MAGNET WIRE
TERMINALS AND
TERMINATION SYSTEMS
MAG-MATE terminals, SIAMEZE
terminals, AMPLIVAR terminals
and splices, and cluster blocks
APPLIANCES /// MAGNET WIRE TERMINATION
Magnet Wire Terminals and Termination Systems
Catalog 82221
Table of Contents
Standard MAG-MATE Terminals
Introduction..................................................................................................................................... 1
Interconnection System .................................................................................................................. 2
Termination Sequence ................................................................................................................... 2
Test Results .................................................................................................................................... 3
300 Box Poke-In Terminals ............................................................................................................ 4
500 Box Poke-In Terminals ............................................................................................................ 6
Poke-In Tab Terminals ................................................................................................................... 7
MAG-MATE Terminals with extended leaf-spring .......................................................................... 8
300 Box Poke-In Terminals ............................................................................................................ 9
Tab Receptacle Terminals .............................................................................................................. 9
187 Box F-Crimp Terminals .......................................................................................................... 10
300 Box F-Crimp Terminals .......................................................................................................... 10
Posted PCB Terminals ................................................................................................................. 11
300 Box Posted PCB Terminals ................................................................................................... 11
MAG-MATE Edge Leaf Terminals ................................................................................................ 12
187 Box Posted PCB Terminals ................................................................................................... 13
187 Box Tab Terminals ................................................................................................................ 13
300 Box Tab Terminals ................................................................................................................ 14
Pin Receptacle Terminals ............................................................................................................. 15
Pin I/O Terminals .......................................................................................................................... 16
110 Series FASTON Tab Terminals .............................................................................................. 17
187 Series FASTON Tab Terminals .............................................................................................. 18
187 Series Combination Poke-In FASTON Terminals ................................................................. 18
250 Series FASTON Tab Terminals .............................................................................................. 21
Typical Plastic Cavity .................................................................................................................... 23
Slim Line MAG-MATE Terminals
Introduction................................................................................................................................... 25
187 Series FASTON Tab Terminals .............................................................................................. 26
250 Series FASTON Tab Terminals .............................................................................................. 26
Posted PCB SOLDER Terminal ................................................................................................... 26
Offset Tab Terminals ..................................................................................................................... 27
Mini MAG-MATE Terminals
Introduction................................................................................................................................... 29
Poke-In Terminal .......................................................................................................................... 30
Posted Terminal ........................................................................................................................... 31
FASTON Tab Terminals ................................................................................................................ 31
Crimp Wire Barrel Terminal ..........................................................................................................31
SIAMEZE Terminals
Introduction................................................................................................................................... 32
Lead Lok Terminals Introduction .................................................................................................. 33
SIAMEZE Interconnection System ............................................................................................... 34
Lead Lok Interconnection System ................................................................................................ 35
Wire-to-Wire Terminals ................................................................................................................. 36
Receptacle Terminals (Wire to Blade) ......................................................................................... 37
Pin Terminals ................................................................................................................................ 37
Post Terminals .............................................................................................................................. 38
110 Series (2.8 mm wide) FASTON Tab Terminals ...................................................................... 39
187 Series (4.75 mm wide) FASTON Tab Terminals .................................................................... 40
250 Series (6.3 mm wide) FASTON Tab Terminals ...................................................................... 41
Typical Plastic Cavity Pockets ...................................................................................................... 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.
