Application Specification
STRATO-THERM* Terminals,
Splices, and Spare Wire Caps
114-2162
19 NOV 08
Rev C
NOTE
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and
inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2 .
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Figures and illustrations are for identification only and are not drawn to scale.
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1. INTRODUCTION
This specification covers the requirements for application of STRATO–THERM terminals, splices, and spare
wire caps for high temperature applications. There are two types of these terminals, splices, and spare wire
caps. One type is insulated, which consist of PIDG* (pre–insulated diamond grip) ring tongue terminals,
splices, and spare wire caps insulated with polytetrafluoroethylene (PTFE), post–insulated, or pre–insulated ;
and the other type is uninsulated, which consist of DIAMOND GRIP* (insulation support) ring tongue terminals,
spade tongue terminals, and splices with SOLISTRAND* (non–insulation support). The uninsulated are
available in heat resistant and high temperature. The terminals, splices, and spare wire caps accept solid or
stranded wire for single applications.
The pre–insulated terminals, splices, and spare wire caps are designed for reliable performance at maximum
temperatures of 288 C [550 F] and at 260 C [500 F] for silver–plated post–insulated terminals and splices.
The uninsulated heat resistant terminals and splices operate at maximum temperature of 343 C [650 F], and
at 649 C [1200 F] for high temperature terminals and splices.
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The terminals and splices are color 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 or dimples inside the wire barrel provide maximum contact and tensile strength after crimping. The
terminals are suitable for mounting and accept stud sizes M2.5 [4] through M8 [.375] (inside diameter range of
2.95 through 9.80 [.116 through .386]). The terminals, splices, and spare wire caps are available in loose–piece
for terminating with manual and pneumatically–powered hand–held tools, and in tape–mounted form for
terminating with semi–automatic hand–held tools and electrically–powered machines.
When corresponding with personnel, use the terminology provided in this specification to facilitate your
inquiries for information. Basic terms and features of this product are provided in Figure 1.
PIDG Insulated Terminals
Ring Tongue
Terminal
Insulating Restricting (IR)
Ring Tongue Terminal
Ring Tongue
Terminal
Post-Insulated Terminals and Splices
Butt Splice
Butt Splice
Pre-Insulated Splices and Spare Wire Caps
Window Butt Splice
Spare Wire Cap
Figure 1 (Cont’d)
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2008 Tyco Electronics Corporation, Harrisburg, PA
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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LOC B
*Trademark. Other products, logos, and company names used are the property of their respective owners.
STRATO-THERM Terminals, Splices, and Spare Wire Caps
114-2162
DIAMOND GRIP Heat Resistant
Uninsulated Terminals and Splices
Ring Tongue Terminal
Strap Butt Splice
DIAMOND GRIP High Temperature
Uninsulated Terminals and Splices
Ring Tongue Terminal
Strap Butt Splice
SOLISTRAND Heat Resistant
Uninsulated Terminals and Splices
Ring Tongue Terminal
Parallel Splice
Butt Splice
Strap Butt Splice
SOLISTRAND High Temperature
Uninsulated Terminals and Splices
Ring Tongue Terminal
Spade Tongue Terminal
Parallel Splice
Butt Splice
Strap Butt Splice
Figure 1 (End)
2. REFERENCE MATERIAL
2.1. Revision Summary
Revisions to this application specification include:
S
Updated application specification to corporate requirements
S
Added note to Machine 565435–5 in Section 5 and removed reference to 409–5128 from Paragraph 2.4
S
Removed Tool 59083, Machines 1338600–[ ], and Crimping Heads 356744–1 and 356744–2
2.2. Customer Assistance
Reference Product Base Part Number 50836 and Product Code 3027 are representative of STRATO–THERM
terminals, splices, and spare wire caps. Use of these numbers will identify the product line and expedite your
inquiries through a service network established to help you obtain product and tooling information. Such
information can be obtained through a local Representative or, after purchase, by calling PRODUCT
INFORMATION at the number at the bottom of page 1.
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. If there is a conflict
between the information contained in the Customer Drawings and this specification or with any other technical
documentation supplied, call PRODUCT INFORMATION at the number at the bottom of page 1.
