makng Machne 217500--[ ] 409--5870 Crmp Qualty Montors (CQM) for AMPOMATOR CLS IV Lead--Makng Machnes 409--5878 AMPOMATOR CLS IV+ Lead--Makng Machne 356500--[ ] 409--10012 AMP--O--MATIC* Sde Feed Strpper--Crmper III Machne 1320895--[ ] 409--10016 Entry Level Termnator (ELT) Machne 1338600--[ ] 409--10027 Strppng Modules 1490500 and 1490502 409--10029 Strppng Modules 1490501 and 1490503 3. REQUIREMENTS 3.1. Storage A. Ultravolet Lght Prolonged exposure to ultravolet lght may deterorate the chemcal composton used n the contacts. B. Reel Storage When usng reeled contacts, store col wound reels horzontally and traverse wound reels vertcally. C. Shelf Lfe The contacts should reman n the shppng contaners untl ready for use to prevent deformaton to the contact. The contacts should be used on a frst n, frst out bass to avod storage contamnaton that could adversely affect sgnal transmssons. 2 of 10 Rev L
D. Chemcal Exposure Do not store contacts near any chemcals lsted below as they may cause stress corroson crackng n the contacts. Alkales Ammona Ctrates Phosphates Ctrates Sulfur Compounds Amnes Carbonates Ntrtes Sulfur Ntrtes Tartrates NOTE Where the above envronmental condtons exst, phosphor -bronze contacts are recommended nstead of brass f avalable. 3.2. Specal Characterstcs The solder type and solder tab versons wll accept varous szes of sold or stranded wre. For solderng requrements, follow the recommendatons of the wre manufacturer and solderng equpment manufacturer. Refer to Manual 402--40. 3.3. Wre Selecton and Preparaton The total wre sze range for these contacts s 30 through 14 AWG. The wre must be strpped to the dmensons shown n Fgure 2. NOTE The appled crmp dmenson (wthn the functonal range of the product) s dependent on the termnaton toolng beng used. Refer to the documentaton (applcator logs and nstructon sheets) suppled wth the termnaton toolng for the appled crmp heght. See Secton 5, TOOLING. CAUTION! DO NOT nck, scrape, or cut the wre conductor durng the strppng operaton. Strp Length 4.34-3.58 [.171 -.141] Conductor Insulaton WIRE SIZE, INSULATION WIRE BARRELCRIMP INSULATION BARREL AWG DIAMETER HEIGHT WIDTH CRIMP WIDTH 0.36-0.76 [.014 -.030] 1.05-0.89 [.0415 -.035] 1.75-1.57 [.069 -.062] 1.60-1.20 [.063 -.047] 30-26 1.02-1.52 [.040 -.060] 1.05-0.89 [.0415 -.035] 1.75-1.57 [.069 -.062] 1.98-1.58 [.078 -.062] 26 0.89-1.40 [.035 -.055] 0.84-0.74 [.033 -.029] 1.57-1.40 [.062 -.055] 1.98-1.58 [.078 -.062] 24 (2) 24 2.03-2.54 [.080 -.100] 1.04-0.86 [.041 -.034] 1.75-1.57 [.069 -.062] 3.25-2.85 [.128 -.112] 1.52-3.43 [.060 -.135] 0.97-0.76 [.038 -.030] 1.75-1.57 [.069 -.062] 3.25-2.84 [.128 -.112] 1.02-2.03 [.040 -.080] 1.05-0.86 [.0415 -.034] 1.75-1.57 [.069 -.062] 2.49-2.09 [.098 -.082] 0.89-1.40 [.035 -.055] 0.89-0.74 [.035 -.029] 1.57-1.40 [.062 -.055] 1.98-1.58 [.078 -.062] 1.52-3.43 [.060 -.135] 1.07-0.86 [.042 -.034] 1.75-1.57 [.069 -.062] 3.25-2.84 [.128 -.112] 1.02-2.03 [.040 -.080] 1.07-0.97 [.042 -.038] 1.75-1.57 [.069 -.062] 2.49-2.09 [.098 -.082] 2.03-2.54 [.080 -.100] 1.04-0.91 [.041 -.036] 1.75-1.57 [.069 -.062] 3.25-2.85 [.128 -.112] 22 1.52-3.43 [.060 -.135] 1.02-0.81 [.040 -.032] 1.75-1.57 [.069 -.062] 3.25-2.84 [.128 -.112] 1.02-2.03 [.040 -.080] 1.05-0.91 [.0415 -.036] 1.75-1.57 [.069 -.062] 2.49-2.09 [.098 -.082] Fgure 2 (cont d) Rev L 3 of 10
