62934-1

Catalog 82221 Magnet Wire Terminals and Termination Systems Revised 10-02 Standard MAG-MATE Terminals Product Facts Terminates all magnet wire film insulations ■ Eliminates need for prestripping conductors ■ Eliminates need to post insulate termination ■ Excess magnet wire is automatically trimmed during the termination process ■ Simultaneously terminates two magnet wires of the same size in one terminal (for splicing or bi-filing) ■ Various lead wire attachment options available ■ Available in strip form for semi-automatic or fully automatic insertions ■ Available in loose piece form for hand tool insertions ■ Varnish resist tab terminals are available for special applications ■ High speed, fully automated integrated systems provide uniform terminations reliability at the lowest possible applied cost ■ Clean metal-to-metal interface produces stable, gas-tight electrical terminations free of oxides and other contaminants ■ Recognized under the Component Recognition Program of Underwriters Laboratories Inc., File No. E13288 R Standard MAG-MATE Terminals ■ Tyco Electronics offers a full selection of AMP Standard MAG-MATE Insulation Displacement Crimp (IDC) terminals for magnet wire terminations. MAG-MATE terminals are available in poke-in, poke-in tab, splice, crimp wire barrel, solder post, quick connect tab, pin and receptacle styles. Standard MAG-MATE terminates magnet wire ranging from 34-12 AWG [0.16 -2.05 mm]. Each IDC slot terminates up to four consecutive magnet wire ranges. Applications ■ Motor windings and connections ■ Coil connections ■ Transformer windings and connections ■ Bobbin connections ■ Lighting ballasts ■ Power supplies Two magnet wires with the same diameter can be terminated in one terminal down to 23 AWG [0.57 mm]. According to Tyco Electronics specifications MAG-MATE cavities are either integrated into coil bodies or especially designed cavity housings. The magnet wires are precisely positioned in the “U”shaped designed termination slots. The MAG-MATE Inserter cuts the terminals from the strip and places the terminals over the magnet wire into the plastic cavities. During this operation the small stripping devices penetrate the film insulation from the magnet wire. Residual spring energy in the terminal causes the side walls of each IDC slot to function as opposing cantilever beams. This constant pressure results in an intimate metalto-metal interface, providing a reliable, long-term connection. The wiping action between the wire and terminals removes oxides or other contaminants present on both the conductor and the terminal slot side walls, producing a clean, stable, gas-tight electrical termination. The AMP MAG-MATE Inserter may be used as a semi-automatic bench machine or integrated in production lines for fullyautomatic applications. 1 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 Standard MAG-MATE Terminals (Continued) Typical Plastic Cavities Manufacture only according to Tyco Electronics Specification. 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. 114-2050—Poke-In Tab MAG-MATE Terminals 114-2069—Standard MAG-MATE .187 [4.75] Box Height Terminals 114-2046—Standard MAG-MATE .300 [7.62] Box Height Terminals 114-2066—Standard MAG-MATE .500 [12.7] Box Height Terminals 114-2067—Standard MAG-MATE .300 [7.62] Box Height Latch-In Terminals Narrow Body 114-2094—Standard MAG-MATE .300 [7.62] Box Height Latch-In Terminals Wide Body Cavity Size 1, .187 [4.75] Box Height MAG-MATE (Reference Application Spec. 114-2069) Cavity Size 2, .300 [7.62] Box Height MAG-MATE (Reference Application Spec. 114-2046) Cavity Size 3, .300 [7.62] Box Height Latch-In MAG-MATE, Wide Body (Reference Application Spec. 114-2094) .355 [ 9.08] Min. .215 [ 5.46] Min. Cavity Size 4, .500 [12.70] Box Height MAG-MATE (Reference Application Spec. 114-2066) Note: MAG-MATE typical plastic cavities are not for design; Tyco Electronics will supply required dimensions of cavity for each customer application. Plastic cavities, designed to Tyco Electronics specifications, may be molded as part of the coil bobbin or attached to a lamination stack in the area of the magnet wire coil. Each cavity is a rectangular box with two narrow slots on opposing walls and a plastic post or anvil extending upward from the bottom surface. During or after the winding process, the magnet wire is placed across the plastic cavities and into the slots, .235 [ 5.97] Min. Cavity Size 5, .300 [7.62] Box Height Latch-In MAG-MATE, Narrow Body (Reference Application Spec. 114-2067) Cavity Size 6, .300 [7.62] Box Height MAG-MATE (Reference Application Spec. 114-2046) either manually or by coil winding equipment. quick disconnect FASTON tab terminals. Unraveling is prevented by a slight friction fit, suitable bend or by wrapping the magnet wire around a tie-off post. Excess magnet wire is trimmed flush with the outside of the plastic cavity by a shear blade traveling with the terminal insertion ram. During insertion, two insulation displacing terminal slots strip the film insulation from the magnet wire producing a stable electrical termination. The plastic anvil supports the magnet wire, helping to prevent it from being dragged down when the terminal is inserted. Terminal retention is secured in the plastic cavities by either locking barbs or locking latches in addition to locking barbs for The sheared wire end can be tucked inside the plastic cavity, if necessary, by cutting the wire off before the terminal is fully seated allowing the terminal to drag the severed end of the wire into the pocket inside the cavity. Tyco Electronics will provide design and mold engineering resources to manufacture any specifically designed MAG-MATE cavity housing. 2 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 Standard MAG-MATE Terminals (Continued) Standard MAG-MATE Interconnection System How the System Operates ➀ Wire Cutter Standard MAG-MATE Terminals ➀ ➅ Locking Barbs This part cuts off the excess magnet wire and the wire support at the front of the cavity. Terminal retention is secured in the cavity by four locking barbs. ➆ Plastic Cavity ➁ Insertion Finger The insertion finger is part of the MAG-MATE Inserter. It pushes the terminal that was sheared from the carrier strip through the inserter “tube” into the positioned cavity. ➂ Contact Various wire attachments in three different sizes, .187, .300, .500 cavity height (see tables). ➃ IDC Slot Production must be in accordance with Tyco Electronics Application Specifications. Consulting Tyco Electronics is required for design in. ➁ ➇ Cavity Slot for Wire The width has to be in accordance with the wire size (see Application Specification). ➂ ➈ Magnet Wire The magnet wire is positioned in the “U” slot. In different sizes for magnet wire diameters from 34-12 AWG [0.16-2.05 mm]. Strain relief slots available for high vibration applications. ➉ Wire Support Block The block supports the magnet wire during the cutting process. The magnet wire is cut flush to the cavity front side. ➄ Stripping Shoulders During the insertion process, these shoulders strip the film insulation from the magnet wire in four areas. 11 Anvil The anvil supports the wire during the insertion process. ➅ ➃ ➄ ➆ ➈ ➇ Termination Sequence ➁ A = Prepare ➀ B = Insert ➂ C = Finish ➀ Post Trim Blade ➁ Insertion Finger ➂ Poke-In Contact ➃ MAG-MATE Cavity ➄ Magnet Wire ➅ Support Anvil 11 ➉ A B C ➃ ➄ ➅ 3 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 Standard MAG-MATE Terminals (Continued) Test Results Standard and Slim Line MAG-MATE products have been submitted to the following tests without significant millivolt increase: Current Cycling — 480 cycles with each cycle consisting of 15 minutes “ON” followed by 15 minutes “OFF” Thermal Shock — 25 cycles with each cycle consisting of 30 minutes at 125°C followed by 30 minutes at -65°C Humidity — Temperature Cycling 10 cycles between 25°C and 65°C at 95% RH Heat Age — 33 days at 118°C Resistance vs Thermal Shock (Copper Wire) Mini MAG-MATE products have been submitted to the following tests in addition to those listed without significant millivolt increase: Vibration — 10-55-01- Hz traversed in 1 minute at .06 inches total excursion; 2 hours in each of 3 mutually perpendicular directions. Industrial Gas with Chlorine — 1000 exposure to 200 ppb each of sulphur dioxide, nitrogen dioxide, hydrogen sulphide and 50 ppb chlorine. Resistance vs Current Cycles (Copper Wire) 15 AWG 16 AWG 19 AWG 24 AWG 22 AWG 27 AWG 26 AWG ∆T (C) 33 AWG 30 AWG Test Current produces 100°C Magnet Wire Operating Temperature Current Rating Curves The diagram shows the temperature rise of the contact, depending on the magnet wire size being applied. I (A) 4 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. Product Specifications describe technical performance characteristics and verification tests. They are intended for the Design, Test and Quality Engineer. 108-2012 Standard .187and .300 MAG-MATE Terminals 108-2053 Standard .500 Box MAG-MATE Terminals 108-1484 Slim Line MAG-MATE Terminals 108-2016 Mini MAG-MATE Terminals Note: For all applications, Tyco Electronics recommends that samples of the magnet wire to be used be submitted for engineering evaluation. 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 Standard MAG-MATE Terminals (Continued) 300 Box Poke-In Terminals .300 [7.62] .300 [7.62] Tin plated brass (See page 2) Copper Magnet Wire Range1 AWG mm C 300 Box Standard IDC Non-Locking Poke-In Lead Wire Range3 AWG mm2 0.16-0.18 20-18 0.5-0.9 33-31 0.18-0.23 20-18 0.5-0.9 31-28 0.23-0.32 20-18 0.5-0.9 Stock Thickness .010 0.25 .010 0.25 .012 0.30 .012 0.30 0.25-0.36 20-18 0.5-0.9 27-23 0.36-0.57 20-18 — 0.5-0.9 — .016 0.41 25-222 0.45-0.64 20-18 0.5-0.9 .016 0.41 0.64-0.81 .118 [3.00] B 34-33 22-202 B4 300 Box Standard IDC w/ Strain Relief Slot Locking Poke-In .118 [3.00] A 30-27 A 300 Box Standard IDC Locking Poke-In .135 [3.43] .118 [3.00] Typical Cavity Size 2 Type .300 [7.62] .135 [3.43] .135 [3.43] 20-18 0.5-0.9 — — 202 0.81 20-18 0.5-0.9 19-172 0.91-1.15 20-18 0.5-0.9 30 0.25 20-18 0.5-0.9 29-282 0.29-0.32 20-18 0.5-0.9 28-262 0.32-0.40 20-18 0.5-0.9 27-232 0.36-0.57 20-18 0.5-0.9 31-28 0.23-0.32 — — Standard MAG-MATE Terminals Material .016 0.41 .016 0.41 .016 0.41 .012 0.30 .012 0.30 .012 0.30 .016 0.41 .012 0.30 30-27 0.25-0.36 — — .012 0.30 27-23 0.36-0.57 — — .016 0.41 27-26 0.36-0.40 — — 25.5-24 0.43-0.51 — — 23.5-222 0.54-0.64 — — 21.5-202 0.68-0.81 — — .016 0.41 .016 0.41 .016 0.41 .016 0.41 C Strip Part Number* L. P. Dual L. P. — — 63662-1 62431-1 62527-1 1217234-1 — — 62429-1 63636-18 62935-1 63754-15 63658-1 1217084-15 62420-1 62420-46 1217824-11 63725-15 62526-1 — 63044-1 — 1217757-1 63591-1 — 62833-1 — 62524-1 — — — 63855-1 — 62842-1 — — 62841-1 — — — — 62912-1 1217736-1† — — 1217011-1 — — 1217368-1 — — 63789-1 — — 63786-1† 1217026-1 — — — — — — — — — — — — — — 1217192-1 — — 1217191-1 — — 1217190-1 — — 1217189-1 — — 63590-17 63590-2 63590-36 63551-17 63551-2† 63551-36 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger unless otherwise noted. 3 Solid or overcoated stranded lead wire only. Product will also accept Poke-In Tab Terminal shown on page 7. 4 Strain relief slot for high vibration applications. 5 Enhanced anti-overstress behind Poke-In feature for severe applications. Part does not accept lead wires. 6 Finish is tin plated phosphor bronze. 7 Finish is tin over nickel plated brass. 