AMP Standard Terminals and Splices. RoHS. Ready

Transcription

1 AMP Standard Terminals and Splices RoHS Ready

2 Table of Contents Product Facts Solderless terminals and splices performs up to today s standards for reliable termination in applications ranging from control circuits to heavy duty power wiring This catalog describes only standard terminals and splices accommodating wire sizes from 2 AWG through 4/0 AWG These terminals are preinsulated and color coded by wire size for easy identification Funnel entry on many terminals allows for easy wire insertion for high speed production Nylon or vinyl insulation provides high dielectric strength The serration or dimple feature inside the terminal barrel provides exceptional barrel contact and tensile strength Special plating process creates a high resistance to corrosion Use of AMP application tooling is designed for uniform high quality terminations UL, CSA, Military Approved Table of Contents Introduction...2, 3 Performance Specifications... 4, 5 Terminal Stud Hole Sizes... PIDG (Pre-Insulated Diamond Grip) Terminals Splices...31, 32 PIDG FASTON Terminals... 34, 35 Splices...3 PLASTI-GRIP Terminals Splices TERMINYL Terminals... 54, 55 Splices...5 CERTI-SEAL... 57, 58 Splices and Tooling...58 Class 1 and Class 2 Military Approvals Tooling Part Numerical Index Global Contacts...74 Numerical values To convert U.S. customary unit values in this catalog to their metric equivalents, use the following formulas: To convert from to Multiply by inch millimeter (mm) x inch metre (m) x -2 inch centimeter (cm) foot metre (m) x -1 pound-force newton (N) bar pascal (Pa) x 5 pound-force/inch 2 pascal (Pa) x 3 pound-mass kilogram (kg) x -1 ounce-mass kilogram (kg) x -2 To convert wire size (AWG) to the equivalent metric value using the circular mil area of the wire, use the following formula: circular mil area (CMA)/ = square millimeter (mm 2 ) Note: Dimensions in this catalog are for reference purposes only. Customer drawings are available on request. Specifications subject to change. Consult Tyco Electronics for latest design specifications. Need more information? Call Technical Support: The Center is staffed with specialists well versed in Tyco Electronics products. They can provide you with: Technical Support Catalogs Technical Documents Product Samples 1977, 1980, 1982, 1985, 198, 1988, 1995, 2000 and 2008 by Tyco Electronics Corporation. All Rights Reserved. AMP, AMP-O-LECTRIC, AMPOMATOR, TETRA-CRIMP, AMP-TAPETRONIC, AUTO-PRO, CERTI-SEAL, DYNA-CRIMP, FASTON, PIDG, PLASTI-GRIP, PRO- CRIMPER, SHUR-PLUG, TERMINYL, T-HEAD, TE logo and Tyco Electronics are trademarks. 2

3 Terminals and Splices PIDG Terminals and Splices Page 7 ( Restricting Terminals also) PIDG FASTON Terminals and Splices Page 33 ( Restricting Terminals also) PLASTI-GRIP Terminals and Splices Page 37 Terminals and Splices TERMINYL Terminals and Splices Page 53 CERTI-SEAL Splices Page 57 3

4 Terminals and Spices (Continued) Ordering Information Standard Packaging Quantities Terminals and Splices This catalog is designed for easy selection of terminal type to meet your needs. All terminals and splices are cataloged by tongue type and wire size. If the part number is known, refer to the numerical index at the back of this catalog for page location of tabular information. In many instances the part is available in loose piece as well as tape mounted. FASTON terminals are available in strip form. When ordering tape mounted parts, specify the terminal or splice part number, the total quantity of parts required, the part number of the tooling to be used and the type of packaging desired (if applicable). The table shown at top right, lists the wire sizes available and the quantity per package for tape mounted and loose piece. Insulated terminals and splices are color coded to indicate wire range and to help match the terminal with the appropriate tool. The table shown at right identifies the specific wire range insulation color. Range AWG Packaging Quantity Loose Piece Tape Mounted M/Box 2,500/Reel M/Box 5,000/Reel 1-14 H.D. 500/Box 2,500/Reel /Box 2,500/Reel 8 thru 4 0/Box 2 thru 4/0 50/Box Note: Package quantities may vary with specific part numbers. Color Code Color Code Range AWG Comments 2-22 Transparent /Black 1-14 Heavy Duty /0 2/0 3/0 4/0 Terminals and Splices Performance Specifications For detailed test information and product specifications, request appropriate report or refer to the applicable specification listed in the following table. Product Type Test Report Number Application Specification PIDG Terminals Nylon MIL-T-7928 PIDG Restriction GPR Terminals 1-23 MIL-T-7928/1 PIDG FASTON Terminals UL3 PLASTI-GRIP Terminals UL48 TERMINYL Terminals MIL-T-7928 CERTI-SEAL Terminals 4

5 Terminal and Splices Performance Specifications (Continued) The many millions of AMP terminals and splices that have given ten, fifteen and twenty years of service are ample proof of the testing and research that went into their design and manufacturing. Like all AMP solderless wiring devices, they are thoroughly tested to conform to standards of performance under heavy usage. Tests conducted in Tyco Electronics laboratories and research facilities, some of the best-equipped in their field, indicate that these terminals and splices meet or exceed applicable industrial requirements and military specifications. The result of some of the most popular tests are tabulated here. Upon request, a formal test report will be supplied to support these values and document additional performance requirements not listed. MIL-T-7928 Group III Group VI Tensile Strength After Tensile Strength After Wire Spec. Vibration - Lb. Corrosion - Lb. Size Min. lb. Terminal Type Terminal Type PIDG PIDG TERMINYL TERMINYL ,035 1,13 1/ ,781 1,77 2/ ,787 1,721 3/ ,845 2,880 4/ ,048 3,28 Terminals and Splices MIL-T-7928 Group II Group III Group VI Wire Specification Millivolt Drop After Millivolt Drop After Millivolt Drop After Size Maximum Current Cycling 2 Vibration 2 Corrosion 2 Millivolt Drop 1 Terminal Type Terminal Type Terminal Type PIDG PIDG PIDG TERMINYL TERMINYL TERMINYL / / / / Value is millivolt drop permitted after test plus equal length of wire. 2 Value includes equal length of wire. 5

6 Terminal Stud Hole Size Use to Select Proper Size Terminal The chart shows sizes and dimensions of various studs and the corresponding terminal stud hole sizes used with AMP devices. For example, with stud #5 ( Diameter), use AMP device listed for #5 stud (.129 Hole Diameter). Terminal stud hole sizes may easily be checked by fitting sample terminal to black circle. Terminal Stud Hole Sizes Stud Size Minimum Terminal Stud Dia. U.S. Cust. Metric Hole Diameter # # #2 M # # Stud Size Stud Dia. Minimum Terminal U.S. Cust. Metric Hole Diameter 5/8" M /4" #5 M3.129 # M #8 M /8" M # # # " /4" M.20 5/1" M /8" /8" /1" /4" /2" M