WIRE SIZE, INSULATION WIRE BARRELCRIMP INSULATION BARREL AWG DIAMETER HEIGHT WIDTH CRIMP WIDTH 2.03-2.54 [.080 -.100] 1.12-0.94 [.044 -.037] 1.75-1.57 [.069 -.062] 3.25-2.85 [.128 -.112] 20 1.52-3.43 [.060 -.135] 1.12-0.91 [.044 -.036] 1.75-1.57 [.069 -.062] 3.25-2.84 [.128 -.112] 1.02-2.03 [.040 -.080] 1.12-0.95 [.044 -.0375] 1.75-1.57 [.069 -.062] 2.49-2.09 [.098 -.082] 18 16 14 2.79-3.81 [.110 -.150] 1.37-1.24 [.054 -.049] 2.46-2.29 [.097 -.090] 4.16-3.76 [.163 -.147] 2.03-2.54 [.080 -.100] 1.35-1.24 [.053 -.049] 2.20-2.03 [.087 -.080] 3.25-2.85 [.128 -.112] 2.79-3.81 [.110 -.150] 1.55-1.24 [.061 -.049] 2.46-2.29 [.097 -.090] 4.16-3.76 [.163 -.147] 2.03-2.54 [.080 -.100] 1.47-1.24 [.058 -.049] 2.20-2.03 [.087 -.080] 3.25-2.85 [.128 -.112] 2.79-3.81 [.110 -.150] 1.78-1.68 [.070 -.066] 2.46-2.29 [.097 -.090] 4.16-3.76 [.163 -.147] 2.03-2.54 [.080 -.100] 1.78-1.68 [.070 -.066] 2.46-2.29 [.097 -.090] 3.25-2.85 [.128 -.112] 3.4. Crmped Contact Requrements Fgure 2 (end) The contact must be crmped onto the wre accordng to nstructons packaged wth applcable toolng. After crmpng, the contact should appear as shown n Fgure 3. A typcal pn contact s shown as t should appear after crmpng; these requrements apply equally to the socket contact. CAUTION! The wre nsulaton must not be damaged durng the crmpng process. A. Wre Barrel Crmp The crmp appled to the wre porton of the contact s the most compressed area and s most crtcal n ensurng optmum electrcal and mechancal performance of the crmped contact. The contact wre barrel crmp heght must be wthn the dmenson provded n Fgure 2. B. Effectve Crmp Length For optmum crmp effectveness, the crmp must be wthn the area shown n Fgure 3 and must meet the crmp dmensons provded n Fgure 2. Effectve crmp length shall be defned as that porton of the wre barrel, excludng bellmouth(s), fully formed by the crmpng tool. Instructons for adjustng, reparng, and nspectng tools are packaged wth the tools. See Secton 5, TOOLING. C. Bellmouths Front and rear bellmouths shall be evdent and conform to the dmensons gven n Fgure 3. D. Cutoff Tabs The cutoff tab shall be cut to the dmensons shown n Fgure 3. E. Burrs The cutoff burr shall not exceed the dmensons shown n Fgure 3. F. Wre Barrel Flash The wre barrel flash shall not exceed the dmensons shown n Fgure 3, Secton X--X. G. Insulaton Barrel Crmp The nsulaton barrel shall grp the nsulaton frmly. A slght cut n the nsulaton by the nsulaton barrel s permssble as ths causes no problems n actual use. Insulaton crmp shall comply to wdth and heght provded n Fgure 3. H. Wre Locaton The wre conductor and nsulaton must be vsble n the transton area between the wre and nsulaton barrels. 4 of 10 Rev L
I. Conductor Extenson The conductor may extend beyond the wre barrel to the maxmum shown. J. Wre Barrel Seam The wre barrel seam must be closed wth no evdence of loose wre strands vsble n the seam. NOTE Perodc nspectons must be made to ensure crmped contact formaton s consstent as referenced. Wre Conductors and Insulaton Must Both be Vsble n Ths Area 0.81 [.032] Max Conductor Locaton Insulaton Barrel Crmp Wdth Wre Barrel Seam Lockng Lance Undamaged Closed wth No Conductor Strands Showng 0.20-0.64 [.008 -.025] Rear Bellmouth X Crmp Length 0.51 [.020] Max Front Bellmouth X 0.25 [.010] Max Wre Barrel Flash Wre Barrel Crmp Wdth Wre Barrel Crmp Heght Cutoff Tab 0.25 [.010] Max. 0.08 [.003] Max. Burr Secton X -X 3.5. Axal Concentrcty Fgure 3 The axal concentrcty of a crmped contact must be wthn an area defned by the dameter of a crcle that has the same center as the centerlne of the contact. The dameter of the crcle wll depend on the wre szes. See Fgure 4. Ths measurement does not apply to posted contacts. Rev L 5 of 10