8 Deep Poke-In design for enhanced lead wire retention. Special cavity design required. Contact Tyco Electronics Engineering for details. * Recognized under the Component Program of Underwriters Laboratories, Inc. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 Preferred part numbers are printed in bold. Chart continued on next page 5 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 Standard MAG-MATE Terminals (Continued) 300 Box Poke-In Terminals (Continued) .300 [7.62] Material .300 [7.62] .135 [3.43] Tin plated brass .118 [3.00] Typical Cavity Size 2 .455 [11.56] E D (See page 2) .118 [3.00] Copper Magnet Wire Range1 Stock Thickness AWG mm .016 27-26 0.36-0.40 0.41 D4 300 Box .016 25.5-24 0.43-0.51 Standard IDC w/ 0.41 Strain Relief Slot .016 2 23.5-22 0.54-0.64 Non-Locking 0.41 Poke-In .016 0.68-0.81 21.5-202 0.41 .016 30-272 0.25-0.36 0.41 .016 E 2 27-23 0.36 -0.57 0.41 300 Box Standard IDC .016 0.57-0.81 23-202 Tri-Slot 0.41 Non-Locking 0.36-0.57 27-232 Poke-In .016 0.91-1.15 19-172 0.41 182 0.8-0.9 Type Note: Special cavity required for Tri-slot splice terminal. Contact Tyco Electronics Engineering for details. Strip Part Number 1217429-1 . 1217691-13 . 1217428-1 . 1217690-13 1217427-1 . 1217689-13 1217426-1 . 1217688-13 1217221-1† 63632-1 1217533-1† 63975-1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. Enhanced anti-overstress behind Poke-In feature for severe applications. Part does not accept lead wires. 4 Strain relief slot for high vibration applications. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. * Recognized under the Component Program of Underwriters Laboratories, Inc. 1 2 3 500 Box Poke-In Terminals Material .505 [12.83] Tin plated brass .505 [12.83] .281 [7.14] Typical Cavity Size 4 .118 [3.00] (See page 2) A B Copper Magnet Wire Range1 Stock Type Thickness AWG mm .016 23-19.5 0.57-0.86 A 0.41 500 Box .016 19-17 0.91-1.15 Standard IDC 0.41 Non-Locking .016 Poke-In 16-15 1.29-1.45 0.41 .016 23-21.5 0.57-0.68 0.41 .016 B3 21-19.5 0.72-0.86 0.41 500 Box Standard IDC w/ .016 19-17 0.91-1.15 Strain Relief Slot 0.41 Non-Locking .016 16-15 1.29-1.45 Poke-In 0.41 .016 14-132 1.61-1.83 0.41 1 2 3 † .118 [3.00] .281 [7.14] Strip Part Number 1217069-1 1217068-1 1217067-1 1217358-1 1217357-1 1217356-1 1217355-1 1217579-1† Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. Strain relief slot for high vibration applications. These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 6 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 Standard MAG-MATE Terminals (Continued) Poke-In Tab Terminals Standard MAG-MATE Terminals Materials Optional Slot for #20 AWG [0.8 mm] Dia. Solid Copper Diode Slot Tin plated brass A B C .208 [5.28] .340 [8.64] .312 [7.92] D .245 [6.22] .312 [7.92] .135 [3.43] .135 [3.43] F E Type A 90° Up B 90° Up w/Ins. Sup. C Straight D Straight w/Ins. Sup. Poke-In System .110 .370 [2.79] [9.40] E 90° Down F 90° Down w/Ins. Sup. G Flag - 300 Box only H Flag - 500 Box only H G Lead Wire Size1 AWG mm2 22-18 0.3-0.9 Ins. O.D. — 22-18 0.3-0.9 18-14 0.8-2.0 .060-.100 1.52-2.54 .090-.140 2.29-3.56 22-18 0.3-0.9 — 18-14 0.8-2.0 — Stock Thickness .018 0.46 .020 0.51 .018 0.46 .020 0.51 .020 0.51 .020 0.51 22-18 0.3-0.9 .060-.100 1.52-2.54 .018 0.46 18-14 0.8-2.0 .090-.140 2.29-3.56 22-18 0.3-0.9 — .020 0.51 .018 0.46 18-14 0.8-2.0 .090-.140 2.29-3.56 20-16 0.5-1.4 — 18-14 0.8-2.0 .080-.120 2.03-3.05 Stranded, fused stranded or solid lead wire. Shallow tab serrations. 3 Tab serration on top of tab only. 4 No serrations on tab. 5 Includes diode slot for 20 AWG [0.8 mm] diameter solid copper diode wire. 6 Special serration location for deeper poke-in. 1 2 .540 [13.72] .285 .347 [7.24] [8.81] Strip Part Number 62895-1* 63410-1 62896-1* 1217132-12 63218-1 62897-1* 63775-1 62898-1* 63574-13 63631-14,† 1217470-15 63397-1† 63364-1 .020 0.51 63458-1 1217214-16 .020 0.51 .032 0.81 1217406-17 1217875-1† 1217324-1 7 Deeper poke-in. Special cavity detail required. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. * Recognized under the Component Program of Underwriters Laboratories, Inc. Note: All tab terminals accept stranded, fused stranded or solid lead wire. 7 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 Standard MAG-MATE Terminals (Continued) 300 Box Splice Terminals Material Tin plated brass .300 [7.62] Series Box Typical Cavity Size 2, when “C” dimension is .120 [3.05] (See page 2) Typical Cavity Size 6, when “C” dimension is .070 [1.78] (See page 2) .300 [7.62] .455 [11.56] A B Range1 Copper Magnet Wire AWG mm Type Note: Special cavity required for Tri-slot splice terminal. Contact Tyco Electronics Engineering for details. A 300 Box Standard IDC Splice B 300 Box Standard IDC Tri-Slot Splice .120 [3.05] Dim. C Stock Thickness 33-31 0.18-0.23 31-28 0.23-0.32 27-24 0.36-0.50 20-183 0.81-1.02 .070 1.78 .070 1.78 .070 1.78 .120 3.05 28-24 0.32-0.51 — 23-202 0.57-0.81 — .012 0.30 .012 0.30 .012 0.30 .020 0.51 .016 0.41 .016 0.41 27-23 184 19-172 25-223 184 23.5-202 0.36-0.57 0.8-0.9 0.91-1.15 0.45-0.64 0.8-0.9 0.54-0.81 — — Part Number Strip L. P. — 63531-1 — 63532-1 — 63533-1† 62903-1 — 1217858-1† — 1217853-1† — .016 0.41 1217613-1† — .016 0.41 1217209-1 — Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. 3 Bare wire only. 4 Single solid or fused stranded lead wire only. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 Dual Connection Terminals Material Tin plated brass Note: Special cavity required. Contact Tyco Electronics Engineering for details. A Type Copper Magnet Wire Range1 AWG mm A 165 Box Standard IDC Splice 1 Solid Lead Wire Range AWG mm 32-31 0.20-0.23 26-24 0.40-0.51 30-28 0.25-0.32 26-24 0.40-0.51 30-27 0.25-0.36 26-24 0.40-0.51 Stock Thickness .012 0.30 .012 0.30 .012 0.30 Strip Part Number 63005-1† 63087-1† 62766-1† Two magnet wires may be terminated in the same terminal lower slot if diameters are equal. part numbers are available upon special request; contact Tyco Electronics Engineering for details. † These 8 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 Standard MAG-MATE Terminals (Continued) Dual Connection Terminals (Continued) Standard MAG-MATE Terminals Material .345 [8.76] .185 [4.70] Tin plated phos. bronze .110 [2.79] Note: Special cavity required. Contact Tyco Electronics Engineering for details. .070 [1.78] B Copper Magnet Wire Range1 AWG mm Type B 185 Box Standard IDC Tab Receptacle 1 32-31 0.20-0.23 30-28 0.25-0.32 29-28 0.29-0.32 Mating Tab Stock Thickness .070 x .020 1.78 x 0.51 .070 x .020 1.78 x 0.51 .070 x .020 1.78 x 0.51 .010 0.25 .010 0.25 .010 0.25 Strip Part Number 1217538-1 1217457-1 1217458-1 Two magnet wires may be terminated in the same slot if diameters are equal. 300 Box F-Crimp Terminals Material Tin plated brass .300 [7.62] Series Box Typical Cavity Size 2, when “C” dimension is .120 [3.05] (See page 2) Typical Cavity Size 6, when “C” dimension is .070 [1.78] (See page 2) A Type Copper Magnet Wire Range1 AWG mm 33-31 A 300 Box Standard IDC F-Crimp 0.18-0.23 31-28 0.23-0.32 30-27 0.25-0.36 28-24 0.32-0.51 27-24 0.36-0.51 27-23 0.36-0.57 25-22 0.45-0.64 22-202 0.64-0.81 Dim. C Lead Wire Range3 AWG mm2 .070 1.78 .120 3.05 .070 1.78 .120 3.05 .120 3.05 .070 1.78 .120 3.05 .070 1.78 .120 3.05 22-18 0.3-1.0 24-20 0.2-0.6 22-18 0.3-1.0 24-20 0.2-0.6 24-20 0.2-0.6 22-18 0.3-1.0 24-20 0.2-0.6 22-18 0.3-1.0 24-20 0.2-0.6 Stock Thickness .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .016 0.41 .012 0.30 .016 0.41 Strip Part Number L. P. 63235-1 — 63420-1† — 63236-1 — 62992-1 — 63641-1 — 63237-1 — 62459-1 62666-1† 63690-1† — 62458-1 62665-1† Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. Stranded, fused stranded or solid lead wire. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 3 9 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 Standard MAG-MATE Terminals (Continued) 187 Box F-Crimp Terminals .187 [4.75] .360 .187 [9.14] [4.75] Material Tin plated brass .187 [4.75] Series Box Typical Cavity Size 1 (See page 2) .070 [1.78] .090 [2.29] .467 [11.86] .070 [1.78] .090 [2.29] A Type Copper Magnet Wire Range1 AWG mm A 187 Box Standard IDC F-Crimp B 187 Box F-Crimp w/ Ins Sup. B Lead Wire Range3 AWG mm2 Stock Thickness .010 0.25 Ins. O.D. 33-31 0.18-0.23 26-22 0.12-0.3 — 30-28 0.25-0.32 26-22 0.12-0.3 — 27-25 0.36-0.46 26-22 0.12-0.3 — 26-24 0.40-0.51 22-18 0.3-1.0 — 24-222 0.51-0.64 26-22 0.12-0.3 — .012 0.30 .012 0.30 .012 0.30 27-25 0.36-0.46 22-18 0.3-1.0 .071-.088 1.80 -2.23 .012 0.30 Strip Part Number 63039-1 63039-23,5 63036-1 62608-14 62608-34 62609-14 62609-34 .012 0.30 1217146-1 62610-14 63856-1 63856-2 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. 3 Stranded, fused stranded or solid lead wire. 4 Strip rereeled to feed through mini-applicator to crimp lead wire first, magnet wire termination is secondary operation. 1 2 300 Box Posted PCB Terminals .042 [1.07] Solder Terminal L L Material .300 [7.62] Tin over copper plated brass Typical Cavity Size .070 [1.78] .135 [3.43] (See page 2) Type A—Cavity Size 2 Type B—Cavity Size 6 A Type A 300 Box Standard IDC PCB Post B PCB Post Shallow Box Copper Magnet Wire Range1 AWG mm B Dim. L 33-31 0.18-0.23 31-28 0.23-0.32 29-26 0.29-0.40 27-23 0.36-0.57 22-202 0.64-0.81 19-172 0.91-1.15 .540 13.72 .540 13.72 .540 13.72 .460 11.68 .460 11.68 .460 11.68 33-31 0.18-0.23 .475 12.07 Stock Thickness Tab Section Mag Wire .010 .010 0.25 0.25 .010 .010 0.25 0.25 .012 .012 0.30 0.30 .016 .016 0.41 0.41 .016 .016 0.41 0.41 .016 .016 0.41 0.41 .020 0.51 .012 0.30 Strip Part Number 63253-1 62928-1* 62958-1* 63659-1 63660-1 63661-1 1217302-1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. * Recognized under the Component Program of Underwriters Laboratories, Inc. Note: PC Board hole size .050 [1.27]. 1 10 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 Standard MAG-MATE Terminals (Continued) 187 Box Posted PCB Terminals Tin plated brass, except where noted 33-31 0.18-0.23 Typical Cavity Size 1 (See page 2) 30-28 A 187 Box Standard IDC PCB Post L 0.25-0.32 27-25 0.36-0.46 24-222 0.51-0.64 Dim. L Stock Thickness .267 6.78 .330 8.38 .267 6.78 .287 7.29 .330 8.38 .330 8.38 .287 7.29 .010 0.25 .010 0.25 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .330 8.38 Part Number Strip L.P. .012 0.30 63565-10 — 62938-10 62938-23 62934-1 . — 63160-10 — 63818-10 — 62430-10 62430-23 62438-10 62438-20 62874-1 . — Standard MAG-MATE Terminals Copper Magnet Wire Range1 AWG mm Type Material — 63819-10 — 62439-10 62439-24 62439-33 63645-1† — — Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. Reverse reeled version of -1. 4 Finish is tin over nickel plated brass. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 3 A 187 Box Tab Terminals Material Left Right Tin plated brass, except when noted L L Typical Cavity Size 1 (See page 2) L .187 [4.75] .187 [4.75] .187 [4.75] .090 [2.29] .070 [1.78] .090 [2.29] .070 [1.78] .090 [2.29] .070 [1.78] A Type Copper Magnet Wire AWG mm A 187 Box Standard IDC Straight Tab 1 2 3 B Range1 30-28 0.25-0.32 29-27 0.29-0.36 30 0.25 25-222 0.46-0.64 B 187 Box Standard IDC Offset Tab-R.H. 27-25 0.36-0.45 C 187 Box Standard IDC Offset Tab-L.H. 27-25 0.36-0.45 C Dim. L Tab Size .432 10.97 .432 10.97 .550 14.00 .700 17.78 .565 14.36 .700 17.78 .565 14.36 .700 17.78 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .071 x .025 1.80 x 0.63 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 Stock Thickness Tab Section Mag Wire .020 .012 0.51 0.30 .020 .012 0.51 0.30 .025 .012 0.63 0.30 .032 .012 0.81 0.30 .032 .012 0.81 0.30 .032 .012 0.81 0.30 .032 .012 0.81 0.30 .032 .012 0.81 0.30 Strip Part Number 63702-1 1217196-13 1217405-1 1217013-1 1217641-1 1217459-1 1217642-1 1217460-1 Two magnet wires may be terminated in the same terminal if diameters are equal. Single magnet wire only. Finish is tin over nickel plated brass. 