Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR Splices
Product Facts
■
Compression crimp
eliminates cold solder
points, weld burns and wire
embrittlement usually
connected with thermal-type
terminations
■
Excellent tensile strength—
vibration resistant
■
Provides a superior
electrical connection that is
free of many contaminants
such as stripper residue and
solder flux
■
Precision formed, strip-fed
splices terminated in AMP
automatic machines for high
production rates per hour
■
High termination rates, low
wire consumption and the
elimination of rejects
caused by solder flux or
heat damage results in the
lowest applied costs
■
Precisely controlled crimp
termination helps eliminate
human error for maximum
reliability
■
Splice up to 3 magnet wires
together with stranded lead
in one barrel
Applications
■
Motor windings and
connections
■
Coil connections
■
Transformer windings and
connections
■
Solid wire connections
■
Lighting ballasts
■
Power supplies
■
Starters and alternators
Tyco Electronics offers a
full selection of AMP
AMPLIVAR splices that are
specifically designed to
terminate magnet wire to
itself or in combination with
standard solid or stranded
lead wire.
AMPLIVAR splices have
machined, sharp edged
serrations inside the crimp
barrels. These serrations,
made by a special
production process, pierce
the insulating layer of
magnet wires in a manner
that provides a large
contact area.
In a one-step operation the
magnet wire is automatically
multiple ring-stripped of its
insulation as it is forced into
the serrations during the
precisely controlled crimp.
be combined with standard,
pre-stripped solid or
stranded lead wires.
The resulting termination
produces a high tensile
strength, air-sealed
connection that is as
resistant to corrosion as the
insulated conductor.
Depending on your specific
application, AMPLIVAR
splices are available in 5,
7 and 9 serration versions
for terminations in the 100
to 22,000 CMA range as
well as miniature and
subminiature designs for
terminations in the 100 to
1850 CMA range.
As many as three magnet
wires can be terminated
simultaneously in one
splice. In addition, copper
or aluminum magnet wire,
or a combination of both,
can be terminated.
When required, copper or
aluminum magnet wire can
The crimping of AMPLIVAR
splices is done by semiautomatic crimping
machines for high output
per hour production rates.
Stranded Wire
on top
Magnet Wire
on bottom
Section AA
46
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR Splices (Continued)
Test Results
Applicable Types of Wire —
Cu, Al (Solid) together or in
combination with stranded
lead wire
Wire Size Range —
from 300 to 13,000 CMA
(0.1 mm2 to 6.6 mm2)
Terminal Base Material —
Brass, phosphor bronze
Surface Finish — plain and
tin plated except where noted
Temperature Range —
–65°C to +150°C
Rated Current — according
connected wire size
Rated Voltage — according
terminated winding
The AMPLIVAR products have
been subjected to the following
tests without significant millivolt
losses.
Temperature Cycling —
25 cycles with each cycle
consisting of 30 minutes at
+125°C followed by 30 minutes
at –65°C
Heat Age — 96 hours at +150°C
Thermal Shock — 25 cycles
with each cycle consisting of 30
minutes at +150°C followed by
30 minutes at –65°C
Salt Spray — 96 hours at
+35°C with a 5% salt solution
spray
Humidity — 96 hours at
90–95% relative humidity and
+40°C
Current Cycling — 10,000
cycles with each consisting of
3 minutes on and 3 minutes
off at a current (25 A) which
establishes a wire temperature
AMPLIVAR Splices
Technical Features
47
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR Splices (Continued)
General Application Guidelines
Suggested Splice Selection Procedure
To assist you in obtaining the optimum AMPLIVAR
termination, the following guidelines are recommended:
Use the following guide to help you to determine the proper
splice for your application:
1. All magnet wires must be
placed in the bottom of
the wire barrel before
crimping. If lead wire is to
be crimped in the same
termination, it should be
placed on top of the
magnet wires.
1. Use 9-serration splices,
tin plated when
terminating aluminum
magnet wire or
combinations with
aluminum magnet wire.
2. Wire barrels are
designed to accept a
maximum of three
insulated magnet wires
plus stranded lead wires.
3. The ratio of magnet wire
diameters crimped in any
wire barrel should not
exceed 2:1. This ratio is
approximately a range
from the largest to the
smallest magnet wire of
six sizes.
4. The sum of the circular
mil area (CMA) of the
magnet wires and any
lead wires should not
exceed the capacity of
the splice.
5. The sum of the diameters
of the individual magnet
wires plus twice the
terminal stock thickness
must be equal to or less
than the crimp width.
6. Magnet wire of 26 AWG
[0.40 mm] or smaller
should be used with
7-serration splices having
“shallow serrations,” and
magnet wire of 28 AWG
[0.32 mm] or smaller
should be used with
9-serration splices having
“shallow serrations” (part
numbers identified with
asterisk [*] are in the
tabular data on the
following technical
pages).
7. Magnet wire of 20 AWG
[0.81 mm] or larger
having an insulation
thickness heavier than
“single film coated,”
should not be used with
splices having “shallow
serrations” (those part
numbers marked with an
asterisk [*] in the tabular
data on the following
technical pages).
8. When aluminum magnet
wire is used, splices and
terminals must be tin
plated.
9. Consult Tyco Electronics
for splice and terminal
selection and
recommendations for
all non-standard
applications.
2. Use 9-serration splices
for hermetic and severe
environment applications.
3. Use splices identified
with an asterisk [*] when
terminating 7-serration
26 AWG [0.40 mm]
or smaller wires and
9-serration 28 AWG [0.32
mm] or smaller wires.
4. Calculate the total CMA
of the magnet wires plus
any lead wires to be
terminated. Always use
the coated magnet wire
for CMA (see pages
94–96).
5. Calculate the total
magnet wire diameters
(see pages 94 and 95).
6. Select a splice for trial
calculations. It should
have the proper CMA
range. Plating finish
should be considered at
this time.
7. Calculate the sum of the
magnet wire diameters
plus two splice stock
thicknesses. If this total is
less than the crimp width
of the splice selected, it
may be used. If the total
is greater than the crimp
width, a splice with a
greater crimp width must
be selected. Consult
Tyco Electronics for
special wide tooling
recommendations.
Example:
■
Selection of a Pigtail Splice to terminate the following wires:
One 28 AWG [0.32 mm] copper magnet wire.
One 22 AWG [0.64 mm] aluminum magnet wire.
One 18 AWG [0.8–0.9 mm2] 19-strand copper lead wire.
■
■
Calculate the total CMA (Procedure 4):
28 AWG [0.32 mm] coated magnet wire
22 AWG [0.64 mm] coated magnet wire
18 AWG [0.8–0.9 mm2] stranded lead wire
= 185 CMA
= 708 CMA
= 1608 CMA
Total
= 2501 CMA
Calculate the sum of the magnet wire diameters (Procedure 5):
28 AWG [0.32 mm] coated magnet wire
22 AWG [0.64 mm] coated magnet wire
= .0136 [0.35]
= .0266 [0.68]
Total
= .0402 [1.03]
Technical Documents
Select a terminal for trial calculations. Splice No. 62305-2,
page 49 (Procedure 6):
Application Specifications describe requirements for using the
product in its intended application and or crimping information.
They are intended for the Packaging and Design Engineer and the
Machine Setup Person.
CMA range
Stock thickness
Crimp width
■
114-2002
114-2003
114-2005
AMPLIVAR 7Serration Pigtail
Splices
AMPLIVAR 9Serration Pigtail
Splices
AMPLIVAR
Subminiature Thru
Splices
114-2006
114-2009
114-2016
AMPLIVAR
Subminiature Pigtail
Splices
AMPLIVAR 5Serration Thru
Splices
AMPLIVAR
Miniature Pigtail
Splices
= 600–3000
= .016 [0.41]
= .110 [2.79]
9-serration, tin plated for aluminum magnet wire (Procedure 1).
Splice identified with asterisk [*] for 28 AWG [0.32 mm]
(Procedure 3).