WIRE SIZE, AWG CIRCLE DIAMETER 30-28 3.40 [.134] 26-20 3.40 [.134] 18-14 4.16 [.164] Contact Crcle Dameter Contact and Crcle Dameter Centerlnes Fgure 4 3.6. Posted Sockets The posted sockets accept TERMI--POINT* Connectors or wrap--type termnatons. They can accommodate up to three termnatons per post. For termnatng requrements, follow the nstructons pertanng to specfc choce of termnaton method and toolng types used. 3.7. Solder Tab Pn and Sockets Observe all gudelnes and procedures when solder type contacts are requred. Solder, clean, and dry all wre leads to the contacts accordng to the followng: A. Flux Selecton The wre lead and contact wre barrel nteror shall be fluxed pror to solderng usng a mldly actve rosn. Selecton of the proper flux wll depend on the type of pc board and other components mounted on the board. Addtonally, the flux wll have to be compatble wth the wave solder lne, manufacturng, and safety requrements. B. Cleanng After solderng, removal of fluxes, resdues, and actvators s necessary. Consult wth the suppler of the solder and flux for recommended cleanng solvents. The followng s a lst of common cleaners that wll not affect the connectors for the tmes and temperatures shown. See Fgure 5. DANGER Consderaton must be gven to toxcty and other safety and health requrements as recommended n the Materal Safety Data Sheet suppled by the solder cleaner solvent manufacturer. TEMPERATURES CLEANER TIME (Maxmum) (Mnutes) NAME TYPE CELSIUS FAHRENHEIT ALPHA 2110 Aqueous 1 132 270 BIOACT EC -7 Solvent 5 100 212 Butyl CARBITOL Solvent 1 Room Ambence Isopropyl Alcohol Solvent 5 100 212 KESTER 5778 Aqueous 5 100 212 KESTER 5779 Aqueous 5 100 212 LONCOTERGE 520 Aqueous 5 100 212 LONCOTERGE 530 Aqueous 5 100 212 Terpene Solvent Solvent 5 100 212 Fgure 5 C. Dryng When dryng cleaned assembles and pc boards, make certan that temperature lmtatons of --55_ to 105_C [--67_ to 222_F] are not exceeded. Excessve temperatures may cause housng degradaton. D. Solderng Gudelne Refer to Paragraph 2.4, Manuals, for nformaton on solderng requrements. ALPHA, BIOACT, CARBITOL, KESTER, and LONCOTERGEare trademarksoftherrespectve owners. 6 of 10 Rev L
3.8. Repar/Replace Contacts are not reparable once a termnaton has been made. Any defectve or damaged contact must be removed and replaced wth a new one. Use Extracton Tool 305183 to remove ndvdual contacts from housngs for replacement or for relocaton to another housng cavty. 4. QUALIFICATION No qualfcatons or approvals are requred for Type III+ Contacts. 5. TOOLING These contacts can be termnated to wre usng hand, sem--automatc, or automatc crmpng tools. Recommended toolng s provded n Fgure 6. NOTE TE Toolng Engneers have desgned machnes for a varety of applcaton requrements. For assstance n settng up prototype and producton lne equpment, contact TE Tool Engneerng through your local TE Representatve or call the Toolng Assstance Center number at the bottom of page 1. S Hand Crmpng Tool Hand crmpng tools that accommodate the full wre sze range are desgned for prototype and low--volume applcatons such as repar of damaged contacts. S Applcator Applcators are desgned for the full wre sze range of strp--fed, precson formed contacts, and provde for hgh volume, heavy duty, producton requrements. The applcators can be used n bench or floor model power unts. NOTE Each applcator s shpped wth a metal dentfcaton tag attached. DO NOT remove ths tag or dsregard