11 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 Standard MAG-MATE Terminals (Continued) 300 Box Tab Terminals Material Tin plated brass Typical Cavity Size 2 (See page 2) L L .300 [7.62] .135 [3.43] A 300 Box Standard IDC Straight Tab 20 B 300 Box Standard IDC Offset Tab-R.H. C 300 Box Standard IDC Offset Tab-L.H. D 300 Box Standard IDC Universal Offset Tab .135 [3.43] 0.23 33-31 0.18-0.23 30 0.25 33-31 0.18-0.23 .300 [7.62] .135 [3.43] .120 [3.05] .120 [3.05] .120 [3.05] .120 [3.05] A B C D 0.79 31 L .300 [7.62] .135 [3.43] Copper Magnet Wire Range1 AWG mm Type L .300 [7.62] Dim. L Tab Size .750 19.05 .895 22.73 .870 22.10 .660 16.76 .669 17.75 .669 17.75 .660 16.76 .669 17.75 .669 17.75 .063 x .025 1.60 x 0.63 .063 x .025 1.60 x 0.63 .062 x .032 1.57 x 0.81 .071 x .025 1.80 x 0.63 .091 x .025 2.31 x 0.63 .091 x .025 2.31 x 0.63 .071 x .025 1.80 x 0.63 .091 x .025 2.31 x 0.63 .091 x .025 2.31 x 0.63 Stock Thickness Tab Section Mag Wire .025 .016 0.63 0.41 .025 .016 0.63 0.41 .032 .010 0.81 0.25 .025 .010 0.63 0.25 .025 .010 0.63 0.25 .025 .010 0.63 0.25 .025 .010 0.63 0.25 .025 .010 0.63 0.25 .025 .010 0.63 0.25 Part Number Strip L.P. 63965-12 — 1217595-12 — 63810-1 — 63909-1 — 63927-1 — 1217052-12 — 63910-1 63910-23 — — 63926-1 — 1217051-13 — 30 0.25 31-28 0.23-0.32 1.230 31.25 .071 x .025 1.80 x 0.63 .025 0.63 .012 0.30 63773-1 — 32 0.20 1.098 27.90 .118 x .025 3.00 x 0.63 .025 0.63 .010 0.25 63247-1 63247-23 1217032-1 — Two magnet wires may be terminated in the same terminal slot if diameters are equal. Tinsel wire only. 3 Reverse reeled version of -1. 1 2 Type Copper Magnet Wire Range1 AWG mm E 300 Box Standard IDC Twisted Tab C E Typical Cavity Size 2, when “C” dimension is .120 [3.05] (See page 2) Typical Cavity Size 6, when “C” dimension is .070 [1.78] (See page 2) 1 2 33-31 0.18-0.23 31-28 0.23-0.32 27-24 0.36-0.50 212 0.72 19.52 0.86 Dim. C Tab Size .070 1.78 .070 1.78 .070 1.78 .120 3.05 .120 3.05 .125 x .020 3.17 x 0.51 .125 x .020 3.17 x 0.51 .125 x .020 3.17 x 0.51 .118 x .030 3.00 x 0.76 .118 x .030 3.00 x 0.76 Stock Thickness Tab Section Mag Wire .020 .012 0.51 0.30 .020 .012 0.51 0.30 .020 .012 0.51 0.30 .030 .016 0.76 0.41 .030 .016 0.76 0.41 Strip Part Number 63806-1 63807-1 63808-1 63463-1 63216-1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. 12 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 Standard MAG-MATE Terminals (Continued) 300 Box Tab Terminals (Continued) Standard MAG-MATE Terminals Material Tin plated brass L Typical Cavity Size 2 L (See page 2) .300 [7.62] .310 [7.87] .120 [3.05] .132 [3.35] .135 [3.43] .120 [3.05] F Type G Copper Magnet Wire Range AWG mm F 300 Box Standard IDC Timer Tab Tab Size .585 14.86 .585 14.86 .585 14.86 .585 14.86 .585 14.86 .585 14.86 .775 19.68 .585 14.86 .585 14.86 .118 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 .125 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 .125 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 .118 x .020 3.00 x 0.51 0.45-0.64 .665 16.89 .118 x .020 3.00 x 0.51 .020 0.51 .016 0.41 1217210-1 1217210-23 0.54 0.81 .665 16.89 .118 x .020 3.00 x 0.51 .020 0.51 .016 0.41 1217211-1 33-31 0.18-0.23 30 -28 0.25-0.32 27-23 0.36-0.57 25-222 0.45-0.64 23.5-21.52 0.54-0.68 23-202 0.57-0.81 19-172 0.91-1.15 18 Lead2 G4 25-222 300 Box Standard IDC Poke-In 23.5-202 Combination Tab Stock Thickness Tab Section Mag Wire .020 .010 0.51 0.25 .020 .010 0.51 0.25 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 Dim. L 1.02 Strip Part Number 1217746-1† 1217745-1† 63973-1 63489-1 1217596-1† 1217593-1† 63899-1 63972-1 63974-1 63974-23 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. 3 Reverse reeled version of -1. 4 Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] Solid or overcoated stranded lead wire or 90° Poke-In tab. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 13 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 Standard MAG-MATE Terminals (Continued) .092 Dia. [2.34] .092 Dia. [2.34] Pin Receptacle Terminals with Right or Left Hand Diode Lead Slot Material Tin plated brass .913 [23.20] .913 [23.20] Typical Cavity Size 2 (See page 2) .300 [7.62] .300 [7.62] .135 [3.43] .135 [3.43] .120 [3.05] .120 [3.05] B A Range1 Copper Magnet Wire AWG mm Type A 300 Box Diode Offset- R.H. B 300 Box Diode Offset- L.H. Diode Lead AWG mm Mating Pin Dia. Stock Thickness I/O Mag Wire Strip Part Number 32-31 0.20-0.23 22 0.64 .094 2.39 .014 0.36 .010 0.25 63208-1† 63326-1 31-27 0.23-0.36 22 0.64 .094 2.39 .014 0.36 .010 0.25 63209-1† 63308-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. Pin I/O Terminals Material Tin plated brass .300 [7.62] Series Box Styles A, B and C Typical Cavity Size 2 (See page 2) .500 [12.7] Series Box Style D Typical Cavity Size 4 (See page 2) .060 [1.52] .789 [20.29] .300 [7.62] .120 [3.05] .120 [3.05] A Type C 300 Box Offset Pin-L.H. D 500 Box Straight Pin 1 2 3 14 .120 [3.05] .120 [3.05] B Copper Magnet Wire Range1 AWG mm A 300 Box Straight Pin B 300 Box Offset Pin-R.H. .280 [7.11] .135 [3.43] .135 [3.43] .135 [3.43] C D Pin Dia. Stock Thickness I/O Mag Wire Part Number Strip L.P. 27-23 . 0.36-0.57 .060 1.52 .010 0.25 .010 0.25 63722-1 — 33-31 0.18-0.23 .048 1.22 .010 0.25 .010 0.25 63443-1 — 33-31 0.18-0.23 63569-1 63879-1 27-23 0.36-0.57 63570-1 63880-1 25-222 0.45-0.64 63788-1 — 27-23 0.86-1.15 63278-13 — 22-20 0.64-0.81 .010 0.25 .010 0.25 .016 0.25 .016 0.41 .016 0.41 .016 0.41 — 0.23-0.32 .010 0.25 .010 0.25 .010 0.25 .010 0.25 .016 0.41 .016 0.41 63444-1 31-28 .048 1.22 .048 1.22 .048 1.22 .048 1.22 .090 2.29 .090 2.29 63277-13 — Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. Varnish resist coating. 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 Standard MAG-MATE Terminals (Continued) 110 Series FASTON Tab Terminals Standard MAG-MATE Terminals Optional Slot for 22 AWG [0.64 mm] Dia. Solid Copper Diode Wire (2 Wires Max.) Material Tin plated brass Typical Cavity Size 2 (See page 2) A Copper Magnet Wire Range1 AWG mm Type A 300 Box Standard IDC .110 [2.79] Tab w/ Optional Diode Slot 1 33-31 Diode Lead AWG mm Stock Thickness Strip Tab Mag Wire Part Number Tab Size — — .110 x .025 2.79 x 0.64 .025 0.64 .010 0.25 63110-1 22 0.64 .110 x .025 2.79 x 0.64 .025 0.64 .010 0.25 63376-1 0.18-0.23 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Diode Lead Slot L L A Type A 300 Box Standard IDC .110 [2.79] FASTON w/ Diode Slot Offset-R.H. B 300 Box Standard IDC .110 [2.79] FASTON w/ Diode Slot Offset-L.H. 1 † Copper Magnet Wire Range1 AWG mm 31-27 30-27 31-27 30-27 B Diode Lead AWG mm 22 0.64 20 0.81 20 0.81 20 0.81 22 0.64 20 0.81 20 0.81 20 0.81 0.23-0.36 0.25-0.36 0.23-0.36 0.25-0.36 Tab Size Dim. L .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .965 24.51 .965 24.51 .965 24.51 .895 22.73 .965 24.51 .965 24.51 .965 24.51 .895 22.73 Stock Thickness Tab Mag Wire .032 .010 0.81 0.25 .032 .010 0.81 0.25 .032 .014 0.81 0.36 .032 .014 0.81 0.36 .032 .010 0.81 0.25 .032 .010 0.81 0.25 .032 .014 0.81 0.36 .032 .014 0.81 0.36 Part Number Strip L.P. 63319-1† — 63331-1† 63434-1 — 63529-1 63177-1† — 63276-1† — 63330-1† 63433-1 — 63530-1 63178-1† — Two magnet wires may be terminated in the same terminal slot if diameters are equal. These part numbers are available upon special request; contact Tyco Electronics Engineering for details. Note: .110 [ 2.79] Tab Terminals mate with compatible FASTON receptacles. Request AMP Catalog 82004. 15 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 Standard MAG-MATE Terminals (Continued) 110 Series FASTON Tab Terminals (Continued) Material .625 [15.88] Tin plated brass Typical Cavity Size 2 (See page 2) .300 [7.62] .135 [3.43] Note: .110 [2.79] Tab Terminals mate with compatible FASTON receptacles. Request AMP Catalog 82004. .120 [3.05] B A Type Copper Magnet Wire AWG mm A5 300 Box Standard IDC .110 [2.79] FASTON Tab B5,6 300 Box Single IDC w/ Strain Relief Slot C4,5 Poke-In Combination Tab Range1 30-27 0.25-0.36 27-23 0.36-0.57 23-202 0.45-0.64 19-17 0.91-1.15 27-23 0.36-0.57 23.5-202 0.54-0.81 28-24 0.32-0.51 25-222 0.45-0.64 C Tab Size .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 Stock Thickness Tab Mag Wire .020 .012 0.51 0.30 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .020 0.51 0.51 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .012 0.51 0.30 .020 .012 0.51 0.30 Part Number Strip L.P. 63777-1 — 63746-1 — 63486-1 — 63145-1† — 63827-1 — 1217783-1† — 63062-13 1217430-13 63063-13 — — 63063-2 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. Varnish resist coating. 4 Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] Solid or overcoated stranded lead wire or 90° Poke-In tab. 5 After insertion into plastic cavity, tab portion must be bent over 45°-90° or potted in to prevent pullout when mating receptacle is disconnected. 6 Strain relief slot for high vibration applications. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 3 16 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 Standard MAG-MATE Terminals (Continued) 187 Series FASTON Tab Terminals Standard MAG-MATE Terminals Material Tin plated brass Typical Cavity Sizes (See page 2) Type A—Cavity Size 2 A Type Copper Magnet Wire Range1 AWG mm Dim. L 33-31 .630 16.00 .660 16.76 0.18-0.23 30-27 0.25-0.36 .630 16.00 Tab Feature Dimple Hole Dimple Dimple Dimple 27-23 0.36-0.57 .630 16.00 Hole — 23 0.57 A4 300 Box Standard IDC .187 [4.75] 22-202 FASTON Tab .660 16.76 .630 16.00 Hole — Dimple 0.64-0.81 .630 16.00 Hole Dimple Hole 21-193 Aluminum 0.72-0.91 20-182 0.81-1.02 19-172 0.91-1.15 18.5-16.53 Aluminum 0.97-1.22 .630 16.00 .630 16.00 .630 16.00 .630 16.00 Dimple Hole Dimple Hole Dimple Hole Dimple Hole Tab Size .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 Stock Thickness Part Number Tab Mag. Wire Section Section Strip L. P. .020 .010 62513-1* 62663-1 0.51 0.25 .020 .012 63584-1 — 0.51 0.30 .020 .012 62512-1* — 0.51 0.30 63510-15,† — .032 .012 62678-1†* 1217178-1 0.81 0.30 .020 .016 62514-1* 63852-1 0.51 0.41 62514-25* — — .020 .016 63664-15 0.51 0.41 63664-2 — .020 .016 63461-1 — 0.51 0.41 1217243-16 — .020 .016 63585-1 — 0.51 0.41 .020 .016 63776-1 — 0.51 0.41 .020 .016 62511-1* 62661-1 0.51 0.41 62511-25 — — .020 .016 63663-15 0.51 0.41 63663-2 — .032 .016 1217065-1 — 0.81 0.41 .032 .016 1217128-1 — 0.81 0.41 .020 .016 — 63293-1† 0.51 0.41 .020 .016 — 63669-1 0.51 0.41 .020 .020 — 62904-17 0.51 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 .016 0.41 .016 0.41 63670-1 — 63273-1 63511-15 63829-1 — 63665-15 — 63494-1† — 63668-1 — Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. 3 Single aluminum magnet wire only. 4 After insertion into plastic cavity, tab portion must be bent over 45°-90° or potted in to prevent pullout when mating receptacle is disconnected. 5 Varnish resist coating. 6 Special wide body cut off for added stability. 7 Single bare copper wire only. * Recognized under the Component Program of Underwriters Laboratories, Inc. