Shur-Plug*.156 Dameter Termnals and Receptacle Contacts Applcaton Specfcaton 114-2042 07 NOV 12 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 for dentfcaton only and are not drawn to scale. 1. INTRODUCTION Ths specfcaton covers the requrements for applcaton of Shur-Plug.156 Dameter Termnal and Receptacle Contacts. These termnals and contacts have a wre sze range of 22 through 12 AWG wth an nsulaton dameter range of 2.16 to 5.33 mm [.085 to.210 n.]. Shur-Plug Termnal and Receptacle Contacts are termnated wth automatc machnes. When correspondng wth TE Connectvty Personnel, use the termnology provded n ths specfcaton to facltate your nqures for nformaton. Basc terms and features of ths product are provded n Fgure 1. Shur-Plug Termnal wthout Insulaton Barrel Insulaton Barrel Shur-Plug Termnal wth Insulaton Barrel Insulaton Barrel Shur-Plug Receptacle Contact wth Insulaton Barrel Rght-Angle Shur-Plug Receptacle Contact wthout Insulaton Barrel Fgure 1 2. REFERENCE MATERIAL 2.1. Revson Summary Revsons to ths applcaton specfcaton nclude: Updated document to corporate requrements Changed nformaton n Secton 4, QUALIFICATIONS 2.2. Customer Assstance Reference Product Base Part Number 42142 and Product Code 1176 are representatve of Shur-Plug.156 Dameter Termnal and Receptacle Contacts. Use of these numbers wll dentfy the product lne and help you to obtan product and toolng nformaton. Such nformaton can be obtaned through a local TE Representatve, by vstng our webste at www.te.com, or by callng PRODUCT INFORMATION or the TOOLING ASSISTANCE CENTER at the numbers at the bottom of page 1. 2.3. Drawngs Customer Drawngs for each product part number are avalable from the servce network. The nformaton contaned n Customer Drawngs takes prorty f there s a conflct wth ths specfcaton or wth any techncal documentaton suppled by TE. 2012 Tyco Electroncs Corporaton, a TE Connectvty Ltd. company All Rghts Reserved *Trademark TOOLING ASSISTANCE CENTER 1-800-722-1111 PRODUCT INFORMATION 1-800-522-6752 Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.te.com TE Connectvty, TE connectvty (logo), and TE (logo) are trademarks. Other logos, product and/or company names may be trademarks of ther respectve owners. 1 of 8
2.4. Specfcatons Product Specfcaton 108-2027 provdes test and performance requrements. 2.5. 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 provdes setup, operaton, and mantenance of machnes. Document Number Document Ttle 408-3295 Preparng Reel of Contacts for Applcaton Toolng 408-7424 Checkng Termnal Crmp Heght Gagng De Closure 408-8024 Mnature Quck-Change Applcator (End-Feed Type) 408-8039 HD Mnature Quck-Change Applcators (End-Feed Type) 408-8040 HD Mnature Quck-Change Applcators (Sde-Feed Type) 408-8053 Converson Gude for Mnature Quck-Change Applcators 408-8059 General Preventatve Mantenance for Applcators 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-[ ] and 1213127-[ ] 409-5852 AMPOMATOR* CLS III-G Lead Makng Machne 122500-[ ] 409-5878 AMPOMATOR CLS IV+ Lead-Makng Machnes 356500-[ ] and 1213400-[ ] 3. REQUIREMENTS 3.1. Storage A. Reeled Contacts When usng reeled contacts, store col wound reels horzontally and traverse wound reels vertcally. B. Shelf Lfe The contacts should reman n the shppng contaners untl ready for use to prevent deformaton to the contacts and/or damage to the housngs. The products should be used on a frst n, frst out bass to avod storage contamnaton that could adversely affect sgnal transmssons. C. 