■
Calculate the sum of the magnet wire diameters plus two splice
stock thicknesses (Procedure 7):
.0402 + (.016 x 2) = .0722
[1.02 + (0.41 x 2) = 1.84
.0722 [1.84] is less than the splice crimp width of .110 [2.79];
therefore, Part No. 62305-2 may be used.
48
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR Splices (Continued)
9 Serrations —
Pigtail Type
Product Facts
(Plus All 7 Serration Facts)
■
■
■
■
■
AWG/
mm2
24-18.5
0.26-0.80
22-15.5
0.38-1.54
22-15.5
0.38-1.54
18.5-13.5
0.80-2.54
18.5-13.5
0.80-2.54
15.5-12
1.54-3.46
13.5-10
2.54-4.90
12-9
3.46-6.38
10-6.5
4.90-9.45
Serration depths are
varied within the splice
to give optimum electrical/
mechanical performance on
all wire sizes
Serration sidewall angles
are varied to allow better
wire stripping and
serration fill
Flat bottom of splice helps
keep magnet wires on
bottom as required during
crimping
Magnet wires 28 AWG
[0.32 mm] and larger may
be terminated without
requiring shallow serrations
Material
Part
Number
Tin Plated Brass
62303-2*
Tin Plated Brass
62304-2*
Tin Plated Brass
62305-2*
Tin Plated Brass
62306-2*
Tin Plated Brass
62307-2*
Tin Plated Brass
62308-2*
Tin Plated Brass
62309-2*
Tin Plated Brass
62310-2*
Tin Plated Brass
62311-21*
Additional serrations
enhance stability of crimp
■
Taper on both crimper and
anvil improves flex life of
termination
■
Longer “flat” on tooling
improves electrical
performance (.125 vs. .080
[3.18 vs. 2.03])
■
Dim.
L
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.265
6.73
.265
6.73
.265
6.73
.340
8.64
*These splices are recommended for applications using wire size 28 AWG [0.32 mm] or smaller.
Special high force application equipment required.
AWG/
mm2
22-15.5
0.38-1.54
22-15.5
0.38-1.54
22-15.5
0.38-1.54
22-15.5
0.38-1.54
22-15.5
0.38-1.54
18.5-13.5
0.80-2.54
18.5-13.5
0.80-2.54
18.5-13.5
0.80-2.54
15.5-12
1.54-3.46
15.5-12
1.54-3.46
15.5-12
1.54-3.46
12-10
2.10-6.0
12-10
2.10-6.0
12-9
2.10-6.38
Product Facts
■
Crimp
Width
.080
2.03
.110
2.79
.110
2.79
.110
2.79
.110
2.79
.140
3.56
.180
4.57
.180
4.57
.220
5.59
1
7 Serrations —
Pigtail Type
■
Wire Range Wire Range
Stock
Solid Dia.
CMA
Thickness
.020-.039
.016
400-1500
0.55-1.00
0.41
.028-.055
.020
600-3000
0.70-1.40
0.51
.028-.055
.016
600-3000
0.70-1.40
0.41
.039-.071
.020
1500-5000
1.00-1.80
0.51
.039-.071
.016
1500-5000
1.00-1.80
0.41
.055-.083
.020
3000-7000
1.40-2.10
0.51
.071-.098
.025
5000-10,000
1.80-2.50
0.64
.083-.112
.025
7000-13,000
2.10-2.85
0.64
.098-.137
.030
10,000-22,000
2.50-3.47
0.76
AMPLIVAR Splices
■
Splice length is increased
on larger CMA splices for
improved performance
Radius on wire entry end
of splice helps prevent
nicking wires and improves
mechanical performance
Serrations are offset to
sheared end to place
additional serrations in
“electrical” portion of
crimped splice
Splice CMA ranges are
overlapped so that two
splices are available for any
given CMA
Wire Range
Solid Dia.
.028-.055
0.70-1.40
.028-.055
0.70-1.40
.028-.055
0.70-1.40
.028-.055
0.70-1.40
.028-.055
0.70-1.40
.039-.071
1.00-1.80
.039-.071
1.00-1.80
.039-.071
1.00-1.80
.055-.083
1.40-2.10
.055-.083
1.40-2.10
.055-.083
1.40-2.10
.085-.110
2.10-2.85
.085-.110
2.10-2.85
.085-.115
2.10-3.47
Wire Range
CMA
600-3000
600-3000
600-3000
600-3000
600-3000
1500-5000
1500-5000
1500-5000
3000-7000
3000-7000
3000-7000
7000-12,000
7000-12,000
7000-13,000
Stock
Thickness
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.025
0.64
.025
0.64
.025
0.64
Crimp
Width
.110
2.79
.110
2.79
.110
2.79
.110
2.79
.110
2.79
.110
2.79
.110
2.79
.110
2.79
.140
3.56
.140
3.56
.140
3.56
.250
6.35
.250
6.35
.180
4.57
Dim.
L
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
Material
Part
Number
Brass
62000-1*
Brass
62157-1*
Tin Plated Brass
62000-2*
Tin Plated Brass
62157-2*
Tin Plated Brass
62200-21
Brass
62040-2*
Tin Plated Brass
62040-1*
Phosphor Bronze
964156-1
Brass
62001-1*
Tin Plated Brass
62001-2*
Tin Plated Brass
62201-21
Tin Plated Brass
62295-1*
Brass
62295-2*
Tin Plated Brass
62002-2*
*These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller.
Flat bottom.
1
49
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR Splices (Continued)
7 Serrations —
Thru Type
Product Facts
■
L
Crimp bellmouth provides
retention in circular cavity
slot in bobbin
AWG/
mm2
22-15.5
0.38-1.54
Wire Range
Solid Dia.
.028-.055
0.70-1.40
Wire Range
CMA
600-3000
Stock
Thickness
.020
0.51
Crimp
Width
.110
2.79
Dim.
L
.225
5.72
Material
Part
Number
Tin Plated Brass
1217384-1**
*These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller.
5 Serrations —
Thru Type
A
B
Product Facts
■
Wide range of thru splices
■
Serrations centered in splice
to achieve optimum
electrical and mechanical
performance in a thru splice
■
Type
A
CMA range accepts a wide
variety of wire sizes and
combinations
B
AWG/
Wire Range Wire Range
Stock
mm2
Solid Dia.
CMA
Thickness
17-12.5
.045-.075
.020
2000-5400
1.00-2.80
1.15-1.85
0.51
10-8
.100-.125
.032
10,000-16,000
5.00-8.00
2.55-3.20
0.80
10-7.5
.100-.150
.030
10,400-22,900
5.00-11.50 2.60-3.80
0.76
22-15.5
.028-.055
.020
600-3000
0.38-1.54
0.70-1.40
0.51
22-15.5
.028-.055
.020
600-3000
0.38-1.54
0.70-1.40
0.51
22-15.5
.028-.055
.020
600-3000
0.38-1.54
0.70-1.40
0.51
22-15.5
.028-.055
.020
600-3000
0.38-1.54
0.70-1.40
0.51
22-15.5
.028-.055
.020
600-3000
0.38-1.54
0.70-1.40
0.51
18.5-13.5
.039-.071
.020
1500-5000
0.80-2.54
1.00-1.80
0.51
18.5-13.5
.039-.071
.020
1500-5000
0.80-2.54
1.00-1.80
0.51
18.5-13.5
.039-.071
.020
1500-5000
0.80-2.54
1.00-1.80
0.51
18.5-13.5
.039-.071
.020
1500-5000
0.80-2.54
1.00-1.80
0.51
18.5-13.5
.039-.071
.020
1500-5000
0.80-2.54
1.00-1.80
0.51
15.5-12
.055-.083
.020
3000-7000
1.54-3.46
1.40-2.10
0.51
15.5-12
.055-.083
.020
3000-7000
1.54-3.46
1.40-2.10
0.51
15.5-12
.055-.083
.020
3000-7000
1.54-3.46
1.40-2.10
0.51
15.5-12
.055-.083
.020
3000-7000
1.54-3.46
1.40-2.10
0.51
12-10
.083-.110
.025
7000-12,000
3.46-6.00
2.10-2.80
0.64
12-9
.083-.112
.025
7000-13,000
3.46-6.38
2.10-2.85
0.64
12-9
.083-.112
.025
7000-13,000
3.46-6.38
2.10-2.85
0.64
12-9
.083-.112
.025
7000-13,000
3.46-6.38
2.10-2.85
0.64
12-9
.083-.112
.025
7000-13,000
3.46-6.38
2.10-2.85
0.64
Crimp
Width
.110
5.08
.180
4.57
.300
7.62
.110
2.79
.110
2.79
.110
2.79
.110
2.79
.110
2.79
.110
2.79
.110
2.79
.110
2.79
.110
2.79
.110
2.79
.140
3.56
.140
3.56
.140
3.56
.140
3.56
.250
6.35
.180
4.57
.180
4.57
.180
4.57
.180
4.57
Dim.