7 PIDG Terminals and Splices Product Facts Pre-insulated terminal designed for uniform reliability in most difficult circuit environments PIDG Terminals consist of tin plated copper or tin plated phosphor bronze body for spring spades with a copper sleeve and insulation sleeve fitted over terminal barrel Design of the tool dies and construction of the terminal allows for uniform insulation thickness under crimping pressure, transmitting this pressure evenly to the center of the crimp area The AMP Mated Tool/Terminal Concept AMP compression crimping produces crimps for a given size wire and terminal that are alike in appearance and performance Terminal and crimping tool are designed as uniform matched devices Dies are precisionengineered from the finest hard-metal alloys Crimping pressure is controlled by a ratchet device on the hand tool or a corresponding pre-calibration in the crimping jaws of AMP automated crimping machines The Crimp When done properly, crimping pressure can neither overstress nor under stress the terminal barrel machined dies fully bottom to the precise crimp height Resulting termination is free of contamination Resistant to shock and critical environments Tensile strength approaches that of the wire itself PIDG Terminals meet or exceed the requirements of MIL-T-7928, Type II, Class 1 and 2 Refer to AMP Qualified Products for Military Application, Catalog for Military Specification Number to AMP Part Number cross reference Color Coding. Terminal insulation is color-coded by wire range to prevent errors during installation. Serrations. Serrations inside barrel provide maximum contact and tensile strength after crimping. Nylon. Nylon sleeve has high dielectric strength. Temperature Rating: 5 C Max. AMP PIDG Terminals (Use PIDG Tooling) AMP LR7189 Wire Certified Range Solid or Stranded Solid or Stranded 300 V Max., 5 C. Max Solid or Stranded Note: 22-1 terminals are stamped in accordance with MIL-T UL & CSA Nylon Basic Terminal. The basic terminal is constructed of fine grade high conductivity copper per ASTM B-152 and tin-plated per ASTM B-545. Basic material for Spring Spade Tongue Terminals is phosphor bronze per ASTM B-139 and tin-plated per ASTM B-545. Tyco Electronics' special plating process creates durable corrosion resistance to salt spray and most chemical fumes. Copper Sleeve. The specially designed copper sleeve, fitted over the terminal barrel, provides circumferential insulation support to the wire and allows the wire to be bent in any direction, without fraying the wire s insulation or breaking the conductor. Funnel Ramp Entry. Prevents a turned back strand and permits rapid wire insertion during high speed production. Note: Over size expansions are provided in vinyl insulation only. AMP PIDG Nylon Butt Window Splice (Use PIDG Tooling) AMP LR7189 Wire Certified Range Stranded or Solid Stranded or Solid 300 V Max., 5 C. Max Stranded or Solid Note: 22-1 splices are stamped in accordance with MIL-T PIDG Terminals and Splices 7

8 PIDG Terminals and Splices (Continued) Ring Tongue Terminals L E W C -Nylon, UL 94V-2 Terminal Body and Metallic Sleeve-Copper per ASTM B-152 Plating-Tin per ASTM B-545 Application Tooling -pg. PIDG Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted M M [ ] M * * M /Br * * [ ] M * * * M * Natural M Natural Natural Natural , [ ] Natural.0 M M Natural Natural Note: C dimension applies from edge of metal wire barrel to center of stud hole. Must be crimped with or 22-1 PIDG (red) Tooling. 8

9 PIDG Terminals and Splices (Continued) Ring Tongue Terminals (Continued) Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted M * /Green 32754* * * * Black * * * , [ ] M * * * * M * * * * * * * * Slightly larger than standard #4 stud hole. (.128 in./3.25 mm.) PIDG Terminals and Splices Note: C dimension applies from edge of metal wire barrel to center of stud hole. 9

10 PIDG Terminals and Splices (Continued) Ring Tongue Terminals (Continued) L E W C -Nylon, UL 94V-2 Terminal Body and Metallic Sleeve-Copper per ASTM B-152 Plating-Tin per ASTM B-545 Application Tooling-pg. PIDG Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted * /4 M Black * * / * , M [ ] * / * /2 M * 20-1HD , [ ] M * * * * M * * * * * * M * * Heavy duty for extra mechanical strength. Note: C dimension applies from edge of metal wire barrel to center of stud hole.

11 PIDG Terminals and Splices (Continued) Ring Tongue Terminals (Continued) Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted * * * * / M * Black / * M * / * * / M * /Blk /Blk * M /Blk. 3534* /Blk /Blk * M /Blk * /Blk * HD /Blk * /Blk /Blk * /Blk /4 M /Blk /Blk. 3480* /1 M /Blk Heavy duty for extra mechanical strength. PIDG Terminals and Splices Note: C dimension applies from edge of metal wire barrel to center of stud hole. 11

12 PIDG Terminals and Splices (Continued) Ring Tongue Terminals (Continued) L E W C -Nylon, UL 94V-2 Terminal Body and Metallic Sleeve -Copper per ASTM B-152 Plating-Tin per ASTM B-545 except where noted. Application Tooling-pg. PIDG Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted 3/ /Blk HD /Blk. 3531*.050 1/ M /Blk / /Blk * * * M * * * * M * * ,180-13, [2.2-.4] * * * * * /4 M * * Heavy duty for extra mechanical strength. 2 Terminal body plating Gold per MIL-G Type II over Nickel per QQ-N Terminal body plating Nickel per QQ-N-290. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 12

13 PIDG Terminals and Splices (Continued) Ring Tongue Terminals (Continued) Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted M / * M * * / * ,180-13, [2.2-.4] / M * 5/8 M Note: C dimension applies from edge of metal wire barrel to center of stud hole. Vinyl insulation material PIDG Terminals and Splices 13

14 PIDG Terminals and Splices (Continued) Ring Tongue Terminals (Vinyl) L E W C -Vinyl, UL 94V-0 Terminal Body and Metallic Sleeve-Copper per ASTM B-152 Plating-Tin per ASTM B-545 except where noted. PIDG Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted M , M [ ] /Blk * 1-14HD 1/ /Blk *.050 M / /Blk..300 M /2 M /Blk M M * * mm ,180-13, [2.2-.4] / M * /1 M * / Heavy duty for extra mechanical strength. 2 Terminal body plating Gold per MIL-G Type II over Nickel per QQ-N # stud may be substituted. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 14

15 PIDG Terminals and Splices (Continued) Ring Tongue Terminals ( Restricting) [mm 2 ] L E W C -Nylon, UL 94V-2 Terminal Body-Copper per ASTM B-152 Plating-Tin per ASTM B-545 Metallic Sleeve-Copper per ASTM B-152 Plating-Nickel per QQ-N-290 or Tin per ASTM B-545 Application Tooling-pg. Tongue Dimensions Terminal Wire Part Numbers Stud W C E L Loose Tape Thickness Size Color Diameter Min. Max. Max. Piece Mounted Max. Solid/Stripe Range 2 M /Black /Black /Black [0.15] 0.74 M M /Black /Black / / M / M / / M [0.24] / M / M / / M /Green /Green /Green M /Green /Green M [0.38] /Green /4 M /Green /1 M /Green / /Green /2 M /Green Note: C dimension applies from edge of metal wire barrel to center of stud hole. Must be crimped with or 22-1 PIDG (red) Tooling * * * * * PIDG Terminals and Splices 15

16 PIDG Terminals and Splices (Continued) PIDG Terminals and Splices 1 Ring Tongue Terminals ( Restricting) (Continued) [mm 2 ] L E W C Tongue Dimensions Terminal Wire Part Numbers Stud W C E L Loose Tape Thickness Size Color Diameter Min. Max. Max. Piece Mounted Max. Solid/Stripe Range 2 M / / / M / / M ,18 [0.0] / /4 M / /1 M / / / /2 M / /White /White M /White M /White /White , [0.9] 1/ /White M /1 M /White / /White /2 M /White / / M / M / / , [1.42] 1/ / M /1 M / / / /2 M / Note: C dimension applies from edge of metal wire barrel to center of stud hole. -Nylon, UL 94V-2 Terminal Body-Copper per ASTM B-152 Plating-Tin per ASTM B-545 Metallic Sleeve-Copper per ASTM B-152 Plating-Nickel per QQ-N-290 or Tin per ASTM B-545 Application Tooling-pg * * * * * * * * * * * * *

17 PIDG Terminals and Splices (Continued) Ring Tongue Terminals ( Restricting) (Continued) Tongue Dimensions Terminal Wire Part Numbers Stud W C E L Loose Tape [mm 2 ] Thickness Size Color Diameter Min. Max. Max. Piece Mounted Max. Solid/Stripe Range /Green /Green M /Green * M /Green * /Green , * [2.15] 1/ /Green M /1 M /Green / /Green /2 M /Green M / / M * / * / / , M [3.37] 5/ / M / / /2 M / M /Brown M /Brown * /Brown / /Brown , M [.11] 5/ /Brown M / /Brown /2 M /Brown Note: C dimension applies from edge of metal wire barrel to center of stud hole. PIDG Terminals and Splices 17

18 Ring Tongue Terminals 90 Bend PIDG Terminals and Splices (Continued) -Vinyl, UL 94V-0 Terminal Body and Metallic Sleeve-Copper per ASTM B-152 Plating-Tin per ASTM B-545 Application Tooling-pg. PIDG Terminals and Splices Tongue Dimensions Wire Part Number Stud Terminal Cicular Mils Thickness Size W D Diameter Loose [mm 2 ] Max. Min. Color Max. Piece Vinyl , [ ] Nylon 12-5,180-13, [2.2-.4]