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 Where the above envronmental condtons exst, phosphor-bronze contacts are recommended nstead of brass. 3.2. Wre Sze and Preparaton A. Wre Strp Length Recommended wre strp lengths for the termnal wre barrels are lsted n Fgure 2. WIRE BARREL LENGTH WIRE STRIP LENGTH FIXED SPACER BLOCK 2.36-2.74 [.093-.108] 3.18 [.125] 3.18 [.125] 2.77-3.58 [.109-.141] 3.96 [.156] 3.96 [.156] 3.61-4.42 [.142-.174] 4.78 [.188] 4.78 [.188] 4.44-5.26 [.175-.207] 5.56 [.219] 5.56 [.219] 5.28-6.10 [.208-.240] 6.35 [.250] 6.35 [.250] 6.12-6.93 [.241-.273] 7.14 [.281] 7.14 [.281] Fxed spacer blocks used to set wre strp lengths n most commercally avalable wre strppng machnes come n 0.79 mm [.031 n.] lengths. Fgure 2 2 of 8
B. Wre Preparaton The contacts wll accept a wre sze range of 22 to 12 AWG and may be termnated to ether stranded or sold wre. CAUTION 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. DO NOT nck, scrape, or cut the wre conductor durng the strppng operaton.! 3.3. Crmped Contact Requrements Crmp contact to wre accordng to nstructons packaged wth applcable toolng. Fgure 3 shows a typcal contact as t should appear after crmpng; these requrements apply equally to the socket contact. CAUTION When crmpng, do not damage wre nsulaton! A. Crmp Heght 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 area shown n Fgure 3. B. Crmp Length For optmum crmp effectveness, the crmp must be wthn the area shown n Fgure 3. 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. D. Cutoff Tabs The cutoff tab shall be cut to the dmensons shown. E. Burrs The cutoff burr shall not exceed the dmensons shown. F. Flash The wre barrel flash shall not exceed the dmensons shown n Secton X-X. G. Insulaton Barrel Crmp The nsulaton barrel shall grp the nsulaton frmly wthout cuttng nto t. Care must be taken to prevent cuttng, nckng, or scrapng of the nsulaton. H. Wre Locaton After crmpng, the wre conductor and nsulaton must be vsble n the transton area between the wre and nsulaton barrels. I. Conductor Extenson The conductor may extend beyond the wre barrel to the maxmum shown. J. Seam The wre barrel seam must be closed wth no evdence of loose wre strands vsble n the seam. 3 of 8
K. Twst and Roll There shall be no twst, roll, deformaton or other damage to the matng porton of the crmped contact that wll mpar usage of the contact. See Fgure 3. 0.25 [.010] Max Front Cutoff Tab wth 0.13 [.005] Max Burr Effectve Crmp Length Shall be 1.47 [.058] Mnmum and s Defned as That Porton of the, Excludng Bellmouth(s), Fully Formed by the Crmpng Tool Seam Closed wth No Conductor Strands Showng No Damage or Dstorton to Contact 0.76 [.030] Max Conductor Locaton 0.51 [.020] Max Front Bellmouth X Rear Bellmouth 0.51-0.76 [.020-.030] Wre Conductors and Insulaton Must Both be Vsble n ths Area X See Vew A 0.13 [.005] Max Flash Crmp Wdth Secton X-X Crmp Heght Front of Receptacle Contact 15 Max Vew A 0.25 [.010] Max Rear Cutoff Tab 0.13 [.005] Max. Burr Fgure 3 L. Straghtness The force appled durng crmpng may cause some bendng between the crmped wre barrel and the matng porton of the contact. Such deformaton s acceptable wthn the lmts provded n Fgure 5. 1. Up and Down The crmped contact, ncludng cutoff tab and burr, shall not be bent above or below the datum lne more than the amount shown. See Fgure 4. 4 of 8
