324557 datasheet, PDF - EEWORLD Datasheet

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Application Specification

Pre- Insulated Diamond Grip (PIDG*)

Terminals, Splices, and End Caps

NOTE

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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 PIDG terminals, splices, and end caps in various

operating environments. Each consists of a precision--formed metal wire barrel and a copper sleeve encased in

insulating material made of nylon, polyvinyl chloride (PVC) or polyvinyl fluoride (PVF

2

). The insulation is color

coded (solid primary color or a primary color with a color stripe) to correspond with a specific wire size or wire

size range. The terminals, splices, and end caps accept a combination of solid and stranded wire. The wire

barrel contains serrations that provide maximum contact and tensile strength after crimping the terminal, splice,

or end cap onto the wire. The terminals are available with a variety of tongue lengths and configurations; and

the terminals, splices, and end caps are available with various wire barrel lengths and diameters to

accommodate different wire sizes, wire types, and combination of wire sizes.

The terminals, splices, and end caps are available in loose piece form to be terminated with manual and

pneumatically--powered hand held tools and tape mounted to be terminated with bench mount semi--automatic

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.

Terminal

In--Line Ring Tongue

Wire Barrel

Tongue

Copper

Sleeve

Multiple Stud Hole

Spring Spade Tongue

Insulation

Right Angle Ring Tongue

Offset Ring Tongue

Flanged Spade Tongue

Hook Tongue

In--Line Rectangular Tongue

Right--Angle Rectangular Tongue

Knife Connect/Disconnect

Figure 1 (Cont’d)

E2011

Tyco Electronics Corporation, a TE Connectivity Ltd. Company

*Trademark

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.te.com

1

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LOC B

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.

114- 2157

Butt Splice

Opaque Insulation

Transparent Insulation Window

Wire Barrel

End Cap

Insulation

Window

Figure 1 (End)

Copper

Sleeve

2. REFERENCE MATERIAL

2.1. Revision Summary

Revisions to this application specification include:

S

Changed company logo

2.2. Customer Assistance

Reference Product Base Part Number 51864 and Product Code 3022 are representative of PIDG terminals,

splices, and end 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. Specifications

Product Specification 108--11023 provides test and performance results for insulated terminals and splices for

Class 1 E Nuclear applications.

2.5. Instructional Material

Instruction Sheets (408--series) provide product assembly instructions or tooling setup and operation

procedures and Customer Manuals (409--series) provide machine setup and operation procedures. Documents

available which pertain to this product are:

408--1261

408--1559

408--1610

408--1632

408--2095

408--2423

408--2498

408--2822

408--2823

408--3295

408--4099

408--4105

408--7424

408--8044

408--8053

Hand Crimping Tools 59239--4 and 59287--2

Hand Crimping Tools 46121, 47386, and 47387

“T”--Head Crimping Tools 59250 and 59275

Terminal and Splice Crimping Dies 69344, 47806--2, 47807--1, 47808--5, and 47808--6

Hand Crimping Tool 69710--1

Crimping Die Assemblies for Tape--Mounted PIDG Terminals and Splices

Crimping Head Cross Reference for Pneumatic Tools

Crimping Die Assemblies 59826--1, 59827--1, and 59828--1

TETRA--CRIMP* Hand Crimping Tool 59824--1

Preparing (Reel--Wrap) Reel of Contacts for Applicator Tooling

Pneumatic TETRA--CRIMP Adapter 679305--1

Straight Action Crimper 217200--[ ]

Checking Terminal Crimp Height or Gaging Die Closure

Miniature Quick--Change Applicator for Tape--Mounted Closed Barrel Terminals

Miniature Quick--Change Applicators

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408--8082

408--9252

408--9586

408--9640

408--9816

409--1993

409--5842

409--5862

409--5878

Miniature Quick--Change Applicators (Side--Feed Type) with Air Feed

PRO--CRIMPER* III Hand Crimping Tool 58433--3

Pneumatic Crimping Heads 314269--1, 314270--3, and 314537--1

Crimp Quality Monitor Applicators for Side--Feed and End--Feed Applications

Handling of Reeled Products

AMP--TAPETRONIC* Machine 69875

AMP--O--LECTRIC* Model “G” Terminating Machine 354500--1

626 Pneumatic Tooling Assemblies 189721--[ ]

AMPOMATOR* CLS IV+ Lead--Making Machines 356500--[ ]