19 Rectangular Tongue Terminals PIDG Terminals and Splices (Continued) -Nylon except where noted. Terminal Body and Metallic Sleeve -Copper per ASTM B-152 except where noted. Application Tooling-pg. Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L X Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted M [ ] M M M ,20 [ ] M * * M * M Vinyl PIDG Terminals and Splices 2 Terminal Body - Brass per MIL-C-50. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 19

20 Rectangular Tongue Terminals (Continued) PIDG Terminals and Splices (Continued) -Nylon except where noted. Terminal Body and Metallic Sleeve -Copper per ASTM B-152 Application Tooling pg. PIDG Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L X Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted M * * M M ,180-13, M3.5 [2.2-.4] M Note: C dimension applies from edge of metal wire barrel to center of stud hole. 20

21 PIDG Terminals and Splices (Continued) Rectangular Tongue Terminals (Continued) -Nylon, UL 94V-2 Terminal Body -Copper per ASTM B-152 Metallic Sleeve -Copper per ASTM B-152 Plating Nickel per QQ-N-290 Application Tooling-pg. Tongue Dimensions Terminal Wire Part Numbers Stud [mm 2 Thickness Size W C E L X Color Diameter Loose ] Max. Min. Max. Max. Solid/Stripe Range Piece / [0.24] 0.51 M /Brown M ,0 [.11] /Brown M Note: C dimension applies from edge of metal wire barrel to center of stud hole. Spade Tongue Terminals -Nylon, UL 94V-2 Terminal Body and Metallic Sleeve -Copper per ASTM B-152 Application Tooling-pg. PIDG Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L X Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted [ ] 0.74 M [ ] * M * * * * * M ,20 [ ] * M * * * Note: C dimension applies from edge of metal wire barrel to center of stud hole. 21

22 Spade Tongue Terminals (Continued) PIDG Terminals and Splices (Continued) -Nylon, UL 94V-2 Terminal Body and Metallic Sleeve -Copper per ASTM B-152 Application Tooling-pg. PIDG Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L X Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted * M * * * M * * * * M * ,180-13,0 [2.2-.4] M * * * Note: C dimension applies from edge of metal wire barrel to center of stud hole. 22

23 Flanged Spade Tongue Terminals PIDG Terminals and Splices (Continued) -Nylon, UL 94V-2 Terminal Body and Metallic Sleeve -Copper per ASTM B-152 Application Tooling-pg. Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L X H Diameter Loose Tape ] Max. Min. Max. Max. Min. Color Max. Piece Mounted 2 M * * [ ] M * M * * M * , * [ ] M * M * * * M * * M * ,180-13,0 [2.2-.4] M * * Note: C dimension applies from edge of metal wire barrel to center of stud hole. PIDG Terminals and Splices 23

24 Short Spring Spade Tongue Terminals PIDG Terminals and Splices (Continued) -Nylon, UL 94V-2 Terminal Body -Phosphor Bronze per ASTM B-139 Metallic Sleeve -Copper per ASTM B-152 Application Tooling-pg. PIDG Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L X Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted 2 M * * M [ ] M * M * M * * M ,20 [ ] M * * /4 M * 5 M * * M * * M * * /4 M M * M * ,180-13, M * [2.2-.4] * /4 M * Note: C dimension applies from edge of metal wire barrel to center of stud hole. 24

25 Long Spring Spade Tongue Terminals PIDG Terminals and Splices (Continued) -Nylon, UL 94V-2 Terminal Body -Phosphor Bronze per ASTM B-139 Metallic Sleeve -Copper per ASTM B-152 Application Tooling-pg. Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L X Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted [ ] 0.51 M * M , [ ] 8 M * * * M * * M * * /4 M M M ,180-13,0 [2.2-.4] /4 M Note: C dimension applies from edge of metal wire barrel to center of stud hole. PIDG Terminals and Splices 25

26 Slotted Ring Tongue Terminals PIDG Terminals and Splices (Continued) -Nylon except where noted. Terminal Body and Metallic Sleeve -Copper per ASTM B-152 Application Tooling-pg. PIDG Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted [ ] 0.51 M M * * M ,20 [ ] / M M M HD / /Black / M ,180-13,0 [2.2-.4].040 3/ Vinyl. Note: C dimension applies from edge of metal wire barrel to center of stud hole. Hook Tongue Terminals -Nylon except where noted. Terminal Body and Metallic Sleeve -Copper per ASTM B-152 Application Tooling-pg. 2 [mm 2 ] ,20 [ ] Vinyl. Tongue Dimensions Wire Part Numbers Stud Terminal Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted M * M M M * Note: C dimension applies from edge of metal wire barrel to center of stud hole.

27 Multiple Stud Terminals PIDG Terminals and Splices (Continued) -Nylon, UL 94V-2 Terminal Body -Copper per ASTM B-152 Metallic Sleeve -Copper per ASTM B-152 Plating -Nickel per QQ-N-290 Application Tooling-pg. Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 Thickness Size W C E L Diameter Loose Tape ] Max. Min. Max. Max. Color Max. Piece Mounted , [ ] * ,180-13, [2.2-.4] * Note: C dimension applies from edge of metal wire barrel to center of stud hole. Offset Ring Tongue Terminals -Nylon, UL 94V-2 Terminal Body and Metallic Sleeve -Copper per ASTM B-152 Application Tooling-pg. PIDG Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal Thickness Size W C E L Diameter Loose [mm 2 ] Max. Min. Max. Max. Color Max. Piece ,20 [ ] 0.84 M M Note: C dimension applies from edge of metal wire barrel to center of stud hole. 27

28 Offset Ring Tongue Terminals ( Restricting) PIDG Terminals and Splices (Continued) -Nylon, UL 94V-2 Terminal Body and Metallic Sleeve -Copper per ASTM B-152 Application Tooling-pg. PIDG Terminals and Splices Tongue Dimensions Terminal Wire Part Numbers Stud [mm 2 Thickness Size W C E L Color Diameter Loose ] Max. Min. Max. Max. Solid/Stripe Range Piece /Green [0.38] 0.84 M / M ,18 [0.0] / , / [1.42] 0.84 M , /Green [2.15] Note: C dimension applies from edge of metal wire barrel to center of stud hole. 28

29 SHUR-PLUG Terminal PIDG Terminals and Splices (Continued) -Nylon, UL 94V-2 Terminal Body and Metallic Sleeve -Copper per ASTM B-152 Application Tooling-pg. Dimension Terminal Wire Part Numbers L Diameter Loose Tape [mm 2 ] Max. Color Max. Piece Mounted * Receptacle PIDG Terminals and Splices 3-Way Connector Terminal -Nylon, UL 94V-2 Terminal Body and Metallic Sleeve -Copper per ASTM B-152 Rivet -Brass per QQ-B-2 Application Tooling-pg. Tongue Dimensions Terminal Wire Part Number W L Diameter Loose [mm 2 ] Thickness Max. Max. Max. Color Max. Piece *

30 Tabs PIDG Terminals and Splices (Continued) -Nylon, UL 94V-2 Terminal Body and Metallic Sleeve -Copper per ASTM B-152 Application Tooling-pg. PIDG Terminals and Splices Tongue Dimensions Wire Part Numbers Terminal Style Thickness W C L D Diameter Loose [mm 2 ] Max. Min. Max. Color Max. Piece , A [ ] * B ,180-13,0.042 C [2.2-.4] * Note: C dimension applies from edge of metal wire barrel to end of tab. 30