L
.235
5.97
.267
6.78
.310
7.87
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
.225
5.72
Material
Part
Number
Brass
63564-1
Tin Plated Brass
63561-1
Tin Plated Brass
63562-1
Brass
42076
Brass
42192-1*
Tin Plated Brass
42192-2*
Brass
42778-1*1
Tin Plated Brass
42778-2*1
Brass
41765
Tin Plated Brass
41899
Brass
42119-1*
Brass
42776-1*1
Tin Plated Brass
42776-2*1
Brass
41766
Tin Plated Brass
41900
Brass
42779-11
Tin Plated Brass
42779-21
Tin Plated Brass
61074-11,2
Brass
41770
Tin Plated Brass
41904
Brass
42780-11
Tin Plated Brass
42780-21
* These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller.
Increased terminal pitch.
Increased U-diameter.
1
2
50
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR Splices (Continued)
5 Serrations —
Pigtail Type
Product Facts
■
■
Serration depths are varied
within the splice to give
optimum electrical /
mechanical performance on
all wire sizes
Flat bottom of splice helps
keep magnet wires on
bottom as required during
crimping
L
AWG/
mm2
20-17
0.50-1.00
Wire Range
Solid Dia.
.030-.045
0.80-1.15
Wire Range
CMA
1000-2000
Stock
Thickness
.016
0.41
Crimp
Width
.100
2.54
Dim.
L
.225
5.72
Material
Part
Number
Tin Plated Brass
62670-2*1
*These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller.
Flat bottom.
1
AMPLIVAR Splices
Miniature Splice —
Pigtail Type
Product Facts
■
■
The Miniature AMPLIVAR
splice was developed for
crimping thinner copper
magnet wires having a
diameter between .003 and
.016 [0.08 and 0.40 mm]
and has to be connected
with a stranded conductor
The diameter of one
conductor strand should not
exceed the magnet wire
diameter to be applied
AWG/
mm2
27-21
0.10-0.40
25-18
0.16-0.90
24-18.5
0.20-0.75
24-18.5
0.20-0.75
24-18
0.20-0.80
Wire Range
Solid Dia.
.014-.030
0.35-0.75
.015-.045
0.45-1.10
.020-.039
0.55-1.00
.020-.039
0.55-1.00
.020-.040
0.55-1.00
Wire Range
CMA
AWG/
mm2
30-26
0.05-0.15
24-19
0.26-0.60
24-19
0.26-0.60
Wire Range
Solid Dia.
.010-.015
0.30-0.50
.020-.035
0.55-0.90
.020-.035
0.55-0.90
Wire Range
CMA
200-850
300-1850
480-1500
480-1500
480-1700
Stock
Thickness
.012
0.30
.012
0.30
.014
0.36
.014
0.36
.016
0.41
Crimp
Width
.055
1.40
.070
1.78
.080
2.03
.080
2.03
.070
1.78
Dim.
L
.195
4.95
.195
4.95
.195
4.95
.195
4.95
.195
4.95
Stock
Thickness
.010
0.25
.016
0.41
.016
0.41
Crimp
Width
.042
1.08
.070
1.78
.070
1.78
Dim.
L
.080
2.03
.100
2.54
.100
2.54
Material
Part
Number
Tin Plated Brass
63431-1
Copper-Nickel
61166-1
Tin Plated Brass
62341-1
Brass
62341-2
Brass
62044-1
Material
Part
Number
Tin Plated Brass
63621-2
Tin Plated Brass
62194-2
Gold Plated Brass
62194-4
Subminiature Splice —
Thru or Pigtail Type
Product Facts
■
■
The compactness of these
splices makes them ideal
for use in small subfractional
motors, transformers,
relays, solenoids, indicator
lamps and small appliance
terminations
These splices provide the
same reliability as the
larger AMPLIVAR splices
100-300
400-1300
400-1300
51
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR Terminals
Products Facts
■
Ring tongue terminals
available for 2 to 3/8 stud
diameters
■
FASTON Tab terminals
accept .125 [3.18], .187
[4.75] and .250 [6.35]
receptacle terminals
■
FASTON Receptacle
terminals accept .187 [4.75]
and .250 [6.35] tab
terminals
■
FASTON Stator Receptacle
accept .250 x .032 [6.35 x
0.81] tab terminal
■
Pin receptacle terminals
accept .062 [1.57] and .090
[2.29] diameter pins
Applications
■
Motor windings
■
Transformers
■
Power supplies
■
Starters and alternators
AMPLIVAR magnet wire
terminals are designed to
terminate copper and/or
aluminum magnet wire.
Terminals are insulation
displacing; therefore,
magnet wires do not require
a separate prestripping
operation.
The unique wire barrel
design, with serrations and
burrs, produces a superior
metal-to-metal compression
crimp with excellent tensile
strength.
Terminals are available in a
variety of ring tongue,
FASTON straight, flag and
stator receptacles and tab
quick-disconnect style
terminals.
Direct connection to
magnet wire eliminates the
need for separate stranded
wire terminal connection to
input/output devices.
Product Specifications describe the
product qualification test results
completed by Tyco Electronics for
consideration of product use in a
specific application. They are intended
for the Design and Product Reliability
Engineer.
108-16000 — AMPLIVAR Ring Tongue
Terminals
108-1718 — AMPLIVAR .125 Blade
Terminals [Type A]
Matched with AMP
automated application
tooling allows high
production rates for stripform terminals.
Technical Documents
Application Specifications describe requirements for using the
product in its intended application and or crimping information.
They are intended for the Packaging and Design Engineer and the
Machine Setup Person.
114-2145
114-2146
114-2070
AMPLIVAR .125
Blade Terminals
AMPLIVAR
FASTIN-FASTON
Series 187 Tab
Terminals
AMPLIVAR
FASTON Series
250 Tab Terminals
114-2144
114-2152
AMPLIVAR
FASTON Series
.250 Straight
Receptacle
Terminals
AMPLIVAR Flag
FASTON Series
187 & 250
Receptacle
Terminal
114-2080
114-2128
AMPLIVAR Pin
Receptacle
Terminals [Type A]
AMPLIVAR Stator
Receptacle with
FASTON Mating
End
52
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR Terminals (Continued)
Ring Tongue Terminals
A
Wire Size Range 29–22 AWG [0.287–0.643 mm]
Type
Insulation
Dia. Range
Hole
Dia.
Stud
Size
Stock
Thk.
Material
B
.040-.060
1.02-1.52
.197
5
10
.020
0.51
Tin Plated Brass
W
.342
8.69
Dimensions
L
E
.833 .662
21.16 16.81
C
.312
7.92
W
.342
8.69
.300
7.62
.342
8.69
.300
7.62
Dimensions
L
E
.833 .662
21.16 16.81
.700 .550
17.78 13.97
.833 .662
21.16 16.81
.695 .545
17.65 13.84
C
.312
7.92
.230
5.84
.312
7.92
.230
5.84
Dimensions
W
L
E
.420 .872 .662
10.67 22.15 16.81
.290 .500 .355
7.37 12.7 9.02
.420 .702 .492
10.67 17.83 12.5
.290 .500 .355
7.37 12.7 9.02
C
.312
7.92
.195
4.95
.312
7.92
.195
4.95
Part
Number
63399-1
Wire Size Range 23–19 AWG [0.574–0.912 mm]
B
Type
Insulation
Dia. Range
Hole
Dia.
