MAGNET WIRE
TERMINALS AND
TERMINATION SYSTEMS
MAG-MATE terminals, SIAMEZE
terminals, AMPLIVAR terminals
and splices, and
cluster blocks
APPLIANCES
/// MAGNET WIRE TERMINATION
Magnet Wire Terminals and Termination Systems
Catalog 82221
Table of Contents
Standard MAG-MATE Terminals
Introduction..................................................................................................................................... 1
Interconnection System .................................................................................................................. 2
Termination Sequence ................................................................................................................... 2
Test Results .................................................................................................................................... 3
300 Box Poke-In Terminals ............................................................................................................ 4
500 Box Poke-In Terminals ............................................................................................................ 6
Poke-In Tab Terminals ................................................................................................................... 7
MAG-MATE Terminals with extended leaf-spring .......................................................................... 8
300 Box Poke-In Terminals ............................................................................................................ 9
Tab Receptacle Terminals .............................................................................................................. 9
187 Box F-Crimp Terminals .......................................................................................................... 10
300 Box F-Crimp Terminals .......................................................................................................... 10
Posted PCB Terminals ................................................................................................................. 11
300 Box Posted PCB Terminals ................................................................................................... 11
MAG-MATE Edge Leaf Terminals ................................................................................................ 12
187 Box Posted PCB Terminals ................................................................................................... 13
187 Box Tab Terminals ................................................................................................................ 13
300 Box Tab Terminals ................................................................................................................ 14
Pin Receptacle Terminals ............................................................................................................. 15
Pin I/O Terminals .......................................................................................................................... 16
110 Series FASTON Tab Terminals .............................................................................................. 17
187 Series FASTON Tab Terminals .............................................................................................. 18
187 Series Combination Poke-In FASTON Terminals ................................................................. 18
250 Series FASTON Tab Terminals .............................................................................................. 21
Typical Plastic Cavity .................................................................................................................... 23
Slim Line MAG-MATE Terminals
Introduction................................................................................................................................... 25
187 Series FASTON Tab Terminals .............................................................................................. 26
250 Series FASTON Tab Terminals .............................................................................................. 26
Posted PCB SOLDER Terminal ................................................................................................... 26
Offset Tab Terminals ..................................................................................................................... 27
Mini MAG-MATE Terminals
Introduction................................................................................................................................... 29
Poke-In Terminal .......................................................................................................................... 30
Posted Terminal ........................................................................................................................... 31
FASTON Tab Terminals ................................................................................................................ 31
Crimp Wire Barrel Terminal ..........................................................................................................31
Introduction................................................................................................................................... 32
Lead Lok Terminals Introduction .................................................................................................. 33
SIAMEZE Interconnection System ............................................................................................... 34
Lead Lok Interconnection System ................................................................................................ 35
Wire-to-Wire Terminals ................................................................................................................. 36
Receptacle Terminals (Wire to Blade) ......................................................................................... 37
Pin Terminals ................................................................................................................................ 37
Post Terminals .............................................................................................................................. 38
110 Series (2.8 mm wide) FASTON Tab Terminals ...................................................................... 39
187 Series (4.75 mm wide) FASTON Tab Terminals .................................................................... 40
250 Series (6.3 mm wide) FASTON Tab Terminals ...................................................................... 41
Typical Plastic Cavity Pockets ...................................................................................................... 42
SIAMEZE Terminals
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Table of Contents
AMPLIVAR Splices
Introduction................................................................................................................................... 44
General Application Guidelines .................................................................................................... 46
Suggested Splice Selection Procedure ....................................................................................... 46
Technical Documents ................................................................................................................... 46
9 Serrations —Pigtail Type ........................................................................................................... 47
7 Serrations —Pigtail Type ........................................................................................................... 47
5 Serrations —Thru Type ............................................................................................................. 48
5 Serrations —Pigtail Type ........................................................................................................... 49
Miniature Splice —Pigtail Type .................................................................................................... 49
AMPLIVAR Terminals
Introduction................................................................................................................................... 50
Ring Tongue Terminals ................................................................................................................ 51
Stud Retaining Terminals ............................................................................................................. 52
Alternator Eyelet Terminal ............................................................................................................ 52
125 Series Blade .......................................................................................................................... 53
187 Series FASTON Tabs .......................................................................................................... 53
250 Series FASTON Tabs .......................................................................................................... 53
250 Series FASTON Receptacles .............................................................................................. 64
187 Series FASTON Flag Receptacles ....................................................................................... 55
250 Series FASTON Flag Receptacles ........................................................................................ 55
Pin Receptacles............................................................................................................................ 55
250 Series Stator Receptacles —7 Serrations ............................................................................ 56
Stator Terminal —Receptacle .250 x .032 [6.35 x 0.81] .............................................................. 56
Cluster Blocks
Introduction................................................................................................................................... 57
Cluster Blocks 2.29 [.090] Pin Size (Lead Wire and Direct Connect)........................................... 58
Cluster Blocks 3.18 [.125] Pin Size (Lead Wire and Direct Connect)........................................... 60
MTM Crimpband Splices
- NOT RECOMMENDED FOR NEW DESIGNS
Introduction................................................................................................................................... 62
MTM Crimpband Interconnection System .................................................................................... 63
11 Serrations ................................................................................................................................ 64
9 Serrations .................................................................................................................................. 64
7 Serrations .................................................................................................................................. 65
RTM Crimpband Splices
- NOT RECOMMENDED FOR NEW DESIGNS
Introduction................................................................................................................................... 66
RTM Crimpband Interconnection System..................................................................................... 67
20 Ridges ..................................................................................................................................... 68
14 Ridges ..................................................................................................................................... 68
10 Ridges ..................................................................................................................................... 68
9 Ridges ....................................................................................................................................... 69
8 Ridges ....................................................................................................................................... 69
7 Ridges ....................................................................................................................................... 69
6 Ridges ....................................................................................................................................... 72
3 Ridges ....................................................................................................................................... 73
Power Splice
Introduction................................................................................................................................... 74
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Table of Contents
Introduction................................................................................................................................... 76
AMPLIVAR Product Terminator (APT) Machine............................................................................ 77
Power Splice Machine .................................................................................................................. 77
AMPLIVAR Terminator for Parallel and End Connections ............................................................ 78
AMP-O-LECTRIC Model G Terminator with Thru-Splice Applicator ............................................. 78
Crimpband Application Tooling
- NO LONGER AVAILABLE..........................................................
