Application Specification
Miniature AMP-IN* Contacts
114-1016
01 JUL 08
Rev W
NOTE
i
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 .
Figures and illustrations are for identification only and are not drawn to scale.
_
1. INTRODUCTION
This specification covers the requirements for application of Miniature AMP–IN Contacts, and Miniature
AMP–IN 2000 Contacts. These requirements are applicable to automatic machine crimping tools. The contacts
are designed to be inserted into printed circuit (pc) board holes. Figure 1 shows typical product features.
NOTE
The Miniature AMP-IN Contact is designed not as an electrical contact, but as a mechanical holding device to
enhance soldering of hookup wires to pc boards.
i
When corresponding with Tyco Electronics Personnel, use the terminology provided on this specification to
help facilitate your inquiry for information. Basic terms and features of components are provided in Figure 1.
Wire Strands and Insulation
Both Visible
Stabilizer Barrel
Wire Barrel
Stabilizer Barrel
Insulation Barrel
Rear Bellmouth
0.25 [.010]
Flush to
0.38 [.015] Max.
Wire Barrel Flash
0.08 [.003]
Locking Lance
3.56 [.140] Min
Wire Barrel
Locking Lance
0.64 [.025] Min
Cutoff Tab 0.38 [.015]
Max. and Burr 0.08
[.003]
Wire Barrel
Insulation Stop/Positive
Board Stop
Wire Barrel
Seam
Locking Lance
Insulation Barrel
Miniature AMP-IN 2000 Contact
Figure 1
2. REFERENCE MATERIAL
2.1. Revision Summary
This paragraph is reserved for a revision summary covering the most recent additions and changes made to
this specification which include the following:
S
Updated document to corporate requirements
S
Changed strip length dimension in Figure 2
E
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.
Miniature AMP-IN Contacts
2.2. Customer Assistance
114-1016
Reference Part Number 640401 and Product Code 1326 are representative numbers that identify Miniature
AMP–IN Contacts. 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 Tyco Electronics Representative or, after purchase, by calling the Tooling Assistance
Center or the Product Information number at the bottom of this page.
2.3. Drawings
Customer Drawings for specific products are available from the responsible Tyco Electronics Engineering
Department via the service network. The information contained in the Customer Drawings takes priority if there
is a conflict with this specification or with any other technical documentation supplied by Tyco Electronics.
2.4. Specifications
Product Specification 108–1081 provides applicable performance requirements for Miniature AMP–IN
Contacts.
2.5. Instruction Material
The following Instruction Sheets (408–Series) and Customer Manuals (409–Series) are supporting documents
available to assist with product application or tool setup operation.
408–8040
408–9640
409–5128
409–5842
409–5866
2.6. Manuals
Heavy Duty Miniature Quick–Change Applicators with Mechanical Feed System
Crimp Quality Monitor Applicators for Side–Feed and End–Feed Application
AMP–O–LECTRIC* Model “K” Terminating Machine
AMP–O–LECTRIC Model “G” Terminating Machine
AMPOMATOR* CLS IV Machine
Manual 402–40 is available from the service network. This manual provides information on various flux types
and characteristics along with the commercial designation and flux removal procedures. A checklist is included
in the manual as a guide for information on soldering problems.
3. REQUIREMENTS
3.1. Wire Preparation
A. Wire Size
The contacts will accept wires from 10 to 26 AWG.
B. Wire Insulation Diameter
Wire insulation diameter shall have minimum and maximum dimensions according to the wire sizes
indicated in Figure 2.
C. Wire Strip Length
Wire strip length shall be as indicated in Figure 2.
D. Workmanship
Care shall be taken during the stripping operation to ensure the conductor is not nicked, scraped, or cut.
3.2. Crimped Contact
A. Crimping Requirements
Contacts shall be crimped in accordance with the specifications listed in Figure 2.
CAUTION
Care shall be taken to ensure that the wire insulation is not cut or broken during the crimping operation and ensure
that the insulation is not crimped into the stabilizer or wire barrel.
!