2. Sde-to-Sde The sde-to-sde bendng of the contact may not exceed the lmts provded n Fgure 4. 0.76 [.030] (Max) Datum Lne 0.51 [.020] (Max) 5 Max : Angles are drawn for clarfcaton only and are not to scale. 5 Max Fgure 4 Perodc nspectons must be made to ensure crmped contact formaton s consstent as shown. The crmped termnal plug contact shall pass through a 25.4 mm [1.000 n.] long metal tube wth an nsde dameter of 5.08 mm [.200 n.]. 3.4. Contact Repar Once a termnal or contact has been damaged, t can not be used. It must be cut from the wre and replaced wth a new one. 4. QUALIFICATIONS Contact TE for agency evaluaton and approval nformaton for specfc product part numbers. 5. TOOLING Ths secton provdes a selecton of tools for varous applcaton requrements. Modfed desgns and addtonal toolng concepts may be avalable to meet other applcaton requrements. For addtonal nformaton, contact one of the servce groups at the bottom of page 1. A lstng of toolng recommendatons coverng the full wre sze range s provded n Fgure 5. TE Tool 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. Applcators 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. 5 of 8
Power Unts 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. 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. The Model K AMP-O-LECTRIC Termnatng Machne PN 565435-5 has been superseded by the Model G Termnatng Machne PN for new applcatons. For exstng applcatons, the Model K s stll recommended because of the large number of nstalled machnes. WIRE SIZE, AWG INSULATION DIAMETER APPLICATOR (DOCUMENT) POWER UNIT (DOCUMENT) 687959-1 (408-8039) 356500-1 (409-5878) 22-18 2.16-3.18 [.085-.125] 687959-2 (408-8039) 2.41-2.92 [.095-.115] 466120-2 (408-8039) 466436-1 (408-8040) 2.54-3.56 [.100-.140] 466436-2 (408-8040) 20-16 466436-3 (408-8040) 354500-[ ] (409-5842) 680434-1 (408-8040) --- 680434-2 (408-8040 680434-3 (408-8040) 354500-[ ] (409-5842) 466082-2 (408-8039) 2.03-3.05 [.080-.120] 466082-3 (408-8039) 354500-[ ] (409-5842) 2.16-5.33 [.085-.210] 466153-2 (408-8039) 565435-5 (409-5128 687423-2 (408-8024) 3.18-4.06 [.125-.160] 687423-3 (408-8024) 354500-[ ] (409-5842) 18-14 687914-1 (408-8039) 3.3-4.45 [.130-.175] 687914-3 (408-8039) 466168-1 (408-8039) --- 466168-2 (408-8039) (2) 14 or 12 --- Fgure 5 (Cont d) 680335-1 (408-8039) 680335-2 (408-8039) 6 of 8
Typcal HDM Quck-Change Applcator (End-Feed Type) Typcal HDM Quck-Change Applcator (Sde-Feed Type) AMPOMATOR CLS III-G Lead-Makng Machne 122500-[ ] AMP-O-LECTRIC Model G Termnatng Machne Power Unt 354500-[ ], 1213127-[ ] AMPOMATOR CLS IV Lead-Makng Machne 356500-[ ], 1213400-[ ] AMP-O-LECTRIC Model K Termnatng Machne Power Unt 565435-5 : These applcators and power unts are shown for reference only. Contact your TE Representatve, or call one of the phone numbers at the bottom of page 1 for avalablty of all equpment. Fgure 5 (End) 7 of 8
6. VISUAL AID The llustraton below shows a typcal applcaton of ths product. 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 or toolng. WIRE MUST BE VISIBLE AT END OF WIRE BARREL AND MUST NOT ENTER CONTACT BODY WIRE BARREL SEAM MUST BE CLOSED WITH NO PROTRUDING WIRE STRANDS CONTACT CUTOFF TAB MUST BE STRAIGHT AND ALIGNED WIRE AND INSULATION MUST BE VISIBLE IN THIS AREA NO EXCESSIVE WIRE BARREL FLASH CONTACT BODY MUST BE STRAIGHT AND ALIGNED WITH CRIMPED BARRELS INSULATION MUST NOT BE CUT, TORN, OR SCRAPED BY INSULATION BARREL WIRE MUST BE VISIBLE AT END OF WIRE BARREL AND MUST NOT ENTER CONTACT BODY FRONT AND REAR BELLMOUTHS MUST BE VISIBLE FIGURE 6. VISUAL AID 8 of 8