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 Note: .187 [4.75] Tab Terminals mate with compatible FASTON receptacles. Request AMP Catalog 82004. Chart continued on next page 17 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 Standard MAG-MATE Terminals (Continued) .187 [4.75] 187 Series FASTON Tab Terminals (Continued) Hole or Dimple Material Dimple L Tin plated brass .300 [7.62] Typical Cavity Sizes (See page 2) Type B—Cavity Size 5 Type C—Cavity Size 5 Type D—Cavity Size 3 .135 [3.43] B 187 Series Combination Poke-In FASTON Terminals Type Material Tin plated brass C Copper Magnet Wire Range1 AWG mm 33-31 0.18-0.23 31-28 0.23-0.32 30-27 0.25-0.36 27-23 0.36-0.57 Typical Cavity Sizes (See page 2) Type E—Cavity Size 2 Type F—Cavity Size 3 B 300 Box Standard IDC Narrow Body Latch Type 23-202 0.57-0.81 0.54-0.81 .016 0.41 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .010 0.25 .010 0.25 .012 0.30 .012 0.30 .012 0.30 .016 0.41 Hole — Hole — Hole Dimple Hole Poke-In 33-31 Combination Tab F4 Poke-In Combination Tab 28-24 Wide Body Latch Type 0.81-0.23 .630 16.00 Hole .187 x .020 4.75 x 0.51 .020 0.51 .010 0.25 0.32-0.51 .630 16.00 Hole .187 x .032 4.75 x 0.81 .032 0.51 .016 0.41 31-28 30-27 0.18-0.23 0.23-0.32 0.25-0.36 E4,5 Note: .187 [4.75] Tab Terminals mate with compatible FASTON receptacles. Request AMP Catalog 82004. .020 0.51 Hole 0.36-0.57 .187 [4.75] F .187 x .020 4.75 x 0.51 Hole 27-23 D 300 Box Standard IDC Wide Body Latch Type .120 [3.05] Dimple Hole .630 16.00 .730 18.54 .630 16.00 .630 16.00 .730 18.54 .630 16.00 E .135 [3.43] .630 16.00 .630 16.00 0.80-0.92 Stock Thickness Tab Mag. Wire Section Section .020 .010 0.51 0.25 .020 .010 0.51 0.25 .020 .012 0.51 0.30 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 .020 .016 0.51 0.41 — .630 16.00 0.91-1.15 mm2 Tab Size .630 16.00 .630 16.00 19-172 lead2 Tab Feature D .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .630 16.00 33-31 L .630 16.00 .630 16.00 .630 16.00 0.64-0.81 C3 Narrow Body 2 Latch Type w/ 23.5-20 Strain Relief Slot .310 [7.87] Dim. L 22-202 18 .120 [3.05] .120 [3.05] Dimple Hole Dimple .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 Hole Hole Dimple Hole Hole Strip Part Number 63108-1† 62743-1† 63109-1† 63107-1 1217493-1 63340-1 1217493-1 63429-1 63429-26 62888-1 62888-26 63782-1 1217592-1† 1217004-1 63255-1 63544-1† 63505-1 63760-1 63254-1† 63478-1† 63447-1 63256-2 63018-1 1217857-1† Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. Strain relief slot for high vibration applications. Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] solid, fused stranded lead wire or 90° poke-in tab terminal. After insertion into plastic cavity, tab portion must be bent over 45°-90° or potted in to prevent pullout when mating receptacle is disconnected. 6 Splice free reeling. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 3 4 5 Chart continued on next page 18 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 Standard MAG-MATE Terminals (Continued) 187 Series FASTON Tab Terminals .187 [4.75] (Continued) Hole L Material Standard MAG-MATE Terminals .187 [4.75] L .505 [12.83] Tin plated brass .505 [12.83] Typical Cavity Sizes .281 [7.14] (See page 2) Type G—Cavity Size 4 Type H—Cavity Size 4 Type J—Cavity Size 4 .120 [3.05] G H Copper Magnet Wire Range1 AWG mm Type Dim. L 22-20 0.64-0.81 19-17 0.91-1.15 .830 21.08 .830 21.08 1.09-1.29 .830 21.08 Tab Feature Dimple Hole Hole 17.5-16 G3 500 Box Standard IDC Hole Hole Hole 16-15 1.29-1.45 .830 21.08 Hole Dimple 14.5-132 1.54-1.83 27-23 0.36-0.57 22-20 0.64-0.81 H3,5 500 Box Single IDC w/ Strain Relief Slot 19-17 J 500 Box Standard IDC Latch Type .281 [7.14] 0.91-1.15 16-15 1.29-1.45 22-20 0.64-0.81 19-17 0.91-1.15 .830 21.08 .830 21.08 .830 21.08 .830 21.08 .830 21.08 .830 21.08 .830 21.08 Dimple Hole Hole Hole Hole Hole Hole — — .120 [3.05] J Tab Size .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 Stock Thickness Part Number Tab Mag. Wire Section Section Strip L. P. .020 .020 — .. 63708-14 0.51 0.51 .020 .020 63643-1 — 0.51 0.51 .020 .020 63667-14 63599-14 0.51 0.51 .020 .020 — 63427-1† 0.51 0.51 .032 .020 1217075-1 — 0.81 0.51 .020 .020 — 63666-14 0.51 0.51 .020 .020 63762-1 — 0.51 0.51 .020 .020 63353-1 — 0.51 0.51 .020 .016 63428-1 — 0.51 0.41 .020 .020 1217042-1 — 0.51 0.51 .020 .020 63983-1 — 0.51 0.51 .032 .020 1217339-1 — 0.81 0.51 .020 .020 63995-1 — 0.51 0.51 .032 .020 1217090-1 — 0.81 0.51 .020 .020 63996-1 — 0.51 0.51 .020 .020 1217491-1 — 0.51 0.51 .020 .020 1217492-1 — 0.51 0.51 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. 3 After insertion into plastic cavity, tab portion must be bent over 45°-90° or potted in to prevent pullout when mating receptacle is disconnected. 4 Varnish resist coating. 5 Strain relief slot for high vibration applications. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 19 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 Standard MAG-MATE Terminals (Continued) 250 Series FASTON Tab Terminals Hole or Dimple Material Dimple Hole or Dimple L L L Tin plated brass .300 [7.62] Typical Cavity Sizes .135 [3.43] (See page 2) Type A—Use Cavity Size 2 Type B—Use Cavity Size 5 Type C—Use Cavity Size 3 .135 [3.43] .120 [3.05] A Type Note: .250 [6.35] tab terminals mate with compatible FASTON receptacles. Request AMP Catalog 82004. 30-27 A3 300 Box Standard IDC .250 [6.35] FASTON Tab 28-24 27-23 Dim. L Tab Feature .750 0.18-0.231 19.05 Dimple Dimple .750 0.25-0.361 19.05 Hole Dimple & Hole .750 0.32-0.511 19.05 Hole Dimple Dimple 0.36-0.571 .750 Dimple 19.05 Dimple Hole B Narrow Body Latch Type Material Tin plated brass Typical Cavity Sizes 3 (Type D) (See page 2) C Wide Body Latch Type Hole 1 0.18-0.23 .750 19.05 30-28 .750 0.23-0.321 19.05 .750 0.25-0.321 19.05 30-27 0.25-0.361 .750 19.05 27-23 .750 0.36-0.571 19.05 31-28 .250 [6.35] .750 0.64-0.81 19.05 20-182 .750 1 Bare Wire 0.81-1.02 19.05 .750 33-31 0.18-0.231 19.05 .750 30-27 0.25-0.361 19.05 .750 27-23 0.36-0.57 19.05 .750 23-202 0.57-0.81 19.05 33-31 L .310 [7.87] 22-202 .135 [3.43] .120 [3.05] D 19-172 D5 Poke-In Combination Tab 28-24 Wide Body Latch Type .120 [3.05] .750 0.64-0.811 19.05 .750 0.91-1.151 19.05 .750 0.32-0.51 19.05 C Stock Thickness Tab Mag. Wire Section Section .250 x .032 .032 .010 6.35 x 0.81 0.81 0.25 Tab Size .250 x .032 6.35 x 0.81 .032 0.81 .012 0.30 .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .020 0.51 .010 0.25 .012 0.30 .016 0.41 .016 0.41 .250 x .032 6.35 x 0.81 .032 0.81 .010 0.25 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .032 0.81 .032 0.81 .012 0.30 .012 0.30 .250 x .032 6.35 x 0.81 .032 0.81 .012 0.30 .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 Hole .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .032 0.81 .032 0.81 .016 0.41 .016 0.41 Hole .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 1 22-202 250 Series Combination Poke-In FASTON Tab Terminal .135 [3.43] .120 [3.05] B Copper Magnet Wire Range1 AWG mm 33-31 Locking Latch (2) .300 [7.62] .300 [7.62] Dimple Dimple Dimple Dimple Dimple Dimple Dimple Hole Hole Hole Dimple Hole Dimple Dimple Dimple Hole Hole Hole Hole Dimple Dimple Dimple Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64 mm] or larger. After insertion into plastic holder, tab portion must be bent over 45°-90° or potted in to prevent pullout when mating receptacle is disconnected. 4 Varnish resist coating. 5 Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] solid, fused stranded lead wire or 90° Poke-In tab 1 2 3 Part Number Strip L. P. 62600-1* 62655-1 62600-27 —. 62651-1* 62656-1† 63055-1† —. 63328-1 —. . 63607-1 — 62652-17* 62657-1 62652-26,7 —. 62939-13,4,† — . 63920-17,9 —. —. 63159-17,† 62653-1* 62658-1 7 62653-2 1217031-17 62653-36 —. . 63200-1 — 63026-1† — 63027-1† — 1217860-1† — 1217870-1† — 63133-1 63309-1 63309-27 63618-18 63403-2† 1217152-1 . 63132-1 63132-210 63132-34 63499-1 63499-27 63571-1 63571-27 63128-1 63128-37 63601-1 63601-27 63614-1 1217856-2† . . . . —. —. —. —. . — — . 63203-1† —. —. 63898-1 —. —. —. 63207-1† —. —. —. . — —. terminal. 6 Reverse reeled version of -1. 7 Half hard temper brass. 8 Special key hole wire slot block. 9 Special wide neck design. 10 Material is unplated brass. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. * Recognized under the Component Program of Chart continued on next page 20 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 Standard MAG-MATE Terminals (Continued) 250 Series FASTON Tab Terminals Standard MAG-MATE Terminals (Continued) Material L Tin plated brass L Typical Cavity Sizes (See page 2) Type E—Use Cavity Size 4 Type F—Use Cavity Size 4 E Type Copper Magnet Wire Range1 AWG mm 22-20 E3 500 Box Standard IDC Wide Neck F3 500 Box Standard IDC Narrow Neck 0.64-0.81 F Dim. L .952 24.18 .952 24.18 .952 24.18 Tab Feature Hole 19-17 0.91-1.15 16-15 1.29-1.45 14-132 1.61-1.83 .952 24.18 22-20 0.64-0.81 .952 24.18 Dimple 19-17 0.91-1.15 .952 24.18 Dimple 16-15 1.29-1.45 14-132 1.61-1.83 122 2.05 .952 24.18 .952 24.18 .952 24.18 Hole Hole Dimple Hole Dimple Dimple Dimple Tab Size .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 Stock Thickness Tab Mag. Wire Section Section .032 .020 0.81 0.51 .032 .020 0.81 0.51 .032 .020 0.81 0.51 .032 .020 0.81 0.51 .032 .020 0.81 0.51 .032 .020 0.81 0.51 .250 x .032 6.35 x 0.81 .032 0.81 .020 0.51 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .032 0.81 .032 0.81 .032 0.81 .020 0.51 .020 0.51 .020 0.51 Part Number Strip L. P. 63495-14 63882-1 — 63464-2† 63464-34 63598-1 63459-2 63881-1 63459-34 — 63460-14,† 63883-1 — 1217588-1† 63816-1 — 63816-24 — 63155-14 62923-14 62923-24,5 62923-34.6 63064-14 63336-1† — — — 63263-1† 63465-1 63371-14 — — 63425-14 — Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only. 3 After insertion into plastic holder, tab portion must be bent over 45°-90° or potted in to prevent pullout when mating receptacle is disconnected. 4 Varnish resist coating. 5 Box-up reversed reel version of -1. 6 Box-up reeled version of -1. † These part numbers are available upon special request; contact Tyco Electronics Engineering for details. 1 2 21 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 Slim Line MAG-MATE Terminals Product Facts ■ Terminates all magnet wire film insulations ■ Eliminates need for prestripping conductors ■ Eliminates need to post insulate termination ■ Excess magnet wire is automatically trimmed during the termination process ■ Series 187 and 250 Tab terminals available ■ Terminates 33-17 AWG [0.18-1.15 mm] magnet wire ■ Simultaneously terminates two magnet wires of the same size in one terminal from 33-23 AWG [0.180.57 mm] ■ Available in strip form for semi-automatic or fully automatic insertions ■ Available in loose piece form for hand tool insertions ■ Varnish resist tab terminals are available for special applications ■ High speed, fully automated integrated systems provide uniform terminations reliability at the lowest possible applied cost ■ ■ Clean metal-to-metal interface produces stable, gas-tight electrical terminations free of oxides and other contaminants Recognized under the Component Recognition Program of Underwriters Laboratories Inc., File No. E13288 R Applications ■ Motor windings and connections ■ Coil Connections ■ Transformer windings and connections ■ Bobbin connections ■ Lighting Ballasts ■ Power Supplies Tyco Electronics offers a full selection of Series 187 and 250 Slim Line MAG-MATE Tab insulation displacement (IDC) terminals for magnet wire terminations. Slim Line MAG-MATE Series 187 and 250 tab terminals with a single IDC slot terminate 33-17 AWG [0.18 to 1.15 mm]. Each IDC slot terminates up to four consecutive magnet wire ranges. Two magnet wires with the same diameter can be terminated in one terminal down to 23 AWG [0.57 mm]. According to Tyco Electronics specifications MAG-MATE cavities are either integrated into coil bodies or especially designed cavity housings.The magnet wires are precisely positioned in the “U” shaped designed termination slots. The MAG-MATE Inserter cuts the terminals from the strip and places the terminals over the magnet wire into the plastic cavities. During this operation the small stripping devices penetrate the film insulation from the magnet wire. Typical Plastic Cavity Not for design, Tyco Electronics will supply required dimensions of cavity for each customer application. Residual spring energy in the terminal causes the side walls of each IDC slot to function as opposing cantilever beams. .375 [9.53] Min. This constant pressure results in an intimate metalto-metal interface, providing a reliable, long-term connection. The wiping action between the wire and terminals removes oxides or other contaminants present on both the conductor and the terminal slot side walls, producing a clean, stable, gas-tight electrical termination. The AMP MAG-MATE Inserter may be used as a semi-automatic bench machine or integrated in production lines for fullyautomatic applications. .270 Min. [6.86] .115 Min. [2.92] Reference Application Spec. 114-2147 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. 