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Miniature AMP-IN Contacts
114-1016
MINIATURE
AMP-IN
CONTACT
NUMBERS
SIZE
(AWG)
WIRE
INSUL
DIA
STRIP
WIRE BARREL
CRIMP
CRIMP
WIDTH
STABILIZER BARREL
CRIMP
HEIGHT
CRIMP
WIDTH
INSUL
BARREL
CRIMP
WIDTH
640311
22
20
18
26
24
22
18
16
14
26
24
22
26
24
22
22
20
18
22
20
18
12
10
12
1.52 [.060]
to
2.79 [.110]
1.02 [.040]
to
2.54 [.100]
2.29 [.090]
to
3.81 [.150]
1.02 [.040]
to
1.78 [.070]
1.52 [.060]
to
2.54 [.100]
1.52 [.060]
to
2.79 [.110]
1.52 [.060]
to
2.79 [.110]
5.08 [.200]
Max.
2.29 [.090]
to
3.81 [.150]
WIRE
LENGTH
0.38 [.015]
HEIGHT
0.05 [.002]
4.83 [.190]
0.76 [.030]
0.76 [.030]
0.94 [.037]
0.74 [.029]
0.74 [.029]
0.89 [.035]
1.09 [.043]
1.09 [.043]
1.40 [.055]
0.81 [.032]
0.86 [.034]
0.96 [.038]
0.81 [.032]
0.86 [.034]
0.96 [.038]
1.07 [.042]
0.81 [.032]
0.91 [.036]
1.07 [.042]
2.41 [.095]
2.74 [.108]
2.16 [.085]
1.57 [.062]
640401
4.83 [.190]
1.07 [.042]
0.05
.002]
1.02
0.05
[.040
.002]
1.40
[.055
1.57 [.062]
2.79 [.110]
1.07 [.042]
2.79 [.110]
770060
5.21 [.205]
2.79 [.110]
2.79 +0.13/-0.00 2.79 +0.13/-0.00
[.110 +.005/-.000] [.110 +.005/-.000]
--
--
3.94 [.155]
640663
4.51 [.178]
1.07 [.042]
1.78 [.070]
640108
4.51 [.178]
1.07 [.042]
--
--
2.79 [.110]
350566
4.51 [.178]
1.57 [.062]
--
--
2.79 [.110]
770565
794037
794013
MINIATURE
AMP-IN
AMP IN
2000
CONTACT
NUMBERS
3.81 [.150]
5.21 [.205]
5.21 [.205]
1.57 [.062]
2.79 [.110]
3.56 [.140]
2.79 [.110]
2.79
[.110
--
--
2.79 [.110]
3.56 [.140]
2.79 [.110]
2.79 [.110]
5.33 [.210]
3.94 [.155]
0.05
.002]
2.79
0.05
[.110
.002]
CRIMP
HEIGHT
WIRE BARREL
STRIP
CRIMP
STABILIZER BARREL
INSUL
BARREL
SIZE
(AWG)
INSUL
DIA
LENGTH
0.38 [.015]
HEIGHT
0.076 [.003]
CRIMP
WIDTH
CRIMP
WIDTH
CRIMP
WIDTH
794121
22
20
18
26
24
22
1.27 [.050]
to
2.79 [.110]
1.27 [.050]
to
2.79 [.110]
5.08 [.200]
0.76 [.030]
0.86 [.034]
0.91 [.036]
0.71 [.028]
0.79 [.031]
0.86 [.034]
1.57 [.062]
--
--
3.30 [.130]
794122
5.08 [.200]
1.07 [.042]
--
--
3.30 [.130]
Figure 2
B. Wire Barrel Crimp Configuration
The following additional requirements shall apply to the completed wire barrel crimp. See Figure 1.
1. Wire Barrel Seam
Wire barrel seam shall be completely closed with no wire strands loose or visible in the seam.
2. Rear Bellmouth
Rear bellmouth length shall be a maximum of 0.25 mm [.010 in.].
3. Wire Barrel Flash
Wire barrel flash shall be a maximum of 0.08 mm [.003 in.].
C. Stabilizer Barrel
A stabilizer barrel seam opening is acceptable with 10 and 12 AWG wire.
Rev
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Tyco Electronics Corporation
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114-1016
D. Insulation Stop/Positive Board Stop
The Insulation Stop/Positive Board Stop is not terminated, it will remain in the open U–shape.
E. Crimp Location
Conductor end shall be flush with the front end of the wire barrel or extend past the end of the wire barrel
a maximum of 0.38 mm [.015 in.].
Insulation should not be crimped into the stabilizer barrel.
Miniature AMP–IN Contacts, insulation and conductor should be visible between the insulation barrel and
the wire or stabilizer barrel. Mini AMP–IN 2000 Contacts, the insulation and conductor should be visible
between the insulation barrel and insulation stop.