Stud
Size
Stock
Thk.
B
.100-.140
2.54-3.56
.125-.165
3.18-4.19
.100-.140
2.54-3.56
.125-.165
3.18-4.19
.171
4.34
.171
4.34
.197
5
.197
5
8
.020
0.51
.020
0.51
.020
0.51
.020
0.51
A
B
A
8
10
10
Material
Tin Plated Brass
Tin Plated Brass
Tin Plated Brass
Tin Plated Brass
Part
Number
60321-2
60323-2
60319-2
60325-2
Wire Size Range 22–18 AWG [0.643–1.024 mm]
C
Insulation
Dia. Range
Hole
Dia.
B
.125-.165
3.18-4.19
E
—
C
—
.265
6.73
.145
3.58
.265
6.73
.171
4.34
E
—
Stud
Size
1/4
6
1/4
8
Stock
Thk.
.025
0.64
.025
0.64
.025
0.64
.025
0.64
Material
Tin Plated Brass
Tin Plated Brass
Tin Plated Brass
Brass
Tin Plated Brass
Part
Number
63612-1
63649-1
AMPLIVAR Terminals
Type
62835-1
63446-1
63446-2
Wire Size Range 20–16 AWG [0.813–1.29 mm]
D
E
Type
Insulation
Dia. Range
Hole
Dia.
Stud
Size
A
.125-.165
3.18-4.19
.171
4.34
8
H
—
—
8
L
—
—
3/8
M
—
—
3/8
B
.243
[6.15]
.020
0.51
.020
0.51
.020
0.51
.020
0.51
Material
Tin Plated Brass
Brass
Brass
Brass
W
.300
7.62
.340
8.64
.625
15.88
.645
16.38
Dimensions
L
E
C
.695 .545 .230
17.65 13.84 5.84
1.220 .660 .500
30.98 16.76 12.7
.939 .627 .467
23.85 15.93 11.86
.950 .627 .467
24.12 15.93 11.86
W
.342
8.69
.342
8.69
.342
8.69
.370
9.4
.365
9.27
Dimensions
L
E
.833 .662
21.16 16.81
.833 .662
21.16 16.81
.833 .662
21.16 16.81
.915 .730
23.24 18.54
.882 .700
22.4 17.78
C
.312
7.92
.312
7.92
.312
7.92
.380
9.65
.380
9.65
W
.310
7.87
.310
7.87
Dimensions
L
E
.692 .505
17.58 12.83
.692 .505
17.58 12.83
C
.312
7.92
.312
7.92
Part
Number
060322-2
505071-1
505075-1
505072-1
Wire Size Range 18–14 AWG [1.024–1.628 mm]
Type
F
Stock
Thk.
D
1High
Insulation
Dia. Range
Hole
Dia.
.100-.140
2.54-3.56
.100-.140
2.54-3.56
.100-.140
2.54-3.56
.080-.120
2.03-3.05
.080-.120
2.03-3.05
.171
4.34
.171
4.34
.197
5
.173
4.39
.185
4.7
Stud
Size
8
8
10
8
8
Stock
Thk.
.020
0.51
.020
0.51
.020
0.51
.028
0.71
.028
0.71
Material
Brass
Tin Plated Brass
Brass
Lu-Bronze1
Lu-Bronze1
Part
Number
060320-1
060320-2
060318-1
485079-1
485044-1
conductivity copper-tin-zinc alloy.
Wire Range 17–13.5 AWG [1.151–1.78 mm]
Type
Insulation
Dia. Range
Hole
Dia.
Stud
Size
—
—
8
—
—
8
F
G
Stock
Thk.
.020
0.51
.020
0.51
Material
Brass
Tin Plated Brass
Part
Number
63147-1
63147-2*
*Available on request
.243
[6.15]
Wire Size Range 14–12 AWG [1.628–2.05 mm] or (2) 15 AWG [1.45 mm]
Type
Insulation
Dia. Range
Hole
Dia.
Stud
Size
Stock
Thk.
Material
G
—
—
8
.025
0.64
Brass
W
.342
8.69
Dimensions
L
E
C
.945 .750 .570
24.00 19.05 14.48
Part
Number
062755-1
53
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR Terminals (Continued)
Stud Retaining Terminals
H
Wire Size Range 13–11 AWG [1.83–2.3 mm]
Type
Insulation
Dia. Range
Hole
Dia.
Stud
Size
Stock
Thk.
Material
A
.085-.150
2.16-3.81
.180
4.57
.180
4.57
.197
5.00
8
.025
0.64
.025
0.64
.025
0.64
Brass
—
45°
C
—
J
8
10
Tin Plated Brass
Tin Plated Brass
Dimensions
L
E
.833 .662
21.16 16.81
.665 .495
16.89 12.57
.665 .495
16.89 12.57
C
.312
7.92
.312
7.92
.312
7.92
W
.340
8.64
Dimensions
L
E
.955 .660
24.26 16.76
C
.500
12.7
505044-1
W
Dimensions
L
E
C
Part
Number
W
.342
8.69
.342
8.69
.342
8.69
Part
Number
061710-1
350571-1
640212-1
Wire Range (1) 18 AWG [1.024 mm] and (1) 20.5 AWG [0.768 mm]
45°
Type
Insulation
Dia. Range
Hole
Dia.
Stud
Size
Stock
Thk.
Material
J
—
—
8
.020
0.51
Brass
Part
Number
Wire Range (2) 17 AWG [1.51 mm] or (2) 15 AWG [1.45 mm]
K
Type
Insulation
Dia. Range
B
.150-.190
or (2) .115
3.18-4.83
or (2) 2.92
.150-.190
or (2) .115
3.18-4.83
or (2) 2.92
Hole
Dia.
Stud
Size
Stock
Thk.
Material
.171
4.34
8
.025
0.64
Tin Plated Brass
.342
8.69
.827 .656
21.01 16.66
.312
7.92
60752-2
.197
5.00
10
.025
0.64
Tin Plated Brass
.342
8.69
.827 .656
21.01 16.66
.312
7.92
61151-1
W
.340
8.64
Dimensions
L
E
1.220 .660
30.99 16.76
C
.500
12.7
W
.240
6.1
.240
6.1
Dimensions
L
E
.620 .500
15.75 12.7
.620 .500
15.75 12.7
C
.165
4.19
.165
4.19
W
.342
8.69
Dimensions
L
E
.827 .656
21.00 16.66
C
.312
7.92
L
.376
[9.55]
Wire Range 16–13.5 AWG [1.29–1.78 mm]
.388
[9.85]
Type
Insulation
Dia. Range
Hole
Dia.
Stud
Size
Stock
Thk.
Material
K
—
—
10
.020
0.51
Brass
Material
Part
Number
505079-1
M
Wire Range 14.5 AWG [1.539 mm]
Type
Insulation
Dia. Range
Hole
Dia.
Stud
Size
Stock
Thk.
—
—
2
—
—
2
.025
0.64
.025
0.64
N
Tin Plated Brass
Brass
Part
Number
505036-1
505036-3
Wire Range (2) 13 AWG [1.83 mm]
Alternator Eyelet Terminal
N
Type
Insulation
Dia. Range
Hole
Dia.
Stud
Size
Stock
Thk.