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Table of Contents
AMPLIVAR Splices
Introduction................................................................................................................................... 44
General Application Guidelines .................................................................................................... 46
Suggested Splice Selection Procedure ....................................................................................... 46
Technical Documents ................................................................................................................... 46
9 Serrations —Pigtail Type ........................................................................................................... 47
7 Serrations —Pigtail Type ........................................................................................................... 47
5 Serrations —Thru Type ............................................................................................................. 48
5 Serrations —Pigtail Type ........................................................................................................... 49
Miniature Splice —Pigtail Type .................................................................................................... 49
AMPLIVAR Terminals
Introduction................................................................................................................................... 50
Ring Tongue Terminals ................................................................................................................ 51
Stud Retaining Terminals ............................................................................................................. 52
Alternator Eyelet Terminal ............................................................................................................ 52
125 Series Blade .......................................................................................................................... 53
187 Series FASTON Tabs .......................................................................................................... 53
250 Series FASTON Tabs .......................................................................................................... 53
250 Series FASTON Receptacles .............................................................................................. 64
187 Series FASTON Flag Receptacles ....................................................................................... 55
250 Series FASTON Flag Receptacles ........................................................................................ 55
Pin Receptacles............................................................................................................................ 55
250 Series Stator Receptacles —7 Serrations ............................................................................ 56
Stator Terminal —Receptacle .250 x .032 [6.35 x 0.81] .............................................................. 56
Cluster Blocks
Introduction................................................................................................................................... 57
Cluster Blocks 2.29 [.090] Pin Size (Lead Wire and Direct Connect)........................................... 58
Cluster Blocks 3.18 [.125] Pin Size (Lead Wire and Direct Connect)........................................... 60
MTM Crimpband Splices - NOT RECOMMENDED FOR NEW DESIGNS
Introduction................................................................................................................................... 62
MTM Crimpband Interconnection System .................................................................................... 63
11 Serrations ................................................................................................................................ 64
9 Serrations .................................................................................................................................. 64
7 Serrations .................................................................................................................................. 65
RTM Crimpband Splices - NOT RECOMMENDED FOR NEW DESIGNS
Introduction................................................................................................................................... 66
RTM Crimpband Interconnection System..................................................................................... 67
20 Ridges ..................................................................................................................................... 68
14 Ridges ..................................................................................................................................... 68
10 Ridges ..................................................................................................................................... 68
9 Ridges ....................................................................................................................................... 69
8 Ridges ....................................................................................................................................... 69
7 Ridges ....................................................................................................................................... 69
6 Ridges ....................................................................................................................................... 72
3 Ridges ....................................................................................................................................... 73
Power Splice
Introduction................................................................................................................................... 74
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.
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Table of Contents
Application Tooling
Introduction................................................................................................................................... 76
AMPLIVAR Product Terminator (APT) Machine............................................................................. 77
Power Splice Machine................................................................................................................... 77
AMPLIVAR Terminator for Parallel and End Connections............................................................. 78
AMP-O-LECTRIC Model G Terminator with Thru-Splice Applicator.............................................. 78
Crimpband Application Tooling - NO LONGER AVAILABLE.......................................................... 79
MPT-5 MAG-MATE Product Terminator........................................................................................ 80
MAG-MATE Terminal Cavity and Fixture Design........................................................................... 80
MPT-5 S/L Machine for SIAMEZE and Lead Lok Terminals.......................................................... 81
EMT -- Entry Level Magnet Wire Terminator................................................................................. 81
Manual Hand Tool.......................................................................................................................... 82
Manual Arbor Press....................................................................................................................... 82
Hand Insertion Tools...................................................................................................................... 82
Full Line of Crimp Tooling.............................................................................................................. 82
MAG-MATE Inserter MK I with Pneumatic Control........................................................................ 83
MAG-MATE Inserter MK I with Electro Pneumatic Control............................................................ 83
MAG-MATE and SIAMEZE Inserter MARK II with PLC................................................................. 83
MAG-MATE and SIAMEZE Inserter MARK II with PLC and Insertion Force Control.................... 84
Pneumatic Insertion Tool for MAG-MATE Terminals.................................................................... 84
Customer Specific Machines......................................................................................................... 85
Custom Built IDC Terminal Insertion Head.................................................................................... 85
Additional Data
Technical Information .................................................................................................................... 86
Terminal Stud Hole Size................................................................................................................ 90
Part Number Index........................................................................................................................ 91
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.