2.6. Standards and Publications

Military specifications provide industry test and performance requirements. Documents available which pertain

to this product are:

MIL--T 7928/1, “Terminal, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Crimp Style,

Copper, Insulated, Ring Tongue, for Thin Wall Wire, Type II, Class I for 105_C Total Conductor

Temperature”

MIL--T 7928/4, “Terminals, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Insulated, Ring

Tongue, Bell--Mounted Type II, Class I for 150_C Total Conductor Temperature”

MIL--T 7928/5, “Terminals, Lug and Splices, Conductor, Crimp Style”

MIL--T 7928/6, “Terminals, Lug and Splices, Conductor, Crimp Style, Splice, Electric, (Permanent, Type II,

Class 1) for 150_C Total Conductor Temperature”

MS 17182, “Terminal, Lug, Crimp Style, Copper, Insulated (Servo Components), Type II, Class I for 125_C

Total Conductor Temperature”

MS 25036, “Terminal, Lug, Crimp Style, Copper, Insulated, Ring Tongue, Bell Mouthed, Type II, Class 1 for

105_C Total Conductor Temperature”

MS 25274, “Cap, Electrical (Wire End, Crimp Style, Type II, Class 1) for 105_C Total Conductor

Temperature”

3. REQUIREMENTS

3.1. Limitation

These terminals and end caps are suitable for 300 volts maximum, and the splices are suitable for 600 volts

maximum.

The terminals, splices, and end caps having the following insulation can withstand the following temperature

range:

nylon --40 to 105_C [--40 to 221_F]

PVC --10 to 90_C [14 to 194_F]

PVF

2

--65 to 150_C [--149 to 302_F]

3.2. Storage

A. Ultraviolet Light

Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the insulation.

B. Reel Storage

Tape--mounted reeled product should be stored horizontally to prevent sagging and possible stretching or

distortion of the plastic tape which could adversely affect feeding of the product through the tooling.

C. Shelf Life

The product should remain in the shipping containers until ready for use to prevent inadvertent damage.

The product should be used on a first in, first out basis to avoid storage contamination that could adversely

affect signal transmissions.

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114- 2157

D. Chemical Exposure

Do not store product near chemicals listed below. They could cause stress corrosion cracking of product.

Alkalies

Amines

Ammonia

Carbonates

Citrates

Nitrites

Phosphates Citrates

Sulfur Nitrites

Sulfur Compounds

Tartrates

3.3. Wire Selection and Preparation

Terminals and splices accept solid and/or stranded wire sizes 26 through 10 AWG and end caps accept solid

and/or stranded wire sizes 22 through 10 AWG. The wire size used must be within the range stamped on the

underside of the terminal tongue or on the center of the splice or end cap. Generally, the strip length of the wire

should be equal to the wire barrel length plus 0.76 [.030]. Specific strip lengths are given in Figure 2.

Note:

Not to Scale

Strip Length

(See Table)

Insulation

Conductor

(Stranded Shown)

WIRE

SIZE (AWG)

26

26--24

26--22

24

[24[

24--20

24 20

22

22--16

22 16

20

18

16

16--14

16 14

D

16--14

D

DIAMETER RANGE

0.66--1.40 [.026--.055]

Multiple

H

Multiple

H

0.79--1.40 [ 031 055]

0 79 1 40 [.031--.055]

Multiple

H

0.97--2.79 [.038--.110]

Multiple

H

1.17--2.79 [.046--.110]

1.42--2.79 [.056--.110]

1.60--3.30 [.063--.130]

Multiple

H

Multiple

H

1.98--3.30 [.078--.130]

Multiple

H

2.41--5.08 [.095--.200]

3.02--5.08 [.119--.200]

TERMINAL, SPLICE,

OR END CAP

INSULATION COLOR

Yellow/Black

Yellow

Yellow/Blue

White

Natural/White

Red/Green

Red

Natural/Red

Red/Red

Red/White

Blue/Blue

Natural/Blue

Blue

Yellow/Black

Blue/Green

Natural/Yellow

Yellow

Yellow/Yellow

Yellow/Brown

WIRE STRIP LENGTH

TERMINAL

6.35--7.14 [.250--.281]

5.16--5.94 [.203--.234]

3.96--4.78 [.156--.188]

4.78--5.56 [.188--.219]

6.35--7.14 [.188--.281]

4.78--5.56 [ 188 219]

4 78 5 56 [.188--.219]