Material
B
.150-.190
3.81-4.83
.171
4.34
8
.025
0.64
Tin Plated Brass
Part
Number
63864-1
54
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR Terminals (Continued)
A
125 Series Blade
B
Stock Thickness
A = .013 [0.33]
B = .020 [0.51]
.330
[8.38]
.125
[3.18]
.810
[20.57]
.020
[.508]
Mates with Power Blade Receptacle
terminals 61603-1, 61604-1, 770642-1
and 1217039-1
Type
AWG
27-20.5
Housings
A
Contact Tyco Electronics Engineering for
housing options available
24-18
18.5-13.5
27-20.5
B
24-18
18.5-13.5
.940
[23.88]
.370
[9.40]
.020
[.508]
Magnet Wire Range
mm2
Solid Dia.
.015-.030
0.10-0.45
0.35-0.75
.020-.040
0.2-0.8
0.50-1.00
.040-.070
0.75-2.5
0.50-1.80
.015-.030
0.10-0.45
0.35-0.75
.020-.040
0.2-0.8
0.50-1.00
.040-.070
0.75-2.5
0.50-1.80
Material
Material
Thickness
200-850
Tin Plated Brass
400-1600
Tin Plated Brass
1500-5000
Tin Plated Brass
200-850
Tin Plated Brass
400-1600
Tin Plated Brass
1500-5000
Tin Plated Brass
.013
0.33
.013
0.33
.016
0.41
.013
0.33
.020
0.51
.020
0.51
CMA
A
Part
Number
63871-1
63889-1
63870
1217072-1
1217029-1
1217073-1
AMPLIVAR Terminals
187 Series FASTON Tabs1
.125
[3.18]
B
Board Thickness
A = .062–.072 [1.57–1.83]
Stock Thickness
A = .020 [0.51]
B = .032 [0.81]
Type
B
Wire Range
AWG
mm2
Dim.
L
Material
27-23
0.1-0.2
Tin Plated Brass
24-21
0.2-0.4
Tin Plated Brass
22-16
0.3-1.4
Tin Plated Brass
15-13
1.6-2.6
Tin Plated Brass
15-12
1.6-3.0
Tin Plated Brass
.935
23.75
.935
23.75
1.015
25.78
.935
23.75
1.015
25.78
A
2
†
Part
Number
63484-12
61440-3†
62447-1
61442-3†
62445-1
Varnish resist coating.
These part numbers are available upon special request, contact Tyco Electronics Engineering for details.
250 Series FASTON Tabs1
Stock Thickness
.032 [0.81]
Wire Range
AWG
mm2
14-12
2.0-3.0
Material
Part
Number
Quick-Change
Applicator3
Tin Plated Brass
62922-12
466510-1
Varnish resist coating.
3 Quick-Change Applicator for AMP-O-LECTRIC Machine 565435-5. For AMPOMATOR Machine and other machines
not listed, contact Tyco Electronics.
2
1Mates
with FASTON receptacles.
See AMP Catalog 82004.
55
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR Terminals (Continued)
250 Series FASTON Tabs1
(Continued)
Stock Thickness
.032 [0.81]
1
Mates with FASTON receptacles.
See AMP Catalog 82004.
Wire Range
AWG
mm2
Material
28-23.5
0.08-0.2
Tin Plated Brass
25-19.5
0.16-0.6
Tin Plated Brass
23-19
0.2-0.6
Tin Plated Brass
Dimensions
L
E
.580
.342
14.73
8.69
.650
.450
16.51
11.43
.225
.583
5.72
14.81
W
.250
6.35
.250
6.35
.250
6.35
T
Part
Number
45°
63136-1
30°
63140-1
15°
63165-1
Part
Number
Applicator
No.
250 Series FASTON
Receptacles1
.280
[7.11]
.690
[17.53]
Stock Thickness
.016 [0.41]
1
.290
[7.37]
Mates with FASTON tabs.
See AMP Catalog 82004.
Magnet Wire Range
CMA
mm2 Dia.
Insulation
Diameter
Mating
Tab Thk.
Material
Material
Thickness
24-19
0.51-0.98
.050-.080
1.30-2.00
.020
0.51
Brass
Tin Plated Brass
.016
0.41
63623-11
63623-21
567451-22
23-19 or
(2) 24 or
(2) 26
20-16 or
(2) 23 or
(2) 20
0.60-0.98 or
(2) 0.57 or
(2) 0.45
0.85-1.37 or
(2) 0.63 or
(2) 0.88
.050-.100
1.30-2.55
.025
0.64
Brass
.016
0.41
62069-1
567343-22
.032
[0.81]
Brass
Tin Plated Brass
.016
0.41
60384-1
60384-2
466010-12
20-16
0.85-1.37
.020
0.51
Brass
.016
0.41
62080-1
466010-12
18-14 or
(2) 17
1.02-1.71
.100-.140 or
(2) .060 Max.
2.55-3.55
.100-.140
2.55-3.55
.120-.170 or
(2) .060 Max.
3.05-4.30
.120-.170
3.05-4.30
.120-.170
3.05-4.30
.032
[0.81]
Tin Plated Brass
.016
0.41
60385-2
466816-12
63622-11
466816-12
1217835-11
466816-12
18-14 or
(2) 19
18-14 or
(2) 19
1
2
1.02-1.71
1.02-1.71
.020
0.51
.020
0.51
Brass
Brass
.016
0.41
.016
0.41
Low insertion force
Quick-Change Applicator for AMP-O-LECTRIC Machine 565435-5.
56
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR Terminals (Continued)
187 Series FASTON Flag
Receptacles
Stock Thickness
.045
[1.14]
.016 [0.41]
.240
[6.10]
.232
[5.89]
Magnet Wire Range
CMA
mm2 Dia.
1
0.56-0.79
24-20 AWG
0.51-0.81
1500-2350
0.99-1.22
2000-4050
1.14-1.63
2000-4050
1.14-1.63
Insulation
Diameter
Mating
Tab Thk.
Material
Material
Thickness
.020-.040
0.51-1.02
.020-.040
0.51-1.02
.020-.040
0.51-1.02
.020-.040
0.51-1.02
.020-.040
0.51-1.02
.020
0.51
.032
0.81
.020
0.51
.020
0.51
.032
0.81
Tin Plated Brass
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.016
0.41
Tin Plated Brass
Tin Plated Brass
Tin Plated Brass
Tin Plated Brass
Part
Number
Applicator
No.
63942-1
566411-11
1217624-1
566411-11
63941-1
566410-11
63940-1
680353-32
1217417-1
680353-32
Standard Applicator for “G” Splice Terminator No. 356462-2.
Quick-Change Applicator for “G” Splice Terminator No. 356462-1.
AMPLIVAR Terminals
2
500-960
.4.35
[11.05]
250 Series FASTON Flag
Receptacles
Stock Thickness
.018 [0.45]
.070
[1.78]
.305
[7.75]
.600
[15.24]
.300
[7.62]
1
Pin Receptacles
Magnet Wire Range
CMA
mm2 Dia.
Insulation
Diameter
Mating
Tab Thk.
Material
Material
Thickness
Part
Number
Applicator
No.
16-12
.120-.170
3.05-4.32
.032
0.81
Tin Plated
Phos Bronze
.018
0.45
63944-1
680421-31
1.29-2.13
Quick-Change Applicator for ”G” Splice Terminator No. 356462-1.
A
B
Stock Thickness
.016 [0.41]
Type
A
B
Wire Range
AWG
mm2
29-22
21-16
0.07-0.3
0.4-1.4
Insulation
Dia. Range
Material
.040-.060
1.02-1.52
Tin Plated Brass
—
Tin Plated
Phos. Bronze
Dimensions
W Max.
L
.084
.590
2.13
14.99
.235
.660
5.97
16.76
C
.195
4.95
.250
6.35
Part
Number
63506-1
60177-2
57
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR Terminals (Continued)
250 Series Stator
Receptacles —
7 Serrations
.070
[1.78]
.860
[21.84]
.305
[7.75]
.300
[7.62]
AWG
27-22
21-15
22-15.5
Magnet Wire Range
mm2
Solid Dia.