31 PIDG Terminals and Splices (Continued) Butt Splices Sleeve - Standard, Step Down Assembly and Special Nylon Radiation Resistant Polyvinylidene Fluoride (PVF 2 ) Splice Body and Support Sleeve -Copper per ASTM B-152 Application Tooling-pg. Dimension Splice Wire Part Numbers 2 Style L Diameter Loose Tape [mm 2 ] Max. Color Max. Piece Mounted [ ] [ ] * , Natural.0 [ ] Standard , [ ] * * ,180-13, [2.2-.4] * to 509-1,900 [ ] / / Step Down 5,180-13,0 to 509-1,900 [2.2-.4] [ ] Assembly / 5.59/ ,180-13,0 to [2.2-.4] / 5.59/ Radiation.890 Natural w/.082 [ ] Resistant 22.1 Stripes Radiation.890 Natural w/.082 [ ] Resistant 22.1 Stripes , Natural w/.0 [ ] 2.29 White Stripes 2.54 Radiation Resistant 509-3, Natural w/ [ ] Stripes * Natural w/ Stripes * ,180-13,0 1.5 Natural w/.220 [2.2-.4] 42.0 Stripes * 12-5,180-13,0 Special [2.2-.4] Includes adapter insert. 2 When using two or more wires in either end of a butt splice, the combined cross sectional area must be within the (CMA) circular mil area range listed range in accordance with MIL-T splices are range in accordance with MIL-T butt splice, threaded 8-32 one end. AMP-TAPETRONIC machine tools only. PIDG Terminals and Splices 31

32 Butt Splice Step Down Adapter Inserts 1 PIDG Terminals and Splices (Continued) Adapter Body -Copper per ASTM B-152 Plating -Zinc Plate/ DyeChromate Application Tooling-pg. PIDG Terminals and Splices Butt Splice Adapter Insert Part No. Dimension Color Part Numbers L Code [mm 2 ] [mm 2 ] ,900 [ ] * , * 12- [ ] ,180-13, [2.2-.4] * ] Adapter inserts can be ordered separately for use in specific Standard PIDG Butt Splices. Knife Disconnect Splices -Nylon, UL 94V-2 Splice Body and Metallic Sleeve -Copper per ASTM B-152 Application Tooling-pg. Dimensions Splice Wire W L [mm 2 ] Thickness Max. Color Diameter Max ,20 [ ] ,180-13,0 [2.2-.4] Part Numbers Loose Piece Tape Mounted * 3244* * 32448* 32020* 3572* 32

33 Product Facts Pre-insulated terminal designed for uniformed reliability in most difficult circuit environment Consists of an unplated or tin-plated brass body or a tin-plated phosphor bronze body with a specially designed copper sleeve and insulation sleeve fitted over the terminal barrel Design of the tool dies and construction of the terminal permits uniform insulation thickness under crimping pressure, transmitting this pressure evenly to the center of the crimp area The AMP Mated Tool/Terminal Concept AMP compression crimping produces crimps for a given size wire and terminal that are alike in appearance and performance Terminal and the crimping tool are designed as uniform matched devices Dies are precisionengineered from the finest hard-metal alloys Crimping pressure is controlled by a ratchet device on the hand tool or a corresponding pre-calibration in the crimping jaws of AMP automated crimping machines The Crimp When done properly, crimping pressure can neither overstress nor under stress the terminal barrel machined dies fully bottom to the precise crimp height Resulting termination is free of contamination Resistant to shock and critical environments Tensile strength approaches that of the wire itself PIDG FASTON Terminals and Splices Color Coding. Terminal insulation is color-coded by wire range to prevent errors during installation. Copper Sleeve. The specially designed copper sleeve, fitted over the terminal barrel, provides circumferential insulation support to the wire and allows the wire to be bent in any direction, without fraying the wire s insulation or breaking the conductor. Funnel Ramp Entry. Prevents a turned back strand and rapid wire insertion during high speed production. Temperature Rating: 5 C Max. AMP PIDG FASTON Terminals (Use TETRA-CRIMP Tooling) AMP Component Wire Recognized Range File E Stranded LR 7189 Certified Stranded 300 V Max., 5 C. Max Stranded 1 UL & CSA Nylon except where noted Nylon. Nylon sleeve has high dielectric strength. Serrations. Serrations inside barrel provide maximum contact and tensile strength after crimping. Basic Terminal. The basic terminal is constructed of fine grade high conductivity brass per ASTM B-3 or phosphor bronze per ASTM B-139. The brass terminal is either unplated or tin-plated per ASTM B-545. The phosphor bronze terminal is tin-plated per ASTM B-545. Tyco Electronics' special plating process creates durable corrosion resistance to salt spray and most chemical fumes. AMP PIDG FASTON Line Splice Connectors 250 Series Component 5 C LR C Recognized Max. Certified Max. File E 717 (Vinyl) (Vinyl) AMP Part No. 00 V AMP Part No Max V Max V V Max Max. PIDG FASTON Terminals and Splices 33

34 PIDG FASTON Terminals and Splices (Continued) Receptacles Receptacle Style: A - No dimple with wire stop B - Dimple with wire stop C - No dimple, no wire stop -Nylon, UL 94V-2 Receptacle Body -Brass per ASTM B-3 or Phosphor Bronze per ASTM B-139 except where noted. Metallic Sleeve -Copper per ASTM B-152 Application Tooling -pg. 7 PIDG FASTON Terminals and Splices 34 Dimensions Terminal Wire Fits Part Numbers Series Style W L Recept. Stock Tab Loose Tape Strip [mm 2 ] Nom. Max. Color Diameter Matl. Thk. Thk. Piece Mounted Form Max Brass * ,900 B [ ] Brass B Brass * Green Brass * ,831-,470 1 B [ ] Green Phos. Brz * Brass * ,180-13,0 B [2.2-.4] Phos. Brz , Brass [ ] Low Insertion Brass Brass Brass * ,900 B [ ].800 /Black Brass Brass * Brass * B.800 Brass * B Brass * [ ] Brass * ,900 B [ ].800 Brass Not UL or CSA approved or listed. 1 Wire range is limited as noted. 2 Unplated receptacle body.

35 PIDG FASTON Terminals and Splices (Continued) Reseptacles (Continued) Dimensions Terminal Wire Fits Part Numbers Series Style W L Recept. Stock Tab Loose Tape Strip [mm 2 ] Nom. Max. Color Diameter Matl. Thk. Thk. Piece Mounted Form Max Brass * B.900 Brass , Brass [ ] Low Insertion Brass Natural.1 Brass * Natural.1 Brass * Standard 509-1,900 B [ ] Natural.1 Brass * Black.1 Brass A Brass [ ] Brass Standard Brass Low ,900 A [ ] Brass * Low Brass * Insertion A Brass * A Brass * B Brass C Brass Not UL or CSA approved or listed. PIDG FASTON Terminals and Splices Receptacles ( Restricting) -Nylon, UL 94V-2 Receptacle Body -Brass per ASTM B-3 Receptacle Style B -Dimple with wire stop Metallic Sleeve -Copper per ASTM B-152 or Nickel per QQ-N-290 Application Tooling -pg. 7 Dimensions Terminal Wire Fits Part Numbers Series Recept. Stock Style W L Tab Loose Tape Strip [mm 2 ] Color Diameter Matl. Thk. Nom. Max. Thk. Piece Mounted Form Solid/Stripe Range B / Brass Standard [0.38] Green

36 PIDG FASTON Terminals and Splices (Continued) PIDG FASTON Terminals and Splices Line Splice Connector for 250 Series Terminals Dimensions Plating W L E Unplated Tin 22- Unplated Tin Unplated 1 Oval expansion at end opposite w. (.380 x.320 inside diameter.) 2 E min. on expansion end only. Line Splice Connector for 187 Series Terminals -Vinyl, UL 94V-0 Color -Natural Splice Body -Brass per ASTM B-3 except where noted. Max. Min Housing -Nylon, UL 94V-2 Splice Body -Brass per ASTM B-3 Part Numbers Loose Piece * Type Single Dual Dual UL File E V Max Housing Dimensions Temperature Part Numbers Color W L Rating Loose Piece Natural Natural Black C C Receptacle (Low Insertion Force) Dimensions Terminal Wire Fits Part Numbers Series W L Recept. Stock Tab Loose Tape Strip [mm 2 ] Nom. Max. Color Diameter Matl. Thk. Thk. Piece Mounted Form Max. Low , Brass Insertion [ ] Low Brass Insertion Low , Brass Insertion [ ] Low Brass Insertion