114-2140—Slim Line MAG-MATE Terminals 22 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 Slim Line MAG-MATE Terminals (Continued) 187 Series FASTON Tab Terminals Slim Line MAG-MATE Terminals Material Tin Plated Brass Type .187 [4.75] .020 [0.51] Hole or Dimple A .187 [4.75] FASTON Tab Copper Magnet Wire Range1 AWG mm Dim. L 33-31 .630 16.00 0.18-0.23 30-28 0.25-0.32 27-24 0.36-0.51 Tab Feature .630 16.00 .630 16.00 .760 19.31 L 23-202 .135 [3.43] 0.57-0.81 0.91-1.15 19-172 .016 [0.41] .630 16.00 .630 16.00 Hole Dimple Hole Hole Dimple Hole Dimple Plain Hole Dimple Hole Hole Dimple Tab Size .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 Stock Thickness Part Number Tab Mag. Wire Section Section Strip L. P. .020 .012 63710-2 — 0.51 0.30 63738-2 — .032 .012 1217666-1 — 0.81 0.30 .020 .012 63711-2 — 0.51 0.30 63737-2 — .020 .016 63712-2 — 0.51 0.41 63736-2 — .020 .016 1217497-1 — 3 0.51 0.41 1217497-2 — .020 .016 63713-2 1217714-1 0.51 0.41 63735-2 — .032 .016 1217516-1 — 0.81 0.41 .020 .016 63714-2 — 0.51 0.41 63734-2 — Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64] or larger. 3 Reverse reeled version of -1. 1 2 A 250 Series FASTON Tab Terminals Material Tin Plated Brass .250 [6.35] Type .032 [0.81] Hole or Dimple B .250 [6.35] FASTON Tab Copper Magnet Wire Range1 AWG mm 33-31 0.18-0.23 30-28 0.25-0.32 27-24 0.36-0.51 23-202 0.57-0.81 19-172 0.91-1.15 L 1 2 .135 [3.43] Dim. L Tab Feature Tab Size .752 19.10 .752 19.10 .752 19.10 .752 19.10 .752 19.10 Hole Dimple Hole Dimple Hole Dimple Hole Dimple Hole Dimple .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 Stock Thickness Tab Mag. Wire Section Section .032 .012 0.81 0.30 .032 .012 0.81 0.30 .032 .016 0.81 0.41 .032 .016 0.81 0.41 .032 .016 0.81 0.41 Strip Part Number 63716-2 63744-2 63717-2 63743-2 63718-2 63742-2 63719-2 63741-2 63720-2 63740-2 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Single magnet wire only; 22 AWG [0.64] or larger. .016 [0.41] B 23 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 Slim Line MAG-MATE Terminals (Continued) Tab Terminals .139 [3.53] Material .032 [0.81] Tin Plated Brass .059 [1.50] .135 [3.43] L .220 [5.59] .013 [0.33] C Type C Combination Diode Slot/Tab 1 Copper Magnet Wire Range1 AWG mm 33-31 0.18-0.23 33-31 0.18-0.23 33-31 0.18-0.23 Dim. L Diode Size Tab Size .725 18.42 .725 18.42 .760 19.29 #20 0.8 #22.5 0.6 #22.5 0.6 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 Stock Thickness Tab Mag. Wire Section Section 0.032 0.012 0.81 0.30 0.032 0.012 0.81 0.30 0.032 0.012 0.81 0.30 Strip Part Number 63888-1 63903-1 1217709-1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 24 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 Mini MAG-MATE Terminals Product Facts Terminates all fine gauge magnet wire film insulations ■ Eliminates need to prestripping conductors ■ Eliminates need to post insulate termination ■ Terminates 52-30 AWG [0.254-0.0198 mm] diameter copper magnet wire ■ Poke-In leaf style accepts 22 -18 AWG [0.3-0.9 mm] overcoated stranded or solid lead wire ■ Available in strip form for semi-automatic or fully automatic insertions ■ Available in both open and closed cavity systems ■ High speed, fully automated integrated systems provide uniform terminations reliability at the lowest possible applied cost ■ Recognized under the Component Recognition Program of Underwriters Laboratories Inc, File No. E13288 R Applications ■ ■ ■ ■ ■ ■ Ignition coils Small motors Synchronist timers Electric meter coils Solenoids Relays Mini MAG-MATE Terminals ■ Tyco Electronics offer AMP Mini MAG-MATE poke-in, crimp wire barrel, post and quick disconnect tab insulation displacement (IDC) terminals for fine gauge magnet wire terminations. Mini MAG-MATE terminals are designed to terminate 52-30 AWG [0.2540.198 mm] diameter copper magnet wire; poke-in leaf terminals accept 22-18 AWG [0.3-0.9 mm2] overcoated stranded or solid lead wire. The terminal design uses the AMPLIVAR serrated burr technology to penetrate the film insulation of copper magnet wire. Mini MAG-MATE cavity pockets, designed to Tyco Electronics specifications, include a wire receiving slot and wire tie-off post that is either integrated into coil bodies or specially designed cavity housings. The magnet wire is wrapped around the tie-off post and placed across the cavity slot. After the coil is wound, the finish end of the magnet wire is dressed through the second cavity slot and tied to its tie-off post. Typical Plastic Cavity Not for design, Tyco Electronics will supply required dimensions of cavity for each customer application. The Mini MAG-MATE Inserter shears the terminal from the carrier strip and insert the terminal into the cavity by a dual ram insertion mechanism. As the unexpanded terminal approaches the bottom of the cavity the upper ram stops. The lower ram continues to push to a prescribed depth to expand the terminal and complete the termination process. The fully seated terminal fits squarely into the cavity, while the serrated leg of the terminal cams against the pre-positioned magnet wire to penetrate the film insulation and provide a stable electrical termination. Reference Application Spec. 114-2047 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. 114-2047—Mini MAG-MATE Terminals 25 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 Mini MAG-MATE Terminals (Continued) Termination Sequence Terminal Removed from Carrier Terminal Inserted Termination Complete Poke-In Tab Terminal Material .010 [0.25] tin plated brass B A Type A Lead Wire Poke-In B Tab Poke-In Copper Magnet Wire Range Lead Wire Range1 AWG mm AWG mm2 52-42 0.02-0.06 22-18 44-36 0.05-0.13 22-18 38-30 0.10-0.25 22-18 52-42 0.02-0.06 — 44-36 0.05-0.13 — 38-30 0.10-0.25 — Stock Thickness Strip Poke-In Beam Mag Wire Part Number 0.010 0.010 0.3-0.9 — 62781-1 0.25 0.25 0.010 0.010 0.3-0.9 — 62780-1 0.25 0.25 0.010 0.010 0.3-0.9 — 62606-1 0.25 0.25 .050 x .020 0.010 0.010 — 63613-13 1.27 x 0.51 0.25 0.25 .060 x .020 0.010 0.010 63795-12 — 1.52 x 0.51 0.25 0.25 63845-12,3 .060 x .020 0.010 0.010 — 63844-12,3 1.52 x 0.51 0.25 0.25 Mating Tab Solid or overcoated stranded lead wire only. 2 Radius on beam leaf tip. 3 Finish is select gold plated on lead tip. 1 26 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 Mini MAG-MATE Terminals (Continued) Posted Terminal .138 [3.51] .138 [ 3.51] .060 [1.52] .060 [1.52] Mini MAG-MATE Terminals Material Tin over premilled brass .169 [4.29] .770 [19.56] .540 [13.72] A B Copper Magnet Wire Range AWG mm Type A PCB Post B Solder Post C Wire Wrap Post † 44-36 0.05-0.13 38-30 0.10-0.25 44-36 0.05-0.13 38-30 0.10-0.25 38-30 0.10-0.25 C Post Size .024 x .020 0.62 x 0.51 .024 x .020 0.62 x 0.51 .150 x .020 3.81 x 0.51 .150 x .020 3.81 x 0.51 .070 x .020 1.78 x 0.51 Stock Thickness Post Mag Wire .020 .010 0.51 0.25 0.020 0.010 0.51 0.25 0.020 0.010 0.51 0.25 0.020 0.010 0.51 0.25 0.020 0.010 0.51 0.25 Strip Part Number 1217804-1† 63675-4 63955-1 63956-1 63041-1 These part numbers are available upon special request; contact Tyco Electronics Engineering for details. FASTON Tab Terminals .138 [3.51] .060 [1.52] Material Tin over premilled brass .880 [22.35] A B Copper Magnet Wire Range AWG mm Type A .110 [2.79] FASTON Tab B .187 [4.75] FASTON Tab C .250 [6.35] FASTON Tab 38-30 0.10-0.25 44-36 0.05-0.13 38-30 0.10-0.25 44-36 0.05-0.13 38-30 0.10-0.25 C Tab Size Stock Thickness Post Mag Wire .110 x .020 2.79 x 0.51 .020 0.51 .010 0.25 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .020 0.51 .020 0.51 .032 0.81 .032 0.81 .010 0.25 .010 0.25 .010 0.25 .010 0.25 Strip Part Number 63161-1 63778-1 62816-1 1217529-1 1217000-1 63999-1 Crimp Wire Barrel Terminal Material Tin plated brass Type A Crimp Wire Barrel 1 † Copper Magnet Wire Range AWG mm Lead Wire Range AWG mm2 52-42 0.02-0.06 26-22 0.12-0.30 44-36 0.05-0.13 26-22 0.12-0.30 38-30 0.10-0.25 22-18 0.3-0.9 Stock Thickness Crimp Barrel Mag Wire 0.010 0.010 0.25 0.25 0.010 0.010 0.25 0.25 0.010 0.010 0.25 0.25 Strip Part Number 63828-1 1217830-11,† 63199-11 1217231-1† Wire and insulation barrel reversed so lead wire exits over magnet wire termination area. These part numbers are available upon special request; contact Tyco Electronics Engineering for details. A 27 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 SIAMEZE Terminals Product Facts ■ Terminates all copper magnet wire film insulations ■ Eliminates need for prestripping conductors ■ Moving Beam contact design connects a wide range of magnet wire sizes with a single terminal ■ Standard range terminals connect 34-18 AWG [0.161.0 mm] magnet wire ■ Fine range terminals connect 36-27 AWG [0.130.38 mm] magnet wire ■ Medium range terminals connect 23-12 AWG [0.562.03 mm] magnet wire ■ Excess magnet wire is automatically trimmed during the termination process ■ Available in strip form for semi-automatic or fully automatic insertions ■ Loose piece terminals available for hand tool insertions ■ High-speed automatic coil winding machine terminations provide uniform reliability at the lowest possible applied cost ■ ■ Clean metal-to-metal interface produces stable, gas-tight electrical terminations free of oxides and other contaminants Recognized under the Component Program of Underwriters Laboratories Inc., File No. E13288 Tyco Electronics offers a full selection of AMP SIAMEZE insulation displacement (IDC) terminals for interconnecting copper magnet wires, lead wires, and other components. The AMP SIAMEZE insulation displacement (IDC) technology eliminates the need to strip the film insulation from copper magnet wires and lead wires. Terminals are available in wire-to-wire, Lead Lok, quick disconnect tabs, posts, pin and receptacle terminals. Standard Range SIAMEZE terminals terminate 34-18 AWG [0.16-1.0 mm] copper magnet wires. R Applications ■ Motor windings and connections ■ Coil connections ■ Transformer windings and connections ■ Ballasts ■ Power supplies ■ Solenoids ■ Actuators Fine Range SIAMEZE terminals terminate 36-27 AWG [0.13-0.38 mm] copper magnet wires. During this operation the small stripping devices penetrate the film insulation from the magnet wire. Medium Range and Heavy Range SIAMEZE terminals terminate 23-12 AWG [0.562.03 mm] copper magnet wires. Residual spring energy in the terminal causes the side walls of the IDC slot to function as opposing cantilever beams. Available with either Moving Beam contacts whereby a single terminal connects to a very wide range of magnet wire sizes, or a Compliant Beam for contacting two magnet wires of the same diameter in one terminal for splicing or bi-filar applications. This constant pressure results in an intimate metalto-metal interface, providing a reliable, long-term connection. According to Tyco Electronics specifications SIAMEZE cavities are either integrated into coil bodies or specially designed cavity housings. The magnet wires are positioned in the “U” shaped slots. The SIAMEZE Inserter cuts the terminals from the strip and places the terminals over the magnet wire into the plastic cavities. The wiping action between the wire and terminals remove all oxides or other contaminants present on both the conductor and the terminal slot side walls, producing a clean, stable, gas-tight electrical termination. The AMP SIAMEZE Inserter may be used as a semiautomatic bench machine or integrated in production lines for fully-automatic applications. 