F. Carrier Cutoff Tab And Burr
The carrier strip cutoff tab shall have a maximum length of 0.38 mm [.015 in.], and the burr on the cutoff
tab shall be a maximum of 0.08 mm [.003 in.].
G. Locking Lance
Locking lance(s) on bottom or sides of contacts shall be within limits shown in Figure 1.
3.3. Printed Circuit (PC) Boards
Depending on the contact being used, the pc board hole sizes should be within the tolerances specified in
Figure 3.
CONTACT PART NUMBER
WIRE SIZE (AWG)
PRINTED CIRCUIT BOARD HOLE SIZE
640311
640401
770060
640663
640108
350566
770565
794037
794013
794121
794122
22-18
26-22
18-14
26-22
26-22
22-18
22-18
12
10
12
22-20
18
26-22
0.10 [.073
.004]
1.40
0.10 [.055
.004]
3.18
0.08 [.125
.003]
1.40
0.10 [.055
.004]
1.40
0.10 [.055
.004]
1.85
0.10 [.073
.004]
1.83
0.08 [.072
.003]
3.18
0.08 [.125
.003]
3.68
0.08 [.145
.003]
3.18
0.08 [.125
.003]
1.83
0.08 [.072
.003]
1.96
0.08 [.077
.003]
1.40
0.10 [.055
.004]
1.85
Figure 3
3.4. Soldering
NOTE
Manual 402-40 provides guidelines for establishing soldering practices.
i
Miniature AMP–IN Contacts can be soldered using wave, vapor phase, or infrared reflow processes, provided
the temperatures and exposure time are within the ranges specified in Figure 4.
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Miniature AMP-IN Contacts
114-1016
SOLDERING
PROCESS
CELSIUS
260
TEMPERATURE
FAHRENHEIT
500
TIME
(At Max Temp)
WAVE SOLDERING
VAPOR PHASE SOLDERING
INFRARED REFLOW SOLDERING
D
D
5 Seconds
5 Minutes
5 Minutes
215
230
419
446
D
Wave Temperature
Figure 4
A. Flux Selection
The wire barrels must be fluxed prior to soldering with a rosin base flux. Selection of the flux will depend
on the type of printed circuit board and other components mounted on the board. Additionally, the flux
must be compatible with the wave solder line, manufacturing, and safety requirements. Some fluxes that
are compatible with these connectors are provided in Figure 5. Call the Product Information number at the
bottom of page 1 for consideration of other types of flux.
COMMERCIAL DESIGNATION
FLUX TYPE
ACTIVITY
RESIDUE
KESTER
Type RMA (Mildly Activated)
Center (Activated)
Mild
Medium
Noncorrosive
May be Corrosive
Y
ALPHA
611
U
185/197
1544, 1545, 1547
711, 809, 811
Y
Trademark of MacDonald & Co.
U
Designation of Alpha Metals Inc.
Figure 5
B. Cleaning
After soldering, removal of fluxes and activators is necessary. Consult the supplier of the solder and flux
for recommended cleaners. Common organic and aqueous cleaners that these connectors can be
exposed to for a period of 5 minutes at 40.5
_
C [105
_
F] with no harmful effect are provided in Figure 6.
Cleaners must be free of dissolved flux and other contaminants. We recommend cleaning with the pc
board on its edge. If using an aqueous cleaner, we recommend standard equipment such as a soak–tank
or an automatic in–line machine.
DANGER
Consideration must be given to toxicity and other safety and health requirements as recommended in the Material
Safety Data Sheet (MSDS) supplied by the solvent manufacturer.
CLEANER
NAME
TYPE
Aqueous
Solvent
Solvent
Solvent
Aqueous
Aqueous
Aqueous
Aqueous
Solvent
TIME
(Minutes)
(Mi
)
1
5
1
5
5
5
5
5
5
TEMPERATURES (Maximum)
CELSIUS
132
100
FAHRENHEIT
270
212
H
Bioact EC-7
z
Butyl Carbitol
D
Alpha 2110
Isopropyl Alcohol
Room Ambient
100
100
100
100
100
100
212
212
212
212
212
212
s
Kester 5779
s
Kester 5778
D
Loncoterge 530
D
Loncoterge 520
Terpene Solvent
H
Product of Fry’s Metals, Inc.
z
Product of Petroferm, Inc.
D
Product of Union Carbide Corp.
s
Product of Litton Systems, Inc.
Figure 6
Rev W
Tyco Electronics Corporation
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