the nformaton on t. Also, a packet of assocated paperwork s ncluded n each applcator shpment. Ths nformaton should be read before usng the applcator; then t should be stored n a clean, dry area near the applcator for future reference. Some changes may have to be made to the applcators to run n all related power unts. Contact the Toolng Assstance Center number located at the bottom of page 1 for specfc changes. S Power Unts A power unt s an automatc or sem--automatc devce used to assst n the applcaton of a product. Power unt ncludes the power source used to supply the force or power to an applcator. S Inserton/Extracton Toolng Inserton Tools are desgned for contacts crmped to small fragle wre. They are desgned to stablze the contact durng nserton. For use of Inserton Tool 91002 whch may be used wth these contacts, refer to Instructon Sheet 408--7347. Extracton Tools are desgned to release the lockng lance nsde the connector housng wthout damagng the housng or contacts. For use of Extracton Tool 305183 whch may be used wth these contacts, refer to Instructon Sheet 408--1216. WIRE SIZE RANGE, AWG INSULATION DIAMETER RANGE HAND TOOL (DOCUMENT) APPLICATOR (408-8040) POWER UNIT (DOCUMENT) 30-26 1.02-1.52 [.040 -.060] 91515-1 (408-8547) 466598-2 0.36-0.76 [.014 -.030] 90225-2 (408-7414) 466585-3 466321-3 26-24 0.89-1.40 [.035 -.055] 91515-1 (408-8547) 466321-4 466908-2 1320895-1, -3 (409-10012) Fgure 6 (cont d) Rev L 7 of 10
WIRE SIZE RANGE, AWG INSULATION DIAMETER RANGE 1.02-2.03 [.040 -.080] 2.03-2.54 [.080 -.100] HAND TOOL (DOCUMENT) 91505-1 (408-8547) 91515-1 (408-8547) 90225-2 (408-7414) 91523-1 (408-8547) APPLICATOR (408-8040) 466323-3 466323-4 POWER UNIT (DOCUMENT) 466907-2 1320895-1, -3 (409-10012) 466324-1 466324-2 24-20 466942-1 1320895-1, -3 (409-10012) 466383-4 466979-1 1320895-1, -3 (409-10012) 1.52-3.43 [.060 -.135] 90331-1 (408-7773) 567363-1 567363-2 567363-3 567806-1 1320895-1, -3 (409-10012) 466325-1 18-16 2.03-2.54 [.080 -.100] 18-14 GSee Instructon Sheet 408-8039. 91505-1 (408-8547) 91523-1 (408-8547) 2.03-2.54 [.080 -.100] 91519-1 (408-8547) 2.79-3.81 [.110 -.150] 91521-1 (408-8547) Fgure 6 (cont d) 466325-2 466906-1 1320895-1, -3 (409-10012) 466923-2G 1320895-1, -3 (409-10012) 466326-3 466326-4 567364-2 466958-1 1320895-1, -3 (409-10012) 8 of 10 Rev L
Extracton Tool 305183 -[ ] Inserton Tool 91002 -[ ] Typcal Hand Tool ELT Machne 1338600 -[ ] wth Optonal Strppng Module 1490500 -[ ] (Strppng Module Only 1490502 -[ ]) AMP -O -MATIC Sde Feed Strpper -Crmper II Machne 1320895 -[ ] Typcal Heavy Duty Mn (HDM) Applcator AMP -O -LECTRIC Model G Termnatng Machne 354500 -[ ] wth Optonal Strppng Module 1490501 -[ ] (Strppng Module Only 1490503 -[ ]) AMPOMATOR CLS Lead -Makng Machnes 122500 -[ ]; 217500 -[ ]; 356500 -[ ] AMP -O -LECTRIC Model K Termnatng Machne 565435-5 Fgure 6 (end) Rev L 9 of 10
6. VISUAL AID Fgure 7 shows a typcal applcaton of a Type III+ (Sze 16) Contact. Ths llustraton should be used by producton personnel to ensure a correctly appled product. Applcatons whch DO NOT appear correct should be nspected usng the nformaton n the precedng pages of ths specfcaton and n the nstructonal materal shpped wth the product. WIRE BARREL SEAM MUST BE CLOSED, WITH NO CONDUCTOR STRANDS SHOWING REAR BELLMOUTH MUST BE VISIBLE LOCKING LANCE MAY NOT BE DEFORMED WIRE AND INSULATION MUST BE VISIBLE IN THIS AREA WIRE MUST BE FLUSH WITH END OF WIRE BARREL, OR PROTRUDE SLIGHTLY CONTACT MUST BE STRAIGHT FIGURE 7. VISUAL AID 10 of 10 Rev L