6.35--7.13 [.250--.281]

5.16--5.94 [ 203 234]

5 16 5 94 [.203--.234]

6.35--7.13 [.250--.281]

5.16--5.94 [ 203 234]

5 16 5 94 [.203--.234]

7.93--8.71 [.312--.343]

6.35--7.13 [.250--.281]

7.93--8.71 [ 312 343]

7 93 8 71 [.312--.343]

9.53--10.31 [.375--.406]

SPLICE

—

4.37--5.16 [.172--.203]

—

5.56--6.35 [ 219 250]

5 56 6 35 [.219--.250]

—

6.35--7.13 [ 250 281]

6 35 7 13 [.250--.281]

—

6.35--7.13 [ 250 281]

6 35 7 13 [.250--.281]

—

8.71--9.53 [ 343 375]

8 71 9 53 [.343--.375]

—

END CAP

—

7.95--8.74 [.313--.344]

—

7.95--8.74 [.313--.344]

—

8.74--9.53 [.344--.375]

—

14

12--10

12 10

12

10

H

Contact PRODUCT INFORMATION at the number on page 1 for acceptable insulation diameter ranges

[

Large sleeve terminal designed for Class I E Nuclear applications

D

For use with heavy-

-duty terminals having an insulation thickness of 1.02-

-1.27 [.040-

-.050]

Figure 2

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NOTE

The wire conductor(s) must not be nicked, scraped, or cut during the stripping operation.

i

3.4. Wire Placement

The stripped wire must be inserted into the wire barrel until the wire insulation is against the wire barrel but not

inside it. The wire insulation must be inside the metal sleeve. A gap between the wire insulation and wire barrel

is allowed, but not to exceed the dimension given in Figure 3.

Transparent Insulation Window Butt Splice Shown

1.59 [.062]

Maximum Gap

Wire Barrel

Splice

Insulation

Wire Insulation May Butt Against,

But Not Enter, Wire Barrel

Metal Sleeve

Figure 3

Wire Insulation Must Be

Inside Metal Sleeve

3.5. Crimp Requirements

A. Crimp Height

The spring--back of the terminal, splice, or end cap insulation prevents an accurate direct measurement of

crimp height. However, crimping a slug of solder (60% tin and 40% lead) with a diameter slightly larger

than the conductor outside diameter can verify proper termination. The crimp height of the resulting solder

slug can be checked with a standard micrometer or comparator. The measurement must be made over

the most compressed area of the solder slug. See Figure 4.

NOTE

Some tooling with multiple crimping chambers form an embossed dot code in the terminal, splice, or end cap

insulation that indicates which crimping chamber was used. This dot code can be used as a visual inspection to ensure

that the correct wire size and crimping chamber were used.

The resilience of the splice insulation prevents accurate direct measurement of crimp height. Crimp height can be

obtained by measuring a crimped solder slug (60% tin and 40% lead) with a diameter comparable to the wire size.

The slug must be measured over the most compressed area of the slug with a standard micrometer or crimp height

comparator (refer to 408--7424 for specific instructions). The solder slug diameter and crimp height must be within the

dimensions provided in Figure 4.

i

NOTE

i

B. Wire Barrel Crimp Profile and Location

The wire barrel crimp produced by the tooling (dies, heads, hand tools, pneumatic tools, or machines)

must be either a confined crescent crimp which appears as a depressed oval shape or a flat rectangular

crimp over the center of the wire barrel. The crimp must be evenly formed. Refer to Figures 4, 5, and 11.

Crescent crimp tooling produces the crescent crimp, and TETRA--CRIMP tooling produces the flat

rectangular crimp. For a tooling--to--crimp profile cross--reference, refer to Figure 10.

C. Dot Code

The dot code on the insulation must be well formed and correspond with the wire size or color code

marking on the crimping chamber of the tooling used. See Figures 4 and 5.

D. Bellmouths

There shall be no rear bellmouth. The front bellmouth shall be evident on the top and bottom of the wire

barrel as shown in Figure 5. Also see Figure 11.

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Parameter Name	Attribute value
Brand Name	AMP
Is it lead-free?	Lead free
Is it Rohs certified?	conform to
Objectid	1505836777
Reach Compliance Code	compliant
ECCN code	EAR99
Factory Lead Time	12 weeks
terminal gender	FEMALE
Terminal and terminal strip types	FORK TERMINAL
Wire gauge	16 AWG

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