28 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 SIAMEZE Terminals (Continued) Typical Plastic Cavity — Pockets Note: SIAMEZE typical plastic cavities are not for design; Tyco Electronics will supply required dimensions of cavity for each customer application. Each cavity is a rectangular box with two narrow slots on opposing walls and a plastic cutoff or tie-off post. During or after the winding process, the magnet wire is placed across the plastic cavities and into the slots, either manually or by coil winding equipment. Unraveling is prevented by a slight friction fit, suitable bend or by wrapping the magnet wire around the tieoff post. During insertion, the insulation displacing terminal slot strip the film insulation from the magnet wire producing a stable electrical termination. Terminal retention is retained in the plastic cavities by single or multiple locking barbs or locking latches for large quick Cavity Part Number 1601421 .104 [2.63] Min. Cavity Part Number 1601425 .276 [7.01] Min. .140 [3.56] Min. Cavity Part Number 1601423 .380 [9.65] Min. .276 [7.01] Min. Tyco Electronics can provide design and mold engineering resources to manufacture most specifically designed SIAMEZE cavity housings. .270 [6.86] Min. .350 [8.89] Min. .204 [5.18] Min.* Excess magnet wire is trimmed flush with the outside of the plastic cavity by a shear blade traveling with the terminal insertion ram. .570 [14.48] Min. .380 [9.65] Min. .276 [7.01] Min. disconnect FASTON tab terminals. SIAMEZE Terminals Plastic cavities, designed to Tyco Electronics specifications, may be molded as part of the coil bobbin or attached to a lamination stack in the area of the magnet wire coil. Cavity Part Number 1601424 .330 [8.38] Min. .305 [7.75] Min. .276 [7.01] Min. .276 [7.01] Min. .104 [2.63] Min. Cavity Part Number 1601427 .104 [2.63] Min. .116 [2.95] Min. Cavity Part Number 1601431 * Minimum dimension with Lead Lok slot. 29 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 SIAMEZE Terminals (Continued) Typical Plastic Cavity — Pockets (Continued) .380 [9.65] Min. .380 [9.65] Min. .473 [12.01] Min. .116 [2.95] Min. Cavity Part Number 1601432 .490 [12.60] Min. .446 [11.33] Min. .135 [3.44] Min. Cavity Part Number 1601435 .135 [3.44] Min. Cavity Part Number 1601438 .410 [10.41] Min. .167 [4.24] Min. Cavity Part Number 1601462 Cavity Part Number 1601434 .350 [8.89] Min. .580 [14.72] Min. .135 [3.44] Min. Cavity Part Number 1601436 .716 [18.19] Min. .050 [1.27] .204 [5.18] Min.* Cavity Part Number 1601440 .050 Min. [1.27] Wrap Post Part Number 1601447 .380 [9.65] Min. .276 [7.01] Min. .640 [16.26] Min. .404 [10.26] Min. .167 [4.24] Min. Cavity Part Number 1601463 .135 [3.44] Cavity Part Number 1601437 .380 [9.65] Min. .380 [9.65] Min. .276 [7.01] Min. .104 [2.63] Min. .630 [16.00] Min. .520 [13.21] Min. .410 [10.41] Min. .276 [7.01] Min. .204 [5.18] Min.* Cavity Part Number 1601433 .535 [13.59] Min. .293 [7.44] Min. .152 [3.85] Min. Cavity Part Number 1601470 * Minimum dimension with Lead Lok slot. 30 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 SIAMEZE Terminals (Continued) SIAMEZE Interconnection System How the System Operates ➀ Trim Blade ➆ Plastic Cavity Production has to be in accordance with Tyco Electronics specifications (for cavity drawing numbers see tables). Consulting Tyco Electronics is required for design in. ➁ Terminal Insertion Finger The terminal insertion finger is part of the SIAMEZE Inserter. It pushes the terminal that was sheared from the carrier strip through the “tube” into the cavity. ➂ Contact ➀ ➇ Cavity Slot for Wire The width has to be in accordance with the wire size (see cavity drawings). ➁ ➈ Magnet Wire Various wire attachments in standard, fine, medium and heavy duty terminals are available (See tables). ➃ IDC Slot The IDC slot in the terminal will terminate a wide range of magnet wire sizes. ➅ Locking Barbs Terminal retention is provided in the cavity by single or multiple locking barbs. ➂ The magnet wire is positioned in “U” slot manually or automatically by coil winding equipment. ➅ ➃ ➉ Wire Cutoff Block The wire cutoff block supports the magnet wire during the trimming process. The magnet wire is cut plain to the cavity front side. ➄ Stripping Burrs During the insertion process, these burrs strip the film insulation from the magnet wire. SIAMEZE Terminals The trim blade cuts the excess magnet wire and the wire cutoff block at the front of the cavity. 11 ➄ ➆ ➇ Terminal Insertion Complete The magnet wire termination is complete when the terminal is fully seated in the cavity. ➈ ➉ Test Results Standard Range SIAMEZE products have been submitted to the following tests without significant millivolt increase: Current Cycling — 50 cycles with each cycle consisting of 15 minutes “ON” followed by 15 minutes “OFF” 11 Thermal Shock — 10 cycles with each cycle consisting of 30 minutes at 150°C followed by 30 minutes at 21°C Humidity — Temperature Cycling 10 cycles between 25°C and 65°C at 80 to 100% RH 31 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 SIAMEZE Terminals (Continued) Wire-to-Wire Terminals Material Brass .300 [7.62] .300 [7.62] .300 [7.62] .146 [3.71] .146 [3.71] .146 [3.71] .020 [0.51] .020 [0.51] .020 [0.51] A B C .550 [13.97] .300 [7.62] .146 [3.71] .280 [7.11] .020 [0.51] .032 [0.81] D Copper Magnet Wire Range AWG mm2 Lead Wire Range AWG mm2 27–26 0.36–0.13 18-226 0.8-0.3 18-34 1.02-0.16 18-226 0.8-0.3 18–34 1.02–0.16 20 0.5 18-34 1.02-0.16 18 0.8 1601117-1 2-1601117-11 1601000-1 1601000-25 1601056-1 2-1601056-11 1601074-1 2-1601074-11 1601433 1601440 18-34 1.02-0.16 18-226 0.8-0.3 1601046-1 2-1601046-11 4-1601046-12,5 6-1601046-13,5 8-1601046-14,5 1601433 27-36 0.36-0.13 20 0.5 1601125-1 2-1601125-11 4-1601125-12,5 3 6-1601125-1 ,5 1601436 12-23 2.06-0.56 16-20 1.3-0.5 1601136-1 2-1601136-11 4-1601136-12,5 6-1601136-13 Type Recommended Pocket7 A Moving Beam 1601421 1601462 1601463 B Wire Specific 1601421 C High Carry D High Carry Specific E Medium Range E Part Number Reeled Loose 4-1601117-12,5 4-1601000-12,5 4-1601000-22,5 4-1601056-12,5 4-1601074-12,5 ,5 ,5 Reversed Reeled—Consult Tyco Electronics drawing for orientation. Loose Single. 3 Loose Bussed Pair. 4 Loose Bussed Triple. 5 Finish is Post Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). 6 Lead wire may be stranded, solid or bonded with 105°C PVC insulation. Contact Tyco Electronics Engineering when using other types of insulation. 7 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 1 2 32 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 SIAMEZE Terminals (Continued) Lead Lok Terminals Product Facts Provides perpendicular and parallel lead wire strain relief retention forces in excess of 20 lbs. ■ AMP Inserter automatically positions and secures lead wire during insertion ■ Manual, semi-automated, fully automated systems allow for lead wire termination ■ Accepts #18 -#22 [0.3 mm2-0.8 mm2] AWG solid or stranded lead wire with .115 [2.92] max. insulation diameter ■ No lead wire stripping required SIAMEZE Terminals ■ Tyco Electronics features the AMP Lead Lok strain relief terminal system that provides optimum lead wire retention when used in conjunction with SIAMEZE insulation displacement terminals. After the one-step insertion of AMP SIAMEZE wire-towire terminals into Tyco Electronics specified plastic cavities, the application is ready for the secondary lead wire attachment. The lead wire is manually positioned over the magnet wire terminated SIAMEZE wire-to-wire terminal. The AMP Lead Lok Inserter cuts the Lead Lok terminals from the strip and places the terminal over the lead wire in the plastic cavities. This constant pressure results in an intimate metalto-metal interface, providing a reliable, long-term connection. During this operation, the lead wire is automatically seated, the insulation pierced and the exposed solid or stranded conductor is terminated in the IDC slot of the SIAMEZE wire-to-wire terminal. Perpendicular and parallel lead wire strain relief retention forces in excess of 20 lbs are achieved. Residual spring energy in the terminal causes the side walls of the IDC slot to function as opposing cantilever beams. The AMP Lead Lok Inserter may be a secondary station in the AMP SIAMEZE Wireto-Wire semi-automatic bench machine or a separate semi-automatic bench machine inserter depending on the application and required production rates. 33 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 SIAMEZE Terminals (Continued) Lead Lok Interconnection System .250 [6.35] How the System Operates .150 [3.81] 1 2 Type Recommended Pocket A Lead Lok 1601421 1601433 1601440 .025 [0.64] Lead Wire Range AWG mm2 18-222 0.8-0.3 Part Number Reeled 1601140-1 2-1601140-11 Loose 4-1601140-1 Reverse Reeled—Consult Tyco Electronics drawing for orientation. Lead wire may be stranded, solid or bonded with 105°C PVC insulation. Contact Tyco Electronics Engineering when using other types of insulation. ➀ ➀ Lead Lok Insertion Finger The Lead Lok insertion finger pushes the Lead Lok that was sheared from the carrier strip and positions the Lead Lok and lead wire into the IDC slot. ➁ ➁ Lead Lok Terminal ➂ The Lead Lok terminal provides maximum lead wire retention in the cavity. ➂ Locking Barbs ➃ The Lead Lok multiple locking barbs provide retention in the cavity. ➃ Lead Wire Stranded, solid and bonded lead wire with 105°C PVC insulation can be used. Contact Tyco Electronics Engineering for other lead wires and insulation under consideration. ➄ ➅ ➄ IDC Slot The IDC slot will pierce the lead wire during insertion. ➅ Lead Wire Insertion Complete The lead wire termination is complete when the Lead Lok is fully seated in the cavity. 34 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 SIAMEZE Terminals (Continued) Posted Terminals Material Brass SIAMEZE Terminals L L L L L L .146 [3.71] .146 [3.71] .146 [3.71] .020 [0.51] A Type A PC Tab B Extended PC Tab C Long Narrow Width Blade .146 [3.71] .146 [3.71] .020 [0.51] B Recommended Pocket7 C 27-36 0.36-0.13 18-34 1.02-0.16 16-176 1.27-1.15 296 0.29 27-36 0.36-0.13 18-34 1.02-0.16 1601425 D Tab Pair with Diode Slot 1601425 E Long Medium Width Blade 1601425 F Long Medium Blade Medium Range 1601438 18-34 1.02-0.16 27-36 0.36-0.13 18-34 1.02-0.16 18-34 1.02-0.16 12-23 0.56-2.06 .032 [0.81] .020 [0.51] D 1601424 1601431 .020 [0.51] .020 [0.51] Copper Magnet Wire Range AWG mm2 .280 [7.11] E F Part Number L Dim. Tab SIze .345 8.76 .345 8.76 .345 8.76 .345 8.76 .485 12.32 .485 12.32 .456 11.57 .754 19.16 .669 17.00 .756 19.21 .904 22.96 1.005 25.53 .974 24.74 .710 18.03 .710 18.03 .837 21.26 .837 21.26 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .047 x .032 1.20 x. 