CMA
.014-.026 200-700
0.10-0.3
0.35-0.66
.028-.060 800-3600
0.4-1.6
0.71-1.52
.053-.086 2800-7400
0.3-1.5
1.35-2.18
Mating Tab
Thickness
Stock
Thickness
Crimp
Width
.032
0.81
.032
0.81
.032
0.81
.018
0.44
.018
0.44
.018
0.44
.070
1.77
.110
2.79
.155
3.94
Material
Part
Number
Tin Plated Brass
63480-1
Tin Plated Brass
62381-1
Tin Plated Brass
63964-1
Stator Terminal —
Receptacle
.250 x .032 [6.35 x 0.81]
➀
➁
Stator Terminal with
Receptacle .250 x .032
[6.35 x 0.81]
Plastic Cavity
➂
For design and
material selection
Tyco Electronics
Engineering has to be
contacted before
decision.
The terminal is
separated from the strip
and placed automatically into the cavity.
The magnet wire is
positioned via posts
into the AMPLIVAR
crimp barrel and fixed
inside clamping barrel.
➀
Production only
according to
Tyco Electronics
Specifications (Contact
Tyco Electronics
Engineering for details).
Wire Clamping Barrel
➃
➂
AMPLIVAR Crimp
The AMP application
equipment crimps the
AMPLIVAR connection
and cuts the extending
clamping barrel in one
operation.
➃
➁
Additional versions
upon request.
Application Tooling
for Production Line
Integrating available
upon request.
58
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
Cluster Blocks
Product Facts
Pin receptacle terminals
available in tin-plated
phosphor bronze
■
Versions available to accept
.090 [2.29] and .125 [3.18]
header pins
■
Accepts wire range 18–16
AWG [0.8–1.4 mm2] and
14–12 AWG [2.0–3.0 mm2]
■
Thermoplastic polyester
housing
■
Impervious to many oils and
refrigerants
■
Insulation compatibility
■
Housings available to
accept standard and
reversed header pin layouts
■
High-performance electrical
and mechanical contact
■
High-impact resistance
housings
■
Assemblies accept pins
from one side only to
prevent reversed polarity
■
High-speed application of
pin receptacle terminals
with AMP automatic
terminating machines and
quick-change applicators for
high volume production
rates at the lowest
installed cost
■
Pin receptacle terminals are
easily removed from the
housing for maintenance
and repair
■
Recognized under the
Component Program of
Underwriters
Laboratories Inc.,
File No. E28476
R
Tyco Electronics features
AMP Cluster Blocks that
offer manufacturers of
air conditioning and
refrigeration products a
low-cost, fully insulated,
quick-connect means for
electrically connecting
sealed hermetic header
pins on compressors.
Cluster Blocks feature high
impact resistance to shock
and abuse, and long-life
performance in the
presence of oils and
refrigerants. Since the
connectors accept pins
from only one side, the
danger of reversing polarity
at the time of installation is
prevented.
The one-piece housings are
molded from thermoplastic
polyester. The connector
accepts .090 [2.29] and
.125 [3.18] diameter pin
sizes in either standard or
reverse pin layouts.
Housings accept both lead
wire and AMPLIVAR direct
connect pin receptacle
Cluster Blocks
■
terminals made from
phosphor bronze material.
These are precision formed
and available on reels for
high-speed application.
High retention pin
receptacle terminals are
available to provide
optimum terminal retention
in housings.
Pin Receptacle Terminal
(Crimped to Wire)
Typical Assembly
59
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
Cluster Blocks .090 [2.29] Pin Size (Lead Wire)
Housings
K
W
K
.530
Dia.
[13.46]
H
.229
[5.82]
H
L
.090 ± .001
[2.29 ± 0.03]
Pin Dia.
3 Plcs.
.459
[11.66]
W
A
B
Pin Location
A and B
.108
[2.74]
L
W
.108
[2.74]
.683
Dia.
[17.35]
H
.324
[8.23]
L
K
.108
[2.74]
.108
[2.74]
.090 ± .001
[2.29 ± 0.03]
Pin Dia.
4 Plcs.
.324
[8.23]
C
.324
[8.23]
Pin Header Pin
Type Center
Position
Circle Dia.
.530
Forward
13.46
.530
A
Forward
13.46
.530
Forward
13.46
.530
Back
13.46
B
.530
Back
13.46
.683
C
—
17.35
Pin Location
C
Dim.
L
1.245
31.60
1.240
31.50
1.220
31.00
1.225
31.10
1.200
30.50
1.490
37.85
Dim.
W
.710
18.05
.710
18.05
.695
17.65
.810
20.55
.695
17.65
.900
22.85
Dim.
H
.355
9.00
.320
8.15
.260
6.60
.320
8.15
.310
7.85
.355
9.00
Dim.
K
.850
21.60
.840
21.35
.820
20.85
.840
21.35
.805
20.40
.845
21.45
Material
PBT Polyester
15% Glass Reinforced
PBT Polyester
15% Glass Reinforced
PBT Polyester
15% Glass Reinforced
PBT Polyester
15% Glass Reinforced
PBT Polyester
Non-Reinforced
PBT Polyester
15% Glass Reinforced
Pin Receptacles
A
A
B
—
—
—
360033-1
281006-0
1217262-1
.115
[2.92]
.115
[2.92]
CMA
521078-1
.180
[4.57]
.180
[4.57]
Wire Range
Solid Dia.
.025-.065
0.65-1.65
.040-.050
1.00-1.30
.040-.050
1.00-1.30
360050-1
.313
[7.95]
.313
[7.95]
AWG/
mm2
22-14
0.3-2.0
18-16
0.8-1.4
18-16
0.8-1.4
1217263-1
.670
[17.02]
.670
[17.02]
Type
Part
Number
Crimp
Width
.100
2.54
.110
2.79
.110
2.79
B
Insulation
Diameter
.080-.150
2.00-3.80
.060-.100
1.50-2.55
.090-.170
2.30-4.30
Crimp
Width
.130
3.30
.140
3.56
.180
4.57
Stock
Thickness
.016
0.41
.016
0.41
.016
0.41
Material
Part
Number
Tin Plated Phos Bronze
1217264-1
Tin Plated Phos Bronze
62131-3
Tin Plated Phos Bronze
63448-1
60
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
Cluster Blocks .125 [3.18] Pin Size (Lead Wire and Direct Connect)
Housings
W
K
W
K
H
.530
Dia.
[13.46]
H
L
.229
[5.82]
L
.125 ± .001
[3.18 ± 0.03]
Pin Dia.
3 Plcs.
.459
[11.66]
A
B
Pin Location
A and D
W
W
Cluster Blocks
.687
Dia.
[17.45]
K
H
H
.125 ± .001
[3.18 ± 0.03]
Pin Dia.
3 Plcs.
.297
[7.55]
K
L
L
.595
[15.12]
Pin Location
B
C
.815
Dia.
[20.70]
Type
A
B
.353
[8.96]
.706
[17.92]
Pin Location
C
.125 ± .001
[3.18 ± 0.03]
Pin Dia.
3 Plcs.
C
D
Center Pin Header Pin
Position
Circle Dia.
.530
Forward
13.46
.530
Forward
13.46
.687
Forward
17.45
.687
Forward
17.45
.815
Forward
20.70
.530
Back
13.46
.530
Back
13.46
.687
Back
17.45
D
Dim.
L
1.755
44.60
1.755
44.60
1.730
43.95
1.595
40.50
1.975
50.15
1.860
47.25
1.755
44.60
1.850
47.00
Dim.
W
.765
19.45
.765
19.45
.895
22.75
.895
22.75
1.015
25.80
.765
19.45
.765
19.45
.895
22.75
Dim.
H
.525
13.35
.470
11.95
.615
15.60
.380
9.65
.590
15.00
.525
13.35
.470
11.95
.615
15.60
Dim.