37 PLASTI-GRIP Terminals and Splices Product Facts Pre-insulated PLASTI- GRIP solderless terminals and splices Designed specifically to answer the need for inexpensive, insulated electrical terminations Can be used in almost every type of commercial application Accommodate wire sizes from 22 AWG through 2/0 AWG The Crimp Carefully engineered application tooling has been developed to ensure uniformly high quality terminations Tool and terminal have been designed as a team to promote ease and speed of application and at the same time to provide precise crimping pressure for every wire size The wire and the terminal barrel form a homogeneous mass of metal, providing a connection of maximum conductivity, tensile strength, and high resistance to corrosion The quality performance, the facility of installation and the inherent simplicity make them wellsuited for many industrial applications Color Coding. Terminal insulation is color-coded by wire size range to eliminate errors during installation. Funnel Entry. Assures rapid wire insertion during high speed production. (Except 8 to 2/0 range.) Temperature Rating: 90 C Max. Basic Terminal. The basic terminal is constructed of fine grade high conductivity copper per ASTM B-152 and tin-plated per ASTM B-545. Basic material for Spring Spade Tongue Terminals is phosphor bronze per ASTM B-139 or brass per ASTM B-3 and tinplated per ASTM B-545. Tyco Electronics' special plating process creates durable corrosion resistance to salt spray and most chemical fumes. Serrations. Serrations inside barrel provide maximum contact and tensile strength after crimping. Dimples on 8 to 2/0 range.. Vinyl insulation sleeve provides good dielectric strength and supports the wire insulation so that no bare wire is exposed. AMP PLASTI-GRIP Terminals and Splices (Use PLASTI-GRIP or PIDG Tooling) AMP Wire Range Listed Except as noted with individual part number listing. LR thru 4/0 Certified 00V Terminals, Butt & Parallel Splices 22-1 Solid or Stranded 1 00 V Max. Recognized under Terminals, Butt & Parallel Splices (00 V Fixture the component program 1-14 Solid or Stranded 1 or Sign) of Underwriters Terminals, Butt & Parallel Splices 90 C Max. Laboratories Incorporated File No. E Solid or Stranded 1 Note: 22-1 terminals and splices are stamped in accordance with MIL-T Stranded wire only using TETRA-CRIMP tooling. PLASTIC-GRIP Terminals and Splices 37

38 PLASTI-GRIP Terminals and Splices (Continued) Ring Tongue Terminals L E W C -Vinyl, UL 94V-0 Terminal Body -Copper per ASTM B-152 Application Tooling-pg. A PLASTI-GRIP Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal Style [mm 2 ] Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted 2 M2 A * * A * * * * * A M Black * * , [ ] * M4 A * * * * Black A * * * /4 M A * Black

39 PLASTI-GRIP Terminals and Splices (Continued) Ring Tongue Terminals (Continued) Tongue Dimensions Wire Part Numbers Stud Terminal Style [mm 2 ] Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted Note: C dimension applies from edge of metal wire barrel to center of stud hole. (Styles A & E) * / A M Black , [ ] * /8 A Black A * * * M3.5 A * * * * A M * * * A Black * /4 M A * Black /1 M8 A * /8 A * Black A /Blk..200 M HD 1 8 A /Blk M /Blk * A /Blk Not UL or CSA Approved or Listed. 1 Heavy Duty for extra mechanical strength. Note: C dimension applies from edge of metal wire barrel to center of stud hole. (Styles A & E). PLASTIC-GRIP Terminals and Splices 39

40 PLASTI-GRIP Terminals and Splices (Continued) Ring Tongue Terminals (Continued) L E W C -Vinyl, UL 94V-0 Terminal Body -Copper per ASTM B-152 Application Tooling - pgs. & 7 A E PLASTI-GRIP Terminals and Splices 40 [mm 2 ] Tongue Dimensions Wire Part Numbers Stud Terminal Style Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted /Blk. 1/ A M /Blk HD /1 A /Blk M /8 A /Blk /2 M12 A /Blk A A A M A M A Black 5,180-13, [2.2-.4] E / Black M A /1 M8 A Black /8 A /2 M12 A Heavy Duty for extra mechanical strength. Note: C dimension applies from edge of metal wire barrel to center of stud hole. (Styles A & E) * * * * * * * * * * * *

41 PLASTI-GRIP Terminals and Splices (Continued) Ring Tongue Terminals (Continued) B C D F Tongue Dimensions Wire Part Numbers Stud Terminal Style [mm 2 ] Thickness Size W C E L Diameter Loose Tape Max. Max. Max. Color Max. Piece Mounted 8 M4 C D B ,0-20, [.4-.5] /4 M C * /1 M8 C * /8 C * /2 M12 A * C M B * C * 20,800-33, [.5-1.8] 1.22 F / M C * /1 M8 B * /8 B * /2 M12 C *1 Note: C dimension applies from edge of metal wire barrel to center of stud hole. (Styles A & E). PLASTIC-GRIP Terminals and Splices 41

42 PLASTI-GRIP Terminals and Splices (Continued) Ring Tongue Terminals (Continued) -Vinyl, UL 94V-0 Terminal Body -Copper per ASTM B-152 Application Tooling -pg. 7 B PLASTI-GRIP Terminals and Splices [mm 2 ] Tongue Dimensions Wire Part Numbers Stud Terminal Style Thickness Size W C E L Diameter Loose Tape Max. Max. Max. Color Max. Piece Mounted B * /4 M B * ,0-52, [ ] / B M * 3/8 B * / B M * ,00-83, / B [ ] 1.52 M /8 B /1 M8 B / , , /8 B [ ] /2 M12 B /0 119, , /1 B [0.-7.3] 2.11 M

43 PLASTI-GRIP Terminals and Splices (Continued) Ring Tongue 90 Bend Terminals -Vinyl, UL 94V-0 Terminal Body -Copper per ASTM B-152 Application Tooling -pg. 7 Tongue Wire Dimensions Stud Terminal Part Numbers Thickness Size W D Diameter Loose [mm 2 ] Max. Min. Color Max. Piece ,0-20,800 [.4-.5] / M ,800-33,0 [.5-1.8] / M Rectangular Tongue Terminals -Vinyl, UL 94V-0 Terminal Body -Copper per ASTM B Performance Specifications - Application Tooling-pg. Tongue Dimensions Wire Stud Terminal Part Numbers Thickness Size W C E L X Diameter Loose Tape [mm 2 ] Max. Min. Max. Max. Color Max. Piece Mounted M Note: C dimension applies from edge of metal wire barrel to center of stud hole. PLASTIC-GRIP Terminals and Splices 43

44 PLASTI-GRIP Terminals and Splices (Continued) Spade Tongue Terminals -Vinyl, UL 94V-0 Terminal Body -Copper per ASTM B-152 Application Tooling-pg. PLASTI-GRIP Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal Thickness Size W C E L X Diameter Loose Tape [mm 2 ] Max. Min. Max. Max. Color Max. Piece Mounted * M * * , [ ] M * * * * M * M * * ,180-13, [2.2-.4] * Gold Note: C dimension applies from edge of metal wire barrel to center of stud hole. 44

45 PLASTI-GRIP Terminals and Splices (Continued) Flanged Spade Tongue Terminals -Vinyl, UL 94V-0 Terminal Body -Copper per ASTM B-152 Application Tooling-pg. Tongue Dimensions Wire Part Numbers Stud Terminal Thickness Size W C E L X H Diameter Loose Tape [mm 2 ] Max. Min. Max. Max. Min. Color Max. Piece Mounted * M , [ ] M * * * M M M * ,180-13, M * [2.2-.4] Note: C dimension applies from edge of metal wire barrel to center of stud hole. PLASTIC-GRIP Terminals and Splices 45

46 PLASTI-GRIP Terminals and Splices (Continued) Short Spring Spade Tongue Terminals -Vinyl, UL 94V-0 Terminal Body -Phosphor Bronze per ASTM B-139 for wire sizes 24 to 14 Brass per ASTM B-3 for wire sizes 12 to except where noted Application Tooling-pg. PLASTI-GRIP Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal Thickness Size W C E L X Diameter Loose Tape [mm 2 ] Max. Min. Max. Max. Color Max. Piece Mounted , White [ ] * M * * M * * * , [ ] M * * * * * * M * * M * * * * * Terminal body plating Gold per MIL-G over Nickel per QQ-N-290. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 4