2.4. Instructional Material
Instruction Sheets (408–series) provide assembly instructions and Customer Manuals (409–series) provide
machine setup and operation procedures. Documents available which pertain to this product are:
A. Product
408–7424
408–9816
Checking Terminal Crimp Height or Gaging Die Closure
Handling of Reeled Products
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B. Tooling
408–1254
408–1259
408–1310
408–1311
408–1532
408–1535
408–1542
408–1610
408–1632
408–1697
408–1745
408–1826
408–1836
408–1927
408–1939
408–2095
408–2395
408–2423
408–2452
408–2454
408–2457
408–2458
408–2498
408–2648
408–4072
408–4105
408–4110
408–4190
408–4303
408–4321
408–4450
408–6758
408–6803
408–8044
408–8082
408–9684
408–9786
409–1950
409–1993
409–2426
409–2500
409–5842
409–5852
409–5860
409–5862
409–5878
Crimping Tool 69355
STRATO–THERM Hand Crimping Tools 59294 and 59461
Pneumatic Tool 69015
Pneumatic Crimping Heads 48172, 48173, 48174, 48183, and 49956
Hand Crimping Tools 45730 and 46468
STRATO–THERM Hand Crimping Tools 46673, 46673–1, and 46988
Hand Crimping Tool 46447
“T”–Head* Crimping Tools 69692–1 and 69693–1
Crimping Dies 69731, 69732, 69733, 69734, and 69735
SOLISTRAND Crimping Dies 45433, 45436, 46133, 46134, 46135, 46136, 46137, 46138,
46145, 46146, 69216, 69217, and 69218
DYNA–CRIMP* Head 69069
STRATO–THERM Post–Insulated Terminal and Splice Die Assembly 69211–1
Hand Crimping Tool 69272–1 for Pre–Insulated Spare Wire Caps
ROTA–CRIMP* Hand Crimping Tool 600850
Crimping Dies 69327, 69328, and 69329 for Pre–Insulated Splices
Hand Crimping Tool 69710–1
Terminal and Splice Crimping Jaws 68135
Crimping Die Assembly 69937
Hydraulic Crimping Head 69065
Hydraulic Crimping Head 69067
DYNA–CRIMP Crimping Head 69097
DYNA–CRIMP Crimping Head 69099
Crimping Head Cross–Reference for Pneumatic Tools
AMP–TAPEMATIC* Crimping Dies 69930, 69931, 69932, 69954, 69955, and 69956
626 Pneumatic Crimping Heads 1338757–1 and 1338758–1
Straight Action Crimper 217200–1
626 Pneumatic Crimping Head 217206–1
C–Head Pneumatic Adapter 318161–1
Pneumatic CERTI–CRIMP* Tool Holder Assembly (Large) 356302–1
Pneumatic CERTI–CRIMP Tool Holder 356304–1
626 Pneumatic Crimping Head 904870–1
Hydraulic Hand Crimping Tool 59975–1
Hydraulic Hand Crimping Tool 59973–1
Miniature Quick–Change Applicator (Side–Feed with Mechanical Feed System) 687658–1
Miniature Quick–Change Applicators (Side–Feed with Air Feed System) 567200–2
and 567200–3
Inspection and Servicing of Hydraulic Crimping Heads 69065 and 69067
Crimping Dies 48126, 48127, 48128, 48129, 48130, 48131, 48132, and 48355 for
SOLISTRAND Terminals and Splices
Hydraulic Power Units 69120–1 and 69120–2
AMP–TAPETRONIC* Machine 69875
Pneumatic Tool 68068
Pneumatic Tool 68068–3
AMP–O–LECTRIC Model “G” Terminating Machines 354500–[ ]
AMPOMATOR* CLS III–G Lead–Making Machines 122500–[ ]
Hydraulic Hand Pump 314979–1
626 Pneumatic Tooling Assemblies 189721–[ ] and 189722–[ ]
AMPOMATOR CLS IV+ Lead–Making Machines 356500–[ ]
Rev
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114-2162
3. REQUIREMENTS
3.1. Special Characteristics
PIDG IR terminals prevent insulation of thin–wall insulated wire from entering the wire barrel during crimping.
3.2. Material
A. Insulated
These terminals, splices, and spare wire caps consist of precision formed metal wire barrel and support
sleeve (except spare wire caps) insulated with PTFE.
PIDG Terminals and Pre-Insulated Terminals and Splices
The body is made of copper and plated with nickel or gold over nickel. The metallic sleeve is made of
copper and plated with nickel.
Post-Insulated Terminals and Splices
The body is made of copper and plated with gold over nickel, silver, or nickel. The ring is made of
aluminum or copper and plated with nickel. The bushing is made of PTFE insulation.
B. Uninsulated
These terminals and splices consist of precision formed metal wire barrel with or without a support sleeve.
SOLISTRAND Terminals and Splices
The heat resistant body is made of copper and plated with nickel. The high temperature body is made
of nickel.