K
1.230
31.25
1.230
31.25
1.080
27.45
1.080
27.45
1.050
26.65
1.225
31.10
1.225
31.10
1.225
31.10
Material
PBT Polyester
15% Glass Reinforced
PBT Polyester
15% Glass Reinforced
PBT Polyester
15% Glass Reinforced
PBT Polyester
15% Glass Reinforced
PBT Polyester
Non-Reinforced
PBT Polyester
15% Glass Reinforced
PBT Polyester
15% Glass Reinforced
PBT Polyester
15% Glass Reinforced
Part
Number
1217181-1
360052-1
1217186-1
520995-1
1217261-1
1217200-1
360051-1
1217187-1
61
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
Cluster Blocks .125 [3.18] Pin Size (Lead Wire and Direct Connect) (Continued)
Pin Receptacles
.805
[20.45]
.805
[20.45]
.400
[10.16]
.400
[10.16]
.240
[6.10]
.240
[6.10]
.160
[4.06]
.160
[4.06]
A
B
Lead Wire
Lead Wire
.870
[22.1]
.870
[22.1]
.400
[10.16]
.400
[10.16]
.240
[6.1]
.240
[6.1]
.160
[4.06]
.160
[4.06]
Type
A
B
AWG/
mm2
18-16
0.8-1.4
18-16
0.8-1.4
14-10
2.0-6.0
18-16
0.8-1.4
14-10
2.0-6.0
—
—
—
C
—
—
—
—
—
—
—
D
—
—
—
Wire Range
Solid Dia.
.040-.050
1.00-1.30
.040-.050
1.00-1.30
.065-.100
1.60-2.60
.040-.050
1.00-1.30
.065-.100
1.60-2.60
.020-.040
0.50-1.00
.020-.040
0.50-1.00
.040-.065
1.00-1.65
.040-.065
1.00-1.65
.065-.090
1.65-2.30
.065-.090
1.65-2.30
.065-.090
1.65-2.30
.020-.040
0.50-1.00
.020-.040
0.50-1.00
.040-.065
1.00-1.65
.040-.065
1.00-1.65
.065-.090
1.65-2.30
.065-.090
1.65-2.30
C
D
AMPLIVAR Direct Connect
AMPLIVAR Direct Connect
CMA
—
—
—
—
—
400-1600
400-1600
1500-4200
1500-4200
4000-8500
4000-8500
4000-8500
400-1600
400-1600
1500-4200
1500-4200
4000-8500
4000-8500
Crimp
Width
.110
2.79
.110
2.79
.140
3.56
.110
2.79
.140
3.56
.090
2.27
.090
2.27
.110
2.79
.110
2.79
.140
3.56
.140
3.56
.160
4.06
.090
2.27
.090
2.27
.110
2.79
.110
2.79
.140
3.56
.140
3.56
Insulation
Diameter
.090-.130
2.30-3.30
.090-.130
2.30-3.30
.130-.170
3.30-4.30
.090-.130
2.30-3.30
.130-.170
3.30-4.30
.060-.100
1.50-2.55
.060-.100
1.50-2.55
.075-.125
1.90-3.20
.075-.125
1.90-3.20
.090-.170
2.30-4.30
.090-.170
2.30-4.30
.090-.170
2.30-4.30
.060-.100
1.50-2.55
.060-.100
1.50-2.55
.075-.125
1.90-3.20
.075-.125
1.90-3.20
.090-.170
2.30-4.30
.110-.150
2.80-3.80
Crimp
Width
.155
3.94
.155
3.94
.180
4.57
.155
3.94
.170
4.32
.140
3.56
.140
3.56
.155
3.94
.155
3.94
.170
4.32
.170
4.32
.170
4.32
.140
3.56
.140
3.56
.155
3.94
.155
3.94
.170
4.32
.170
4.32
Stock
Thickness
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
Part
Number
Material
Tin Plated Phos Bronze
62244-3
Phos Bronze
62244-5
Tin Plated Phos Bronze
62243-3
Tin Plated Phos Bronze
1217176-1
Tin Plated Phos Bronze
1217175-1
Tin Plated Phos Bronze
63908-1
Tin Plated Phos Bronze
63453-1
Tin Plated Phos Bronze
63907-1
Tin Plated Phos Bronze
63454-1
Tin Plated Phos Bronze
63906-1
Tin Plated Phos Bronze
63455-1
Tin Plated Phos Bronze
1217122-1
Tin Plated Phos Bronze
1217670-1
Tin Plated Phos Bronze
1217172-1
Tin Plated Phos Bronze
1217671-1
Tin Plated Phos Bronze
1217174-1
Tin Plated Phos Bronze
1217672-1
Tin Plated Phos Bronze
1217173-1
62
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR and Cluster Blocks Application Tooling
AMPLIVAR Product
Terminator (APT)
Product Facts
■
No need to strip magnet
wire
■
Connects up to 3 wires in
1 splice
■
Crimp Quality Monitor
(CQM) system measures
crimp heights
■
Machine shut height easily
adjusts in .0005 [0.013]
increments
■
Quick-change tooling without major shut-height
adjustments
Specifications
APT III A
For pigtail splices or direct
connection of contacts to
magnet wire, the AMPLIVAR
Product Terminator (APT)
and strip-form AMPLIVAR
products offer a fast and
efficient system, with no
need to strip mag-wire
insulation. To apply a splice
or contact, simply place the
wires in the target area and
depress the foot switch. The
machine automatically
shears the splice or contact
from the strip, crimps it,
shears off excess wire, and
advances the next splice or
contact into position.
APT semi-automatic bench
machines are available in
two versions: the IIIA with
automatic precision
adjustment controlled by
the Crimp Quality Monitor
(CQM), and the IIE with
manual precision
adjustment.
With CQM, the APT IIIA
assists in achieving 6-sigma
processing capability. In
addition to providing 100%
inspection and automatic
adjustment of crimp heights
as needed, the CQM also
evaluates the quality of
each crimp. If a
questionable crimp is
detected, visual and
audible alarms alert the
operator.
For operations with multiple
wire sizes, the APT IIIA
provides programmable
sequencing of different
crimp-height settings, and
it can store up to 2,000
different programs of 7
different settings each. The
maximum time to autoadjust between
programmed crimp heights
is 2 seconds.
The lower cost, manual
adjust IIE is a simpler
version without CQM
capability, with the
advantage of faster set-up
times.
AMPLIVAR and Cluster Blocks
Application Tooling
Weight — Approximately 150 lb
[68 kg] with CQM
Width — 38 [965] with CQM and
product reel
Depth — 35 [889]
Height — 14 [356]
Electrical — 120 VAC, 60 Hz, 1 A, 1f,
or 240 VAC, 50 Hz, .5 A, 1f
Air — 80-100 psi [5.52-7.59 bar],
22 scfm [0.000141 m3/s]
To avoid the need to
change product reels when
wire combinations are
smaller than the CMA range
of the splice or contact, an
optional stuffer (part no.
679323-1 for APT IIIA, part
no. 679323-2 for APT IIE.)
inserts a stuffer wire into
the splice or contact prior
to crimping, increasing
the total CMA to the
recommended range. The
wire stuffer unit is for pigtail
splices only.
APT III A with vertical base
(679984-1) for direct connect
terminals
APT II E
63
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR and Cluster Blocks Application Tooling (Continued)
AMPLIVAR Product
Terminator (APT) (Continued)
Machine Ordering Information
A “Base Part Number” is
selected from the Basic
Machine Part Numbers
table. Then, a dash number
or numbers are selected
from one of the other two
tables depending on the
type of product to be
applied.
Note: The wire stuffer is
available for Pigtail-Type
Splice only and may be
added to the machine after
installation.
679323-1 — APT IIIA
679323-2 — APT IIE
Basic Machine Part Numbers
Machine Features
Precision
Adjust
Crimp Quality
Monitor
Manual
Automatic
Not included
Included
Programmable
Crimp-Height
Sequencing
Not included
Included
Model
APT IIE**
APT IIIA
Base Part Number*
Direct
Connect
Contact
"-1338906- " "-1338907- "
"-679453- "
"-679457- "
Pigtail-type
Splice
*See tables below for suffix and prefix dash numbers which indicate product to be applied, product crimp width, and
voltage requirement.