47 PLASTI-GRIP Terminals and Splices (Continued) Short Spring Spade Tongue Terminals (Continued) Tongue Dimensions Wire Part Numbers Stud Terminal Thickness Size W C E L X Diameter Loose Tape [mm 2 ] Max. Min. Max. Max. Color Max. Piece Mounted * M * * * M ,180-13,0 [2.2-.4] * * * * * Terminal body plating Gold per MIL-G over Nickel per QQ-N-290. Note: C dimension applies from edge of metal wire barrel to center of stud hole. Long Spring Spade Tongue Terminals -Vinyl, UL 94V-0 Terminal Body -Phosphor Bronze per ASTM B-139 for wire sizes 22 to 14 Brass per ASTM B-3 for wire sizes 12 to Application Tooling-pg. PLASTIC-GRIP Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal Thickness Size W C E L X Diameter Loose Tape [mm 2 ] Max. Min. Max. Max. Color Max. Piece Mounted M * , M * [ ] * M * M * * M * ,180-13, * [2.2-.4] Note: C dimension applies from edge of metal wire barrel to center of stud hole. 47

48 PLASTI-GRIP Terminals and Splices (Continued) Slotted Ring Tongue Terminals -Vinyl, UL 94V-0 Terminal Body -Copper per ASTM B-152 Application Tooling-pg. Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 ] Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted M , [ ] M Note: C dimension applies from edge of metal wire barrel to center of stud hole. PLASTI-GRIP Terminals and Splices Hook Tongue Terminals -Vinyl, UL 94V-0 Terminal Body -Copper per ASTM B-152 Application Tooling-pg. Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 ] Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted M Note: C dimension applies from edge of metal wire barrel to center of stud hole. 48

49 PLASTI-GRIP Terminals and Splices (Continued) Flag Tongue Terminals A B -Vinyl, UL 94V-0 Color -Natural Terminal Body -Copper per ASTM B-152 Application Tooling-pg. Tongue Dimensions Terminal Wire Part Numbers Style Stud [mm 2 ] Thickness Size W C L D Stripe Diameter Loose Piece Max. Min. Max. Max. Color Max. 20-1HD 1 8-3, A Green [ ] B A HD Black A Black A ,180-13, [2.2-.4] Heavy Duty for extra mechanical strength. Multiple Stud Terminals -Vinyl, UL 94V-0 Terminal Body -Copper per ASTM B-152 Application Tooling-pg. PLASTIC-GRIP Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal [mm 2 ] Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted , [ ] Note: C dimension applies from edge of metal wire barrel to center of stud hole. 49

50 PLASTI-GRIP Terminals and Splices (Continued) Butt Splices -Vinyl, UL 94V-0 Splice Body -Copper per ASTM B-152 Application Tooling-pg. PLASTI-GRIP Terminals and Splices Dimension Splice Wire Part Numbers 1 L Diameter Loose Tape [mm 2 ] Max. Color Max. Piece Mounted [ ] * / / Stripe * * Natural w/ Letters * 509-3,20 [ ] * Natural w/ Stripes * x x * * Natural w/ Letters * * Natural Stripes w/ * * x x * * Natural w/ Stripes * * 5,180-13,0 [2.2-.4] x x x 3.51 x * Not UL or CSA Approved or Listed. 1 When using two or more wires in either end of a butt splice, the combined cross sectional area must be within the (CMA) circular mil range listed. (Not UL or CSA approved with use of multiple wires.) splices are range in accordance with MIL-T Oval expansion. 4 Funnel entry 50 5 Oval expansion at one end; circular expansion at other end.

51 PLASTI-GRIP Terminals and Splices (Continued) Parallel Splices -Vinyl, UL 94V-0 Splice Body -Copper per ASTM B-152 Application Tooling-pg. Dimension Splice Wire 1 L [mm 2 ] Max. Color Diameter Max ,20 [ ] x x ,180-13,0 [2.2-.4] Part Numbers Loose Piece 1 When using two or more wires in a parallel splice, the combined cross sectional area must be within the (CMA) circular mil area listed. 2 Oval expansion. Shur-Plug (.093,.15 and.180 Series).093 Series.15 Series (.093 Series) -Vinyl, UL 94V-0 Terminal Body -Brass per ASTM B-3 (.15 &.180 Series) -Vinyl, UL 94V-0 Terminal Body -Copper per ASTM B * 34132* 34133* 34134* * * Application Tooling-pg. PLASTIC-GRIP Terminals and Splices.180 Series Tongue Dimension Terminal Wire Part Numbers Series L Diameter Loose Tape [mm 2 ] Thickness Max. Color Max. Piece Mounted Max , [ ] * * Not UL or CSA Approved or Listed. 51

52 PLASTI-GRIP Terminals and Splices (Continued) 3-Way Connector -Vinyl, UL 94V-0 Terminal Body -Copper per ASTM B-152 Rivet -Brass per QQ-B-2 Application Tooling-pg. Tongue Dimensions Terminal Wire Thickness W L Diameter [mm 2 ] Max. Max. Max. Color Max. Part Number Loose Piece * PLASTI-GRIP Terminals and Splices Tube Cap Assembly -Vinyl, UL 94V-0 Terminal Body -Copper per ASTM B-152 Tube Cap -Copper/Zinc alloy per MIL-C-50 Rivet -Brass over Copper Tongue Dimensions Terminal Wire Thickness E L Diameter [mm 2 ] Max. Max. Max. Color Max. Application Tooling-pg. Part Number Loose Piece , Black [ ] Not UL or CSA Approved or Listed. Wire Pins Dimensions Terminal Wire Tab Ins. L Diameter Part Number [mm 2 ] Max. Color Max (Tape) (Loose Piece) 52

53 Product Facts Designed to provide insulated terminals and splices for large wire sizes, many of which are used in airborne and ground support applications Tested under the procedures stipulated by MIL Spec. MIL-T-7928, they meet and exceed requirements Designed and engineered to withstand extreme vibration, shock and structural stresses, elevated temperatures and other conditions which could adversely affect the circuit requirements in complex air and space flight equipment The use of matching AMP tooling provides for precision crimping which makes all terminations identical This uniformity promotes maximum reliability and, coupled with tool die marks on the barrel indicating the wire size and color coding of the insulation sleeve, also serves as a built-in quality control factor Pre-insulated with color coded nylon which also acts as insulation support Wire size range of terminals is 8 AWG through 4/0 AWG TERMINYL Terminals and Splices Funnel Entry. Molded insulation for ease of wire insertion and snug fit over MIL-standard wire diameters. Dimples. Dimples afford maximum contact of barrel and wire and maximum tensile strength. Temperature Rating: 5 C Max. Basic Terminal. The basic terminal is constructed of fine grade high conductivity copper per ASTM B-152 and tin-plated per ASTM B-545. Tyco Electronics special plating process creates durable corrosion resistance to salt spray and most chemical fumes.. Nylon insulation for dielectric strength, color coded to wire size. TERMINYL Terminals meet or exceed the requirements of MIL-T-7928, Type II, Class 2. Refer to AMP Qualified Products for Military Application, Catalog for Military Specification Number to AMP Part Number cross reference. TERMINYL Terminals and Splices 53

54 Ring Tongue Terminals TERMINYL Terminals and Splices (Continued) -Nylon, UL 94V-2 Terminal Body -Copper per ASTM B-152 Application Tooling -pg. 7 TERMINYL Terminals and Splices Tongue Dimensions Wire Part Numbers Stud Terminal Thickness Size W C E L Diameter Loose [mm 2 ] Max. Max. Max. Color Max. Piece 8 M / ,0-20, M [.4-.5] 5/ M / / ,800-33, M [.5-1.8] 5/ M / M / ,0-52, M [ ] 5/ M / * 1/2 M /4 M HD / ,0-52, M [ ] 3/ /4 M / ,00-83, M [ ] 3/ /2 M Rectangular tongue terminal 2 90 bend ring tongue terminal 3 Heavy duty for extra mechanical strength. 54

55 TERMINYL Terminals and Splices (Continued) Ring Tongue Terminals (Continued) [mm 2 ] Tongue Dimensions Wire Part Numbers Stud Terminal Thickness Size W C E L Diameter Loose Max. Max. Max. Color Max. Piece 1/ M /0 83, , / M [ ] 3/ /2 M / M /0 119, , / [0.-7.3] 1/2 M /0 150, , / [ ] /0 3/8 190, , [ ] 1/2 M TERMINYL Terminals and Splices 55