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .071 x .025 1.80 x 0.64 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 .118 x .025 3.00 x 0.51 .118 x .032 3.00 x 0.81 Reeled 2-1601120-231, 2-1601120-21,3 2-1601009-221, 2-1601009-21,2 2-1601147-231, 2-1601147-21,3 2-1601155-221, 2-1601155-21,2 2-1601128-231, 2-1601128-21,3 2-1601041-221, 2-1601041-21,2 2-1601095-241, 2-1601095-21,4 2-1601110-241, 2-1601110-21,4 2-1601099-11,6 2-1601099-11,6 2-1601063-251, 2-1601063-21,5 2-1601037-251, 2-1601037-21,5 2-1601066-241, 2-1601066-21,4 2-1601104-251, 2-1601104-21,5 2-1601121-241, 2-1601121-21,4 2-1601065-241, 2-1601065-21,4 2-1601008-241, 2-1601008-241, 2-1601051-241, 2-1601051-21,4 .872 22.15 .130 x .032 3.30 x 0.81 1601138-1 2-1601138-11,0 Loose 4-1601120-23 4-1601009-22 4-1601147-23 4-1601155-22 4-1601128-23 4-1601041-22 4-1601095-24 4-1601110-24 4-1601099-1 . 4-1601063-25 4-1601037-25 4-1601066-24 4-1601104-25 — — 4-1601008-24 4-1601051-24 4-1601138-1 . 1 2 Finish is Post Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). Reverse Reeled—Consult Tyco Electronics drawing for orientation. Finish is Post Plated Tin over Nickel (Consult Tyco Electronics drawing for specifics). 4 Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). 5 Finish is Pre-Plated Tin (Consult Tyco Electronics drawing for specifics). 6 Two magnet wires may be terminated in the same slot if diameters are equal. 7 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 3 35 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 SIAMEZE Terminals (Continued) 110 Series FASTON Tab Terminals Material Brass L L L L .146 [3.71] .146 [3.71] .146 [3.71] .020 [0.51] .020 [0.51] A Type A Single Barb Recommended Copper Magnet Wire Range Pocket7 AWG mm C Multi-Barb D Multi-Barb w/ 90° Twist B C D 1.02-0.16 .925 23.50 Hole .110 x .020 2.79 x 0.51 18-34 1.02-0.16 .945 24.00 — .110 x .032 2.79 x 0.81 2-1601097-23,0 2-1601097-21,3 27-36 0.36-0.13 1.240 31.50 — .110 x .032 2.79 x 0.81 18-34 1.02-0.16 .655 16.63 Hole .110 x .020 2.79 x 0.51 .630 15.99 1.240 31.50 — .915 23.24 — 2-1601133-22,5 2-1601133-21,2,5 2-1601039-1,00 2-1601039-11,0 2-1601039-23,0 2-1601039-21,3,0 2-1601064-1,00 2-1601064-11,0 2-1601112-22,5 2-1601112-21,2,5 2-1601151-23,0 Tab Feature Tab Size Hole .110 x .020 2.79 x 0.51 Hole .110 x .020 2.79 x 0.51 27-36 0.36-0.13 .640 16.26 18-34 1.02-0.16 .640 16.26 — Hole 1.02-0.16 1601425 1601425 .020 [0.51] 18-34 L Dim. 1601425 1601431 .020 [0.51] Part Number Reeled Loose 2-1601116-1,00 ,0 4-1601116-1 1,0 2-1601116-1 2-1601005-1,00 4-1601005-1 ,0 2-1601005-11,0 2-1601005-23,0 4-1601005-23 , 2-1601005-21,3,0 3,0 2-1601085-1 4-1601085-13 , 2-1601085-11,3,0 ,00 2-1601045-1 4-1601045-1 ,0 2-1601045-11,0 2-1601059-1,00 4-1601059-1 ,0 2-1601059-11,0 2-1601059-24,0 4-1601059-24,0 2-1601059-21,400 2-1601073-1,00 4-1601073-1 ,0 2-1601073-11,0 18-34 B Single Barb Low Transition .146 [3.71] 18-34 1.02-0.16 18-34 1.02-0.16 21-246 .51-.72 .846 21.49 .110 x .020 2.79 x 0.51 .110 x .020 2.79 x 0.51 — .110 x .020 2.79 x 0.51 — .110 x .032 2.79 x 0.81 .110 x .032 2.79 x 0.81 .110 x .020 2.79 x 0.51 2-1601151-21,3 4-1601097-23 , 4-1601133-22 , 4-1601039-1 ,0 4-1601039-23 4-1601064-1 , ,0 4-1601112-22 4-1601151-23 , , Reversed Reeled—Consult Tyco Electronics drawing for orientation. Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). is Pre-Plated Tin (Consult Tyco Electronics drawing for specifics). 4 Finish is Pre-Plated Silver over Nickel (Consult Tyco Electronics drawing for specifics). 5 Dual Carrier Strip. 6 Two magnet wires may be terminated in the same slot if diameters are equal. 7 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 1 2 3 Finish 36 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 SIAMEZE Terminals (Continued) 187 Series FASTON Tab Terminals Material Brass SIAMEZE Terminals L L L L L L .146 [3.71] .146 [3.71] .146 [3.71] .020 [0.51] A Type B C Recommended Copper Magnet Wire Range Pocket6 AWG mm A Single Barb B Single Barb Short Pocket C Multi-Barb 1601425 1601427 1601425 18-34 18-34 18-34 1.02-0.16 1.02-0.16 1.02-0.16 L Dim. .605 15.37 .505 12.83 .590 14.99 .985 25.02 .618 15.70 .655 16.64 .791 20.09 .832 21.14 .655 16.64 D Multi-Barb Short Profile E Multi-Barb .187/.250 Profile F Latch D E Hole .187 x .020 4.75 x 0.51 1601006-23 2-1601006-21,3,0 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 .187 x .032 4.75 x 0.81 .187 x .020 4.75 x 0.51 1601011-1,0 2-1601011-11,0,0 1601018-22,5 2-1601018-21,2,5,0 1601033-22,5 2-1601033-21,2,5,0 1601021-22, 2-1601021-21,2,0,0 1601013-1,0 2-1601013-11,0,0 1601072-22, 2-1601072-21,2,0 1601068-22, 2-1601068-21,2,0 1601035-1,0 2-1601035-11,0,0 1601035-23, 2-1601035-21,3,0 1601040-1,0 2-1601040-11,0,0 1601142-1,,0 2-1601142-11,0,0 1601058-22,4 2-1601058-21,2,4 Hole — — — Hole — — Hole .187 x .032 4.75 x 0.81 1601434 .492 12.50 Hole .187 x .032 4.75 x 0.81 Hole 1601425 1.02-0.16 .655 16.64 .187 x .020 4.75 x 0.51 1.02-0.16 .805 20.45 .775 19.68 1601423 18-34 18-34 F Part Number Tab Size Hole 0.58-0.81 .020 [0.51] Tab Feature .745 18.92 .655 16.64 20-23** .020 [0.51] .020 [0.51] .020 [0.51] .020 [0.51] .146 [3.71] .146 [3.71] .146 [3.71] Hole Hole Hole .187 x .020 4.75 x 0.51 .187 x .020 4.75 x 0.51 Reeled Loose , 1601020-1,0 2-1601020-11,0,0 1601020-23, 2-1601020-21,3,0 1601049-23, 2-1601049-21,3,0 1601004-1,0 2-1601004-11,0,0 4-1601006-23,0,0 4-1601011-1 ,0,0 4-1601018-22 ,0 4-1601033-22 ,0 4-1601021-22 ,0 4-1601013-1 ,0,0 4-1601072-22 ,0 4-1601068-22, 0 4-1601035-1 ,0,0 , 0 4-1601035-23 4-1601040-1 ,0,0 4-1601142-1 ,0,0 4-1601058-22,4 ,0,0 4-1601020-1 4-1601020-23 4-1601049-23 ,0 ,0 4-1601004-1 ,0,0 Reverse Reeled—Consult Tyco Electronics drawing for orientation. Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). Finish is Pre-Plated Tin (Consult Tyco Electronics drawing for specifics). 4 Extra Short Tab-Does not meet UL & NEMA length requirements. 5 Carrier strip not in retention barb area as shown. 6 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 1 2 3 37 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 SIAMEZE Terminals (Continued) 250 Series FASTON Tab Terminals Material Brass L L L L .280 [7.12] .315 [8.00] .032 [0.81] A Type A Single Barb Medium Range B Single Barb Heavy Range C Multi-Barb D Latch 1601435 12-23 2.03-0.56 12-20 2.03-0.8 16-175 1.27-1.15 14-155 1.60-1.40 27-36 0.36-0.13 .885 22.48 .885 22.48 .885 22.48 .745 18.92 .745 18.92 1601425 1601423 L Dim. .778 19.76 18-34 18-34 .146 [3.71] B Recommended Copper Magnet Wire Range Pocket6 AWG mm 1601438 .032 [0.81] 1.02-0.16 1.02-0.16 .146 [3.71] .020 [0.51] C Tab Feature Tab Size D Part Number Reeled Loose — .250 x .032 6.35 x 0.81 1601139-23........ 2-1601139-21,3...... 4-1601139-23 Hole .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 1601115-1........ 2-1601115-11...... 1601159-1........ 2-1601159-11...... 1601161-1........ 2-1601161-11...... 1601118-23...... 2-1601118-21,3... 1601002-23...... 2-1601002-21,3... 1601028-23...... 2-1601028-21,3... 1601028-1... 2-1601028-113...... 1601061-23...... 2-1601061-21,3... 1601044-1........ 2-1601044-11 .... 1601052-22,4... 2-1601052-21,2,4 1601003-1... 2-1601003-11...... 4-1601115-1 Hole Hole Hole Hole Hole .250 x .032 6.35 x 0.81 Dimple .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .805 20.45 1.000 25.4 1.281 32.53 .850 21.59 .020 [0.51] Hole Hole Hole 4-1601159-1 4-1601161-1 4-1601118-2,3 4-1601002-23 4-1601028-23 4-1601028-1 . 4-1601061-23 4-1601044-1 4-1601052-22 4-1601003-12 Reverse Reeled—Consult Tyco Electronics drawing for orientation. Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). Finish is Pre-Plated Tin (Consult Tyco Electronics drawing for specifics). 4 Double Carrier Strip. 5 Two magnet wires may be terminated in the same slot if diameters are equal. 6 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 1 2 3 38 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 SIAMEZE Terminals (Continued) Pin Terminals .084 Dia. [2.13] .039 Dia. [1.00] L .020 [0.51] .146 [3.71] Type Copper Magnet Wire Range AWG mm2 B 1601424 18-34 1.02-0.16 .718 18.24 .084 2.13 Part Number Reeled Loose 1601077-1 4-1601077-1 2-1601077-11 1601432 27-36 0.36-0.13 .855 21.71 .039 1.00 1601130-22,3 2-1601131-22,3,4 Recommended Pocket5 A Round Pin B Pseudo Round Pin with Diode Slot .020 [0.51] .146 [3.71] A SIAMEZE Terminals L L Dim. Pin Dia. — Reverse Reeled—Consult Tyco Electronics drawing for orientation. Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). Diameter is approximate as Pin is not perfectly round. 4 Reverse Reeled Mirror Image—Consult Tyco Electronics drawing for orientation. 5 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 1 2 3 .199 [5.04] Receptacle Terminals .715 [18.15] .300 [7.62] .032 [0.81] A A Edge Contact In Line B Edge Contact Off Line C Blind Mate Full Surround 1 2 3 Recommended Pocket3 .031 [0.79] .315 [8.00] .020 [0.51] Type .146 [3.71] .310 [7.87] .480 [12.19] .146 [3.71] B Copper Magnet Wire Range AWG mm2 1601425 18-34 1.02-0.16 1601421 15-23 1.47-0.56 1601470 21.5 0.71 C L Dim. Mating Tab Size .300 7.62 .310 7.87 .715 18.15 .020 0.51 .032 0.81 .250 x .020 6.35 x 0.51 Part Number Reeled Loose 2-1601075-221, 2 4-1601075-2 2-1601075-21,2 21, 2-1601137-2 4-1601137-22 2-1601137-21,2 2-1601149-221, 4-1601149-22 2-1601149-21,2 Reverse Reeled—Consult Tyco Electronics drawing for orientation. Finish is Pre-Plated Tin over Copper (Consult Tyco Electronics drawing for specifics). Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 39 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 MAG-MATE and SIAMEZE Application Tooling MAG-MATE Product Terminator (MPT) Product Facts ■ Single, dual and triple insertion ■ Two-reel, two-product capability, with alternating feed capability ■ Available as horizontal bench, vertical bench or independent module ■ Module easily integrates into production lines using simple handshake signals ■ Fine adjustment mechanism for insertion depth (.001 increments) ■ Tube-type insertion tooling for standard MAG-MATE terminals ■ Microprocessor controlled operation ■ Holding fixture for bobbin can be designed and built by Tyco Electronics or the customer Solderless MAG-MATE Terminations: ■ ■ ■ ■ ■ ■ For quick, easy and reliable termination of magnet wire without pre-stripping the insulation or soldering, Tyco Electronics offers the MAG-MATE product family and the MPT-5 (MAG-MATE Product Terminator ) airoperated insertion machine with micro-processor control. The MPT-5 machine inserts a MAG-MATE terminal into a customerdesigned cavity in the coil bobbin or similar magnetwire housing, terminating the wire and providing an I/O terminal or other connection. The MAG-MATE system can create a termination that is very close to the coil. Dual reel capability of the MPT-5 allows insertion of two different MAG-MATE terminals, with the capability to alternate between inserting one and two terminals at a time. Two terminations per second are possible with dual insertion. Loaded with two different terminals, a single MPT-5 can cover a range of 8 AWGs. A fifth generation machine, the MPT-5 is lighter and quieter than previous versions. The MPT-5 is available as a horizontal or vertical