**Not upgradable to an APT IIIA
AMPLIVAR Pigtail-Type Splice Suffix and Prefix Dash Numbers
(Aluminum base 679984-1 not included)
Pigtail-type
Splice
Base Number
42775
42776
42777
42778
42779
62000
62001
62001
62201
62002
62040
62157
62200
62295
62303
62304
62305
62306
62306
62307
62308
62308
62309
62309
62310
62310
280002
280004
964156
Crimp
Width
120/240 VAC
IIE Machine
120/240 VAC
IIIA Machine
"-1338906-"
"-679453-"
.110 [2.79]
1-( )-1
3-( )-7
.110 [2.79]
1-( )-2
3-( )-8
.140 [3.56]
.110 [2.79]
.140 [3.56]
.180 [4.57]
.140 [3.56]
.180 [4.57]
.110 [2.79]
( )-8
1-( )-2
( )-7
( )-6
( )-8
( )-3
1-( )-1
3-(
3-(
3-(
3-(
3-(
2-(
3-(
.110 [2.79]
1-( )-2
3-( )-8
.250 [6.35]
.080 [2.03]
( )-1
1-( )-3
2-( )-7
3-( )-9
)-4
)-8
)-3
)-2
)-4
)-9
)-7
.110 [2.79]
1-( )-2
3-( )-8
.140 [3.56]
1-( )-0
3-( )-6
.110 [2.79]
1-( )-1
3-( )-7
.140 [3.56]
.180 [4.57]
.220 [5.59]
.180 [4.57]
.220 [5.59]
.180 [4.57]
.110 [2.79]
.110 [2.79]
.110 [2.79]
( )-9
( )-6
5-( )-4
( )-5
( )-2
( )-4
1-( )-1
1-( )-2
1-( )-1
3-(
3-(
5-(
3-(
2-(
3-(
3-(
3-(
3-(
)-5
)-2
)-3
)-1
)-8
)-0
)-7
)-8
)-7
AMPLIVAR Direct Connect Contact Suffix and Prefix Dash Numbers
(Aluminum base 679984-1 included)
Extraction Tool
Part No. 274186-1
Direct Connect
Contact
Base Number
63453
63454
63455
63548
63549
63906
63907
63908
1217122
1217172
1217173
1217174
1217670
1217671
1217672
Crimp
Width
.090 [2.286]
.110 [2.79]
.140 [3.56]
.090 [2.286]
.110 [2.79]
.140 [3.56]
.110 [2.79]
.090 [2.286]
.160 [4.064]
.090 [2.286]
.140 [3.56]
.110 [2.79]
.090 [2.286]
.110 [2.79]
.140 [3.56]
120/240 VAC
IIE Machine
120/240 VAC
IIIA Machine
"-1338907-"
"-679457-"
( )-3
( )-2
( )-1
( )-5
( )-4
( )-1
( )-2
( )-3
1-( )-1
( )-3
( )-1
( )-2
( )-3
( )-2
( )-1
( )-8
( )-7
( )-6
1-( )-0
( )-9
( )-6
( )-7
( )-8
1-( )-2
( )-8
( )-6
( )-7
( )-8
( )-7
( )-6
64
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR and Cluster Blocks Application Tooling (Continued)
AMP-O-LECTRIC
Termination Machines
Model “G”
A totally new design of our
most popular machine for
bench-top operation. It
features a quiet and highlyreliable direct motor drive,
electronic controls for ease
of setup and operation, and
improved guarding and
lighting for operator
convenience and safety. All
versions also include either
manual or automatic
precision adjustment for
crimp height. For use with
miniature style applicators
only.
Specifications
Weight — Approximately 240 lb
[110 kg]
Height — 20 [508] without reel
Width — 18.7-25.3 [475-643]
depending on type of applicator used
Depth — 21.5-28.1 [546-713]
depending on type of applicator used
Electrical — 120 or 220 VAC,
50 or 60 Hz
Air — 90-110 psi [6.21-7.59 bar] when
required for use with air-feed applicators
For complete information, request
Catalog 65828.
(Shown with optional Crimp
Quality Monitor.)
Model “K”
Specifications
This unique system provides
100% on-the-fly crimp
inspection. It measures the
crimp height of each
termination, and evaluates
the quality of each crimp. If a
crimp is questionable, the
monitor alerts the operator
with both visual and audible
alarms. It also provides ports
for printing and networking.
Specifications
Weight — Approximately 230 lb
[104 kg]
Height — 24 [610] without reel
Width — 21 [533]
Depth — 20 [508]
Electrical — 120 VAC, 60 Hz, 6 A
Air — 90-110 psi [6.21-7.59 bar] when
required for use with air-feed applicators
AMPLIVAR and Cluster Blocks
Application Tooling
Crimp Quality Monitor
These machines are used
with standard style
applicators, generally to
apply one size and type of
terminal without the need
for frequent changeovers of
applicators or adjustment of
crimp height. The basic
model is Part Number
1-471273-2. Part Number
1-471273-3 is equipped
with a mechanical feed
assembly for applicators
requiring this type of feed
for advancing the terminal
strip.
Height — 4.5 [114]
Width — 8.5 [216]
Depth — 9 [229]
Electrical — 120 VAC, 50 or 60 Hz, or
220 VAC, 50 or 60 Hz
Printer Port — Serial Interface
For further information, request Catalog
82275.
When used with
AMP-O-LECTRIC Model “G”
Termination Machines, the
monitor is mounted to the
machine. When used with
AMPOMATOR CLS IV Lead
Making Machines, it is
integrated into the machine’s
operating system, with the
information displayed on the
machine’s touch screen.
65
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Revised 10-02
AMPLIVAR and Cluster Blocks Application Tooling (Continued)
Model G Splice Terminating
Machine, P/N 356462-2 &
Applicator
Semiautomatic bench
machine crimps reeled
splice product. Uses
Standard G Splice
Applicators to provide
access to both sides of the
splice product. Features a
quiet, reliable motor drive,
microprocessor controls for
ease of setup and operation
and guarding and lighting
designed for operator
convenience. Manual
precision crimp height
adjust is standard and
machine-mounted sensors
are available for crimp
quality monitoring.
Standard G Splice Applicator
Available for the
AMP-O-LECTRIC Model G
splice terminator only.
Two-piece applicator for
crimping end- or side-feed
reeled splice products.
Provides access to both
sides of splice for increased
ease of use and
productivity. Applicators
use an air feed mechanism.
Entry Level Terminator (ELT),
1338600-(x)
Semiautomatic Bench
Terminator for side- and
end-feed reeled terminals
and contacts. The ELT uses
a DC motor with gear box
drive. The result is a smallfootprint design that is fast
and quiet. Cycle time is less
than 0.400 sec. with an
operation sound level of
76dBa. With a crimp force
capacity of 3,000 pounds,
the ELT is available for all
but the highest crimp force
applications. Optional
equipment is also available
to meet your specific
application requirements.
Specifications
AMP-O-LECTRIC Model “G”
Thru Splice Terminator
Capacity — 5 000 lb [2 224 N]
max. crimp force
Deflection — .003 [0.076] max.
per 1 000 lb [445 N] crimp force
Noise — 76 dB max. at 5 000 lb
[2 224 N] full capacity
Weight — Approx. 240 lb
[109 kg]
Height — 20 [508]
Electrical — 120/220 VAC, 50/60
Hz; Avg. 2.6 A at 120 VAC when
used as a bench-top unit at 2 000
cycles per hour operating rate
Air — 90-110 psi [6.21-7.58 bar],
6 scfm [0.00283 m3/s] (when
required for use with air-feed
applicators)
For more information, order Catalog
889021.
Specifications
Width—16.8 [427]
Depth—20.6 [523]
Height—20 [510] w/o reel support
Weight—approx. 150 lb [68 kg]
Electrical—100-240 VAC, 50/60
Hz, 6 A (Note: Avg
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