56 Butt Splices TERMINYL Terminals and Splices (Continued) Sleeve -Nylon, UL 94V-2 Splice Body -Copper per ASTM B-152 Application Tooling -pg. 7 TERMINYL Terminals and Splices Dimension Splice Wire Diameter Max. Style L Part Numbers [mm 2 ] Max. Color Single End Multiple End 8 to 12-13,0-20,800 [.4-.5] Single to Single w/ Step-Down 2.0 at.255 to Assembly adapter end.48 5,180-13, [2.2-.4] to 8 20,800-33,0 [.5-1.8] Single to Single w/ Step-Down 2.25 at.3 to Assembly adapter end ,0-20, [.4-.5] 8 13,0-20, [.4-.5] ,800-33, [.5-1.8] Single to Single Standard Splice 33,0-52, [ ] ,00-83, [ ] ,0-20, [.4-.5] Single to Multiple 20,800-33, [.5-1.8] Standard Splice ,0-52, [ ] ,0-20, [.4-.5] Multiple to Multiple 20,800-33, [.5-1.8] Standard Splice ,00-83, [ ] Step-Down Assembly includes adapter which is visible through insulation sleeve window. 5

57 Product Facts Nylon window splice for military, commercial, aircraft, and missile applications that seals out vapors and fluids and imparts exceptional wire insulation support Metal rings at both ends of splice and permanently crimped to wire insulation for a moisture tight seal, even at altitude Designed to fit more than 0 insulation diameters in MIL-Spec wires from #24 to # AWG, and is available in three types First type is made with a nylon ring adapter within the wire entrance Second type, without nylon ring adapters Third type with a nylon ring adapter in one end only Special notch feature on the outside of the splice allows locator in the crimping tool to precisely position splice before crimping and to prevent twisting or horizontal movement during crimping Window area of each splice permits visual inspection of the linear plane of the crimp in relation to the inner metal sleeve Wire-stops in splice barrel indicate exact insertion depth of stripped wireends CERTI-SEAL Terminals and Splices Color Coding. The splice body is color coded by wire size: Tin plated for 24-20, for 22-18, for 1-14, for 12-. The metal rings are color coded green or orange to identify the presence of adapters. Rings. Metal rings at both ends permanently seal the splice to the wire insulation for a moisture tight seal. Adapters. Nylon ring adapter allows for smaller wire insulation diameters. Basic Splice. The basic splice body is constructed of fine grade high conductivity copper per ASTM B-152 and is either color coded or tin-plated per ASTM B-545. Tyco Electronics special plating process creates durable corrosion resistance to salt spray and most chemical fumes.. Nylon insulation assures high dielectric strength. Special notch feature allows crimping tool locator to position the splice to prevent twisting during crimping. CERTI-SEAL Terminals and Splices 57

58 Splice Splices with nylon wire insulation diameter adapters CERTI-SEAL Terminals and Splices (Continued) -Nylon, UL 94V-2 Splice Body -Copper per ASTM B-152 or Zinc Plate/Dye Chromate Application Tooling -shown below L Body Ring Wire Max. Color Color [mm 2 ] Dia. Max. Part Numbers Hand Tool Part No , Tin Plated Green.05 [ ] , Tin Plated Orange.073 [ ] , Green.1 [ ] Green ,180-13, Green.150 [2.2-.4] CERTI-SEAL Terminals and Splices Splices without nylon wire insulation diameter adapters L Body Ring Wire Max. Color Color [mm 2 ] Dia. Max. Part Numbers Hand Tool Part No , Tin Plated Tin Plated.0 [ ] Tin Plated.133 [ ] Tin Plated ,180-13, Tin Plated.218 [2.2-.4] HD Tin Plated Tin Plated Splices with nylon wire insulation diameter adapter in one end L Body Ring Wire Dia. Max. Part Hand Tool [mm 2 Max. Color Color Adapter End Other End Number Part No. ] , Tin Plated Orange & Tin Plated [ ] Tooling Tool Part No or 4074 Tool Part No or Hand tooling features the AMP CERTI-CRIMP ratchet so that the operator fully closes tool so that crimping dies in tool head fully bottom. Locator feature in head assures that splice is properly oriented in tool. CERTI-SEAL Tools do not require wire insulation adjustment prior to crimping. 58

59 Class 1 and Class 2 Military Approvals Approval Dimensional Application Use Performance Requirement Tooling Requirement Terminals must comply Hand application tool For procurement with the dimensional which must conform to by government Class 1 requirements specified the military s dimensional agencies for by the military. and performance maintenance and specification. repair. Terminals must comply The terminal For procurement Per Military with the dimensional manufacturers by contractors Specification requirements specified recommended and Mil-T-7928G by the manufacturer s application tooling. manufacturers Class 2 customer drawing. For field repair purposes Note: Several tape mounted part numbers for high volume production, Class 2 terminals must are currently Class 2 modification, be capable of being approved. and repair. replaced by Class 1 Terminals. Military Specifications MS 2503 MS2503 PIDG Part Numbers AWG Dash Class Stud Size Loose Piece Tape Mounted Numbers & & & & & & 2 5/ / & 2 5/ / & 2 3/ / & 2 3/ / & & & & 2 5/ / & 2 3/ / & & & & & 2 5/ / & 2 5/ / & 2 3/ & 2 3/ /8 Military Approvals 59

60 Class 1 and Class 2 Military Approvals (Continued) Military Specifications MS 2503 (Continued) AWG MS2503 Dash Numbers TERMINYL Part Numbers Loose Piece Tape Mounted Class Stud Size / / / / / / / / / / / / / / / /4 1/ / / /1 2/ / /2 3/ /8 4/ / /2 1 Tyco Electronics recommends #1/0 AWG terminals for #1 AWG application. Military Approvals 0

61 Class 1 and Class 2 Military Approvals (Continued) Military Specifications MS 2503 (Continued) AWG MS2503 Dash Numbers Loose Piece PIDG Part Numbers Tape Mounted Class Stud Size & & & & & & & & & & 2 1/ / & 2 1/ / & 2 1/ & & & 2 1/ / & 2 1/ & & & 2 1/ / & 2 1/ /4 Military Approvals /2 1

62 Class 1 and Class 2 Military Approvals (Continued) Military Specifications M7928/1 M7928/1 PIDG- Restricting AWG Dash Part Numbers Class Stud Size Numbers Loose Piece Tape Mounted Military Approvals & & & & & & & & & & & & & & & & 2 1/ & 2 5/ & 2 3/ & 2 1/ & & & & & & 2 1/ & 2 5/ & 2 3/ & 2 1/ & & & & & & 2 1/ & 2 5/ & 2 3/ & 2 1/ & & & & & & 2 1/ & 2 5/ & 2 3/ & 2 1/2 2

63 Class 1 and Class 2 Military Approvals (Continued) Military Specifications M7928/1 (Continued) M7928/1 PIDG- Restricting AWG Dash Part Numbers Class Stud Size Numbers Loose Piece Tape Mounted & & & & & & 2 1/ & 2 5/ & 2 3/ & 2 1/ & & & & 2 1/ & 2 5/ & 2 3/ / & & & & 2 1/ / & 2 5/ & 2 3/ /2 Military Specifications M7928/4 M7928/4 PIDG PVF 2 AWG Dash Part Numbers Class Stud Size Numbers Loose Piece Tape Mounted & & & & 2 5/ & 2 3/ & & & & 2 5/ & 2 3/ & & & 2 5/ & 2 3/ & & & & & 2 Military Approvals 3

64 Class 1 and Class 2 Military Approvals (Continued) Military Specifications M7928/4 (Continued) M7928/4 PIDG PVF 2 AWG Dash Part Numbers Class Stud Size Numbers Loose Piece Tape Mounted & & & 2 1/ / & 2 1/ & & & 2 1/ & 2 1/ & & 2 1/ /2 Military Approvals Military Specifications M7928/ 5 Military Specifications M7928/ M7928/5 PIDG Window Splice AWG Dash Part Numbers Class Numbers Loose Piece Tape Mounted & & & & & 2 M7928/ PIDG Window Splice PVF 2 AWG Dash Part Numbers Class Numbers Loose Piece Tape Mounted & & & & 2 4