79
MPT-5 MAG-MATE Product Terminator ....................................................................................... 80
MAG-MATE Terminal Cavity and Fixture Design .......................................................................... 80
MPT-5 S/L Machine for SIAMEZE and Lead Lok Terminals ......................................................... 81
EMT -- Entry Level Magnet Wire Terminator ................................................................................ 81
Manual Hand Tool......................................................................................................................... 82
Manual Arbor Press ...................................................................................................................... 82
Hand Insertion Tools ..................................................................................................................... 82
Full Line of Crimp Tooling ............................................................................................................. 82
MAG-MATE Inserter MK I with Pneumatic Control ....................................................................... 83
MAG-MATE Inserter MK I with Electro Pneumatic Control........................................................... 83
MAG-MATE and SIAMEZE Inserter MARK II with PLC................................................................ 83
MAG-MATE and SIAMEZE Inserter MARK II with PLC and Insertion Force Control ................... 84
Pneumatic Insertion Tool for MAG-MATE Terminals.................................................................... 84
Customer Specific Machines ........................................................................................................ 85
Custom Built IDC Terminal Insertion Head ................................................................................... 85
Application Tooling
Additional Data
Technical Information ................................................................................................................... 86
Terminal Stud Hole Size ............................................................................................................... 90
Part Number Index ....................................................................................................................... 91
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals
Product Facts
Terminates film-insulated
copper and aluminum
magnet wire
E liminates need for
pre-stripping conductors
E liminates need to post
insulate termination
E xcess magnet wire is
automatically trimmed
during the termination
process
S imultaneously terminates
two magnet wires of the
same size in one terminal
( for splicing or bi-filing )
Various lead wire
attachment options available
Available in strip form for
semi-automatic or fully
automatic insertions
Available in loose piece form
for hand tool insertions
Varnish resist tab terminals
are available for special
applications
H igh speed, fully automated
integrated systems provide
uniform terminations
reliably at the lowest
possible applied cost
C lean metal-to-metal
interface produces stable,
gas-tight electrical
terminations free of oxides
and other contaminants
R ecognized under the
C omponent R ecognition
P rogram of U nderwriters
Laboratories Inc., F ile N o.
E 13288,Vol. 1, S ec 29
R
Standard MAG-MATE
Terminals
TE offers a full selection of
Standard MAG-MATE
Insulation Displacement
Crimp (IDC) terminals for
magnet wire terminations.
MAG-MATE terminals are
available in poke-in,
poke-in tab, splice, crimp
wire barrel, solder post,
quick connect tab, pin and
receptacle styles.
Standard MAG-MATE
terminates magnet wire
ranging from 34-12 AWG
[0.16 -2.05 mm ].
Each IDC slot size
terminates a range of up to
four consecutive magnet
wire sizes.
Two magnet wires with the
same diameter can be
terminated in one terminal
except as noted.
According to TE
specifications MAG-MATE
cavities are either
integrated into coil bodies
or specially designed cavity
housings. The magnet
wires are precisely
positioned in the plastic
cavity slots.
The MAG-MATE Inserter
cuts the terminals from the
strip and places the
terminals over the magnet
wire into the plastic
cavities.
During this operation, small
stripping shoulders in the
IDC slot remove the film
insulation from the magnet
wire.
Wiping action between
the wire and terminal
removes oxides or other
contaminants present on
both the conductor and the
terminal slot side walls,
producing a clean, stable,
gas-tight electrical
termination.
Residual spring energy in
the terminal causes the
side walls of each IDC slot
to function as opposing
cantilever beams.
This constant pressure
results in an intimate
metal-to-metal interface,
providing a reliable,
long-term connection.
The MAG-MATE
Inserter may be used as a
semi-automatic bench
machine or integr ated into
production lines for
fully-automatic applications.
Applications
Motor windings and
connections
Coil connections
Transformer windings
and connections
Bobbin connections
Lighting ballasts
Power supplies
*Contact TE Engineering for guidance regarding aluminum
www.te.com/appliances
1
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