DIAMOND GRIP Terminals and Splices
The heat resistant body is made of copper and plated with nickel. The high temperature body is made
of nickel, alumel, or chromel. The metallic sleeve is made of nickel silver.
3.3. Storage
A. Shelf Life
The product should remain in the shipping containers until ready for use to prevent deformation to the
terminals, splices, or spare wire caps. The product should be used on a first in, first out basis to avoid
storage contamination that could adversely affect signal transmissions.
B. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the product
insulation material.
C. Reeled Product
When using tape–mounted reeled product, care must be taken to prevent stretching, sagging, or other
distortion that would prevent smooth feeding of the tape through automatic machine feed mechanisms.
Store coil wound reels horizontally and traverse wound reels vertically.
3.4. Wire Selection and Preparation
The terminals, splices, and spare wire caps accept copper wire sizes 26 through 1/0 AWG (238 through
119,500 circular mil area) with an insulation diameter range of 1.17 through 7.87 [.046 through .310].
PIDG terminals and splices must be used with stranded wire; and PIDG insulation restricting terminals, and
post–insulated and uninsulated terminals and splices with solid or stranded wire. The splices can
accommodate different wire combinations. Proper strip length is necessary to properly insert the wire into the
terminal or splice. The wire must be stripped to the dimensions provided in the instructional material supplied
with the product or application tooling.
CAUTION
Reasonable care must be taken not to nick, scrape, or cut any strands during the stripping operation.
!
The spare wire caps must be used with
unstripped
PTFE insulated stranded wire with insulation diameter
range of 0.91 through 3.50 [.036 through .138].
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114-2162
3.5. Wire Placement
The solid wire conductor or stranded wire conductors must be inside the terminal, splice, or spare wire cap wire
barrel. No strands can be folded back over the wire insulation. The conductor end(s) must be flush with, or
extend slightly beyond, the end of the wire barrel; or, for splices with a wire stop in the center of the splice, the
conductor end(s) must butt against the wire stop. The wire insulation must be inside the insulation of the
product, but must not enter the wire barrel, to provide strain relief for the wire.
3.6. Crimp Requirements
The terminal, splice, or spare wire cap must be crimped to the wire according to instructions packaged with
applicable tooling.
CAUTION
Wire insulation shall NOT be cut or broken during the crimping operation. Reasonable care should be taken to provide
undamaged wire terminations.
!
A. Wire Barrel Crimp
The crimp applied to the wire barrel portion of the terminal, splice, or spare wire cap is the most
compressed area and is most critical in ensuring optimum electrical and mechanical performance of the
crimped product. The crimped area must be symmetrical on both sides of the wire barrel. The crimp may
be off center on the wire barrel but not off the end of the wire barrel. See Figure 2.
NOTE
The resilience of the product insulation prevents accurate direct measurement of crimp height. Tooling used to crimp
product must be dimensionally correct to ensure quality crimp configurations.
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B. Crimp Dot and Hashmark Code
Some tools with multiple crimping chambers will emboss a crimp dot code or hashmark code onto the
product insulation when crimped. The dot or hashmark code must be fully formed on the insulation to
indicate that the correct product and tooling combination was used. The crimp dot or hashmark code must
correspond with the wire size marking on the tooling.
NOTE
The hashmark code should appear on the bottom (side opposite the crimp indents) for high temperature and
heat-resistant terminals and splices.
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C. Wire Conductor and Insulation Location
The wire insulation must be inside, and in firm contact with, the insulation barrel of the product. The wire
insulation must not enter the wire barrel. The conductor end(s) must be flush with, or extend slightly
beyond, the end of the wire barrel; or, for splices with a wire stop in the center of the splice, the conductor
end(s) may butt against the wire stop. See Figure 2.
D. Product Insulation
The terminal, splice, or spare wire cap insulation must not be deformed, cut, or show uneven stress
marks. Some insulation flash or extruded insulation is normal. Holes and thin spots in the insulation
provides evidence of either improper crimping or defective tooling.
E. Bellmouths
The rear bellmouth length must be within 0.51 to 1.27 [.020 to .050], and the front bellmouth must not
exceed 0.51 [.020]. Refer to Figure 2.
F. Sleeve, Ring, and Bushing Position (Post-Insulated Terminal and Splice Only)
After crimping post–insulated terminals or splices, rings, bushings, and a sleeve must be assembled onto
the terminal or splice. The sleeve must be centered over the crimped terminal wire barrel or crimped
splice. The sleeve must extend from the ring and the bushing must extend from the sleeve to the
dimensions shown in Figure 2.
Rev
C
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