65 Class 1 and Class 2 Military Approvals (Continued) Military Specifications MS MS17143 PIDG AWG Dash Part Numbers Class Stud Size Numbers Loose Piece Tape Mounted & & & & & & & & & & & & & & & & & & & & & 2 4 Military Approvals 5

66 Tooling Tooling Insulated Terminals and Splices 30 to AWG Wire Range Description AMP Wire Range 30-2 Tools for Loose Piece Termination Tools for Tape Mounted Terminations Hand Tools Pneumatic Tools Tape Dies for Tape Dies for Tape Dies for Tape Dies for Tape Dies for Single Multi- Heads for Heads for Dies for AMPOMATOR Wire Wire , AMP-TAPETRONIC AMP-O-LECTRIC AUTO-PRO CLS III G, CLS IV AMP-O-LECTRIC Range Range Single Wire Multi-Wire 935-2, No Applicator Model G Applicator Applicator Model K Range Range , Required Applicator Applicator uses 2-22 Terms PIDG Terminals & Splices and PLASTI-GRIP 1-14 ( exp.) Terminals HD (.300 exp.) 4121 (butt spl. only) 4510 (butt spl. only) (parallel spl. only) Std (.300 exp.) 9872* 9872* 9872* 9872* 9872* * 9873* 9873* 9873* 9873* * 9874* 9874* 9874* 9874* (.300 exp.) (.300 exp.) (.300 exp.) (.300 exp.) (.300 exp.) (butt spl. (butt spl. only) only) PLASTI-GRIP (butt spl. only) 1-14 (butt spl. (butt spl. Splices only) only) (parallel spl. only) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only (butt spl. only) (.300 exp. (butt spl HD (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only) butt spl. only) only) (parallel spl. only) Tooling with adjustable insulation crimp. *Same die set/configuration as in hand tools. 1 TETRA-CRIMP die configuration. 2 PRO-CRIMPER II commercial tool not approved for UL applications hand tool. 4-2 Pneumatic Tool Adapter

67 Insulated Terminals and Splices 8 to 4/0 AWG Wire Range Tools for Loose Piece Terminations Tools for Tape Mounted Terminations Description Wire Hand Tools Dies for Crimp Head Dies for Head for Dies for Dies for AMP- Size Crimp Head Pneumatic AMP-TAPETRONIC TAPETRONIC Machine & Hydraulic Hand Tool 90 1 Hand Tool Machine with & Adjustment PLASTI-GRIP Terminals and Splices / / Terminyl Terminals 1/ and Splices 2/ / / HD Heads for Power Units , , or No insulation crimp. 3 Without insulation crimp. 4 With insulation crimp. Tooling (Continued) Tooling Insulated FASTON Terminals and Splices 2 to AWG Wire Range Tools for Tape Mounted Terminations Tools for Strip Form Terminations Hand Tool Tape Dies for Tape Dies for Tape Dies for AMPOMATOR 9875 AMP-TAPETRONIC AMP-O-LECTRIC 1 AMPOMATOR CLS III G, CLS IV No Applicator Required Model G CLS III G, CLS IV Applicators Applicator Applicator * (Natural) * * *Only UL and CSA approved. 1 AMP-O-LECTRIC Model K uses applicator Die included with applicator. 7

68 Tooling (Continued) Loose Form Terminal and Splice Tooling CERTI-CRIMP Hand Tools Double Action Hand Tool Heavy Head Hand Tool C Head Straight Action Hand Tool Part No PRO-CRIMPER II Hand Tool Part No T-HEAD Tool Part No , Tetra-Crimp Hand Tool Tooling Part No Hydraulic Hand Tools Part No (Dies Required) 8

69 Tooling (Continued) Pneumatic Tools Part No. 935 (Hand Actuation) Part No (Foot Actuation) Part No Crimping Heads Part No ( ) Part No. 90 ( ) Tooling Part No Tool 9

70 Tooling (Continued) Tape Mounted AMP-TAPETRONIC Machine 9875, (Requires Dies) AMP-O-LECTRIC, Model G Machine (Requires Applicator and Dies) Tooling AUTO-PRO Machine (Requires Applicator and Dies) AMPOMATOR CLS IV Machine (Requires Applicator and Dies) 70

71 Part Number Index Note: This index lists all cataloged parts by base no. only. Complete part nos. (with prefixes and/or suffixes) are shown on the page(s) indicated. Part No. Page Part No. Page Part No. Page Part No. Page , 15, , 15, , , 15, , 11, 1, , , , , Part Number Index 71

72 Part Number Index (Continued) Part Number Index Part No. Page Part No. Page Part No. Page , 15, , 1, , 1, , 1, , , , 15, , 15, , 15, , 1, , , Part No. Page , , , , , , , , , , , , , , , , , , , , , , , ,

73 Part Number Index (Continued) Part No. Page Part No. Page Part No. Page , , 15, , 1, Part Number Index 73

74 Americas Argentina Buenos Aires Phone: Fax: Brasil São Paulo Phone: Fax: Chile Santiago Phone: Fax: Contact Us Worldwide Canada Toronto Phone: Fax: Product Information Center: Phone: Fax: Colombia Bogota Phone: Fax: Mexico Mexico City Phone: Fax: For Latin/South American Countries not shown Phone: Fax: United States Harrisburg, PA Phone: Fax: Product Information Center: Phone: Fax: Troy, MI Phone: Fax: Asia/Pacific Australia Sydney Phone: Fax: Product Information Center: Phone: Fax: India Bangalore Phone: Fax: Indonesia Jakarta Phone: Fax: Japan Kawasaki, Kanagawa Phone: Fax: Product Information Center: Phone: Fax: Korea Seoul Phone: Fax: Malaysia Selangor Phone: Fax: New Zealand Auckland Phone: Fax: Philippines Makati City Phone: Fax: People s Republic of China Hong Kong Phone: Fax: Shanghai Phone: Fax: Singapore Singapore Phone: Fax: Taiwan Taipei Phone: Fax: Thailand Bangkok Phone: Fax: Vietnam Ho Chi Minh City Phone: Fax: Global Contacts 74 Europe/Middle East/Africa Austria Vienna Phone: Fax: Product Information Center: Phone: Fax: Belarus Minsk Phone: Fax: Belgium Kessel-Lo Phone: Fax: Bulgaria Sofia Phone: Fax: Czech Republic and Slovakia Czech Republic Kurim Phone: Fax: Product Information Center: Phone: Fax: Denmark Glostrup Phone: Fax: Egypt Cairo Phone: Fax: Estonia Tartu Phone: Fax: Finland Helsinki Phone: Fax: France Cergy-Pontoise Cedex Phone: Fax: Product Information Center: Phone: Fax: France Export Divisions Cergy-Pontoise Cedex Phone: Fax: Germany Bensheim Phone: Fax: Product Information Center: Phone: Fax: Greece Athens Phone: /397 Fax: Hungary Budapest Phone: Fax: Product Information Center: Phone: Fax: Ireland Dublin Phone: Fax: Israel Petach-Tikva Phone: Fax: Italy Collegno (Torino) Phone: Fax: Product Information Center: Phone: Fax: Lithuania and Latvia Lithuania Vilnius Phone: Fax: Product Information Center: Phone: Fax: Netherlands s-hertogenbosch Phone: Fax: Product Information Center: Phone: Fax: Norway Nesbru Phone: Fax: Poland Warsaw Phone: Fax: Product Information Center: Phone: Fax: Romania Bucharest Phone: /359 Fax: Russia Moscow Phone: Fax: Product Information Center: Phone: Fax: Russia St. Petersburg Phone: Fax: Slovenia Ljubljana Phone: Fax: South Africa Port Elizabeth Phone: Fax: Spain Barcelona Phone: Fax: Sweden Upplands Väsby Phone: Fax: Switzerland Steinach Phone: Fax: Turkey Istanbul Phone: /2/ /5430 Fax: Ukraine Kiev Phone: Fax: Product Information Center: Phone: Fax: United Kingdom Stanmore, Middlesex Phone: Fax: Product Information Center: Freephone (UK only): Phone: Fax:

75 Engineering Notes Engineering Notes 75

76 Tyco Electronics Corporation Harrisburg, PA Rev. 7/08 - OG3B