bench machine or as a discrete module for integration into automated lines. The discrete module also can be used to make a custom horizontal or vertical bench machine. A fixture to hold the coil assembly, which is required for bench operation, can be designed and built by Tyco Electronics or the customer. The MPT-5 uses three or four air cylinders to feed terminals from one or both reels, cut terminals from the carrier strip, and insert terminals into the cavities. The display shows the operating conditions of the machine such as the batch count, total count, error messages, and ready state. The display also lets the operator step through the machine sequence or manually cycles the machine for set up or easy diagnosis of problems. No need to pre-strip the magnet wire No wire embrittlements due to solder No soldering fumes Compact, clean termination Ideal for automation Fast magnet wire connections: Up to two per second with dual insertion 40 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 MAG-MATE and SIAMEZE Application Tooling (Continued) MPT-5S/L Machine for Mag Wire Coil Termination utilizing SIAMEZE and Lead Lok terminals Product Facts Single, dual and triple insertion ■ Two-reel, two-product capability, with alternating feed capability ■ Available as horizontal bench, vertical bench or independent module ■ Module easily integrates into production lines using simple handshake signals ■ Fine adjustment mechanism for insertion depth (.001 increments) ■ Tube-type insertion tooling for standard SIAMEZE & Lead Lok terminals ■ Microprocessor controlled operation ■ Holding fixture for bobbin can be designed and built by Tyco Electronics or the customer MAG-MATE and SIAMEZE Application Tooling ■ For quick, easy and reliable termination of magnet wire without pre-stripping the insulation or soldering, Tyco Electronics offers the SIAMEZE terminals and Lead Lok product family and the MPT-5S/L (MAG-MATE Product Terminator) air-operated insertion machine with micro-processor control. The MPT-5S/L machine inserts a SIAMEZE terminal into a customer-designed cavity in the coil bobbin or similar magnet-wire housing, terminating the wire and providing an I/O terminal or other connection. The MPT-5S/L can insert both the SIAMEZE terminal for magnet wire termination and the Lead Lok terminal to assure your lead wire connection. Dual reel capability of the MPT-5S/L allows insertion of two different SIAMEZE terminals, with the capability to alternate between inserting one and two terminals at a time. Two terminations per second are possible with dual insertion. A fifth generation machine, the MPT-5s/L is lighter and quieter than previous versions. The MPT-5S/L is available as a horizontal or vertical bench machine or as a discrete module for integration into automated lines. The discrete module also can be used to make a custom horizontal or vertical bench machine. A fixture to hold the coil assembly, which is required for bench operation, can be designed and built by Tyco Electronics or the customer. The MPT-5S/L uses three or four air cylinders to feed terminals from one or both reels, cut terminals from the carrier strip, and insert terminals into the cavities. The display shows the operating conditions of the machine such as the batch count, total count, error messages, and ready state. The display also lets the operator step through the machine sequence or manually cycles the machine for set up or easy diagnosis of problems. Solderless SIAMEZE terminations: ■ No need to pre-strip the magnet wire ■ No wire embrittlements due to solder ■ No soldering fumes ■ Compact, clean termination ■ Ideal for automation ■ Fast magnet and lead wire connections: Up to two per second with dual insertion 41 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 MAG-MATE and SIAMEZE Application Tooling (Continued) Application Tooling for MAG-MATE Terminals The MPT-5 insertion module is the cornerstone of Tyco Electronics magnet wire application tooling. A fifth generation machine, the MPT-5 module is used in conjunction with our bench machine, LPT-522, Rotary Index Table, and can also be order separately when using your equipment manufacture of choice. Electric, pneumatic and de-reeling controls are available allowing for easy integration in your production line. Experienced Tyco Electronics personnel will work with the customer and the equipment manufacturer to adapt the module to their automated assembly system. The Module Specifications Electrical—120 VAC, 60 Hz, 5 A, 1 Ø, or 240 VAC, 50 Hz, 2 A, 1 Ø Air—80 psi [5.52 bar], 3 scfm [0.00142 m3/s] Weight—Approx. 60 lb [27.2 kg] Width—8 [204] Depth—7 [178] Height—30 [762] This insertion tool is capable of applying terminals furnished as loose piece parts. Use for prototype, production startup and moderate volume production runs. Terminals can be inserted at rates up to 300 per hour. Hand Tools Part Number 274250-2 Poke-In Terminals Part Number 274260-1 .187 [4.75] Tab Terminals Part Number 274282-1 .250 [6.35] Tab Terminals 42 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 MAG-MATE and SIAMEZE Application Tooling (Continued) Application Tooling for MAG-MATE Terminals Rotary Index Table Product Facts High-volume rates, up to 600 assemblies per hour ■ Handles Standard and Mini MAG-MATE terminals through interchangeable insertion modules ■ Load-while-run feature increases productivity ■ Fast, simple machine setup and changeover ■ Versions to handle in-line, radial, and linear/angularly opposed cavities ■ Easy programming through hand-held keypad/display ■ Up to 30 insertion sequences stored in EEPROM memory ■ Options include ■ Continuity test station ■ Bend station ■ Dual MAG-MATE modules ■ X- or Y-axis travel ■ Auto-change single/dual insertion modules In operation, the operator places the coil/bobbin/field assembly on the worktable and cycles the machine. The table rotates 90˚ or 180˚ to position the assembly under the insertion module for processing. As each terminal is inserted, the machine automatically indexes to the next insertion position. While this assembly is being processed, the operator can remove the assembly processed during the previous cycle and load a new coil/bobbin/field assembly. This load-while-run feature helps maximize productivity. Assembly rates of up to 600 coils per hour (at six terminations per coil) are possible with dual insertion. A hand-held operator’s terminal contains a keypad and easy-to-read LCD display to allow quick, easy programming of machine functions, including insertion sequences. Up to 30 programs (insertion sequences) can be stored in the EEPROM internal memory. The machine is available with any combination of one or two MPT-5 insertion modules that are fixed or indexing, with or without a rotating fixture for axial insertion. One version allows indexing only in the Y axis for processing in-line cavities. The other includes a rotary fixture that allows the coil/bobbin/field assembly to be rotated to process cavities radially or linear/angularly opposed. MAG-MATE and SIAMEZE Application Tooling ■ The Rotary Index Table is a semiautomatic machine that automatically positions fixtured coils, bobbins, and field assemblies for insertion of MAG-MATE terminals. The table is used with MPT-5 insertion modules, which mount vertically above the table and insert terminals fed from a reel. Modules which are not included as part of the base machine, are available for the entire MAG-MATE line, including Standard and Mini MAG-MATE, SIAMEZE and Lead Lok products. table is also designed to enhance productivity through reliability and easy setup. The number of adjustments required for normal operation has been minimized, while the procedure for product changeovers takes only a few minutes. The result is a machine with little downtime. Options include a continuity test station, a bend station that bends terminals up to 90˚ after insertion, dual modules that insert two identical or different terminals simultaneously, and X-axis travel. Cost savings and productivity are enhanced with Tyco Electronics Field Engineering Service, which provides complete setup and installation assistance, operating and maintenance training, and continuing rapid response through the TollFree Technical Support Center at 1-800522-6752. Besides its fast production rates, the rotary 43 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 MAG-MATE and SIAMEZE Application Tooling (Continued) LPT-522 Linear Product Terminator Product Facts ■ Intermediate to high volume rates, up to 600 assemblies per hour ■ Flexible platform accommodates secondary application modules ■ Version to handle in-line, radial, and linear/angularly opposed cavities ■ Programmable linear slide and rotary table ■ Easy programming through keypad display ■ Palletized fixture system for greater efficiency and production rates ■ Microprocessor controlled ■ Fine insertion depth adjustment (.001 increments) ■ Two-reel, two-product capability with or without alternating feed ■ Single, dual separate, and on-the-fly dual common insertion capability The Linear Product Terminator-522 was designed for intermediate to high volume applications. It is also a very flexible platform since it can accommodate two secondary application modules. These can include, but are not limited to, special wrap-off post trim, continuity testing with defective coil identification, and tab bending. The LPT-522 features our MPT-5 insertion module as well as a programmable linear slide and rotary table system. The flexible system can process coils that have cavity configurations in a linear pattern, axial pattern, or combination of both. The LPT-522 machine is of a serial process design, which allows for a unique coil holding fixture. This fixture can be palletized to increase your efficiency and production rates. The palletized system allows the operator to load/unload a pallet of coils while a second pallet is processing on this machine, increasing the machine up time and decreasing non-productive labor. Specifications Air — 10 scfm@80 psi minimum Electrical — 110 VAC, 5 AMP Footprint — 60"x 52" 44 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 MAG-MATE and SIAMEZE Application Tooling (Continued) LPT-522 Linear Product Terminator (Continued) MAG-MATE and SIAMEZE Application Tooling Rotary Index Insertion Process Optional Continuity Test Station Magnet Wire Termination Machines—Cost Comparison Machine Attribute Applications Horizontal Bench Machine (HBM) Vertical Bench Machine (VBM) LPT-522 Insertion Machine RIT Insertion Machine ● Single row bobbin ● Single terminal feed ● Bottom trim ● Single/Dual/Axial bobbin ● Single or dual feed ● Bottom or top trim ● Same as VBM plus: -Multiple bobbin capacity ✍Auxiliary stations ● Serial Processing ● Same as LPT, plus: -Up to 3 different terminals ● Parallel processing Machine Cost ■ ■■ ■■■ ■■■■ Fixture Cost ■■ ■■■ ■ ■■■■ Complexity ■ ■■ ■■■■ ■■■■ Production Rate ■ ■ ■■■ ■■■■ Cost / Insertion ■■■ ■■■■ ■■ ■ [■ = lowest level] [■ ■ = mid level] [■ ■ ■ = high level] [■ ■ ■ ■ = highest level] Note: All machine options work in conjunction with our MPT-5 module. The MPT-5 module can incorporate an on-the-fly feature, which allows for selection of dual common insertions. The MPT-5 module can also be incorporated in your automated line using your integrator of choice. Please call for details. 45 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 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