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals
Product Facts
Standard MAG-MATE
Terminals
Terminates film-insulated
copper and aluminum
magnet wire
E liminates need for
pre-stripping conductors
E liminates need to post
insulate termination
E xcess magnet wire is
automatically trimmed
during the termination
process
S imultaneously 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
H igh speed, fully automated
integrated systems provide
uniform terminations
reliably at the lowest
possible applied cost
C lean metal-to-metal
interface produces stable,
gas-tight electrical
terminations free of oxides
and other contaminants
R ecognized under the
C omponent R ecognition
P rogram of U nderwriters
Laboratories Inc., F ile N o.
E 13288,Vol. 1, S ec 29
R
Applications
Motor windings and
connections
Coil connections
Transformer windings
and connections
TE offers a full selection of
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 size
terminates a range of up to
four consecutive magnet
wire sizes.
Two magnet wires with the
same diameter can be
terminated in one terminal
except as noted.
According to TE
specifications MAG-MATE
cavities are either
integrated into coil bodies
or specially designed cavity
housings. The magnet
wires are precisely
positioned in the plastic
cavity 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, small
stripping shoulders in the
IDC slot remove the film
insulation from the magnet
wire.
Wiping action between
the wire and terminal
removes oxides or other
contaminants present on
both the conductor and the
terminal slot side walls,
producing a clean, stable,
gas-tight electrical
termination.
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
metal-to-metal interface,
providing a reliable,
long-term connection.
The MAG-MATE
Inserter may be used as a
semi-automatic bench
machine or integr ated into
production lines for
fully-automatic applications.
Bobbin connections
Lighting ballasts
Power supplies
*Contact TE Engineering for guidance regarding aluminum
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1
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
Standard MAG-MATE
Interconnection System
How the System Operates
Trim Blade
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.
Insertion Finger
Integration of plastic cavities
into final unit must be in
accordance with TE
Application Specifications.
Consulting TE
is required for design in.
Plastic Cavity
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.
Cavity Slot for Wire
The width has to be in
accordance with the wire
size (see Application Specification).
Contact
Various wire attachments in
three different sizes,.187,
.300,.500 cavity height (see
tables).
Magnet Wire
The magnet wire is
positioned down into the
plastic cavity slots.
IDC 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.
Wire Support Block
The block supports the
magnet wire during the
cutting process. The magnet
wire is cut flush to the cavity
front side.
Stripping Shoulders
During the insertion process,
these shoulders strip the film
insulation from the magnet
wire in four areas.
11
Support Anvil
The anvil supports the wire
during the insertion
process.
Termination Sequence
11
A = Prepare
B = Insert
C = Finish
Trim Blade
A
B
C
Insertion Finger
Poke-In Contact
Plastic Cavity
Magnet Wire
Support Anvil
2
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
Current Cycling—
Humidity—
Temperature Cycling
480 cycles with each cycle
consisting of 15 minutes “ON”
followed by 15 minutes “OFF”
been submitted to the following
tests without significant millivolt
increase:
10 cycles between 25°C and
65°C at 95% RH
Thermal Shock—
Heat Age—
25 cycles with each cycle
consisting of 30 minutes at 125°C
followed by 30 minutes at -65°C
33 days at 118°C
3”
[ 7.62 mm ]
I1
I2 Current Leads
E1
E2 Voltage
Resistance vs Thermal Shock (Copper Wire)
35
Mini MAG-MATE
products have been submitted to
the following tests in addition to
those listed without significant
millivolt increase:
Standard MAG-MATE
Terminals
Test Results
Standard and Slim Line
MAG-MATE products have
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)
30
Milliohms
Milliohms
25
20
15
10
5
0
0
5
10
15
20
25
15 AWG
16 AWG
19 AWG
22 AWG
24 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)
Product Specifications
describe technical performance
characteristics and verification
tests. They are intended for the
Design, Test and Quality
Engineer.
108-2012 Standard .187 and
.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, TE
recommends that samples of the
magnet wire to be used be
submitted for engineering
evaluation.
www.te.com/appliances
3
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
300 Box Poke-In Terminals
Material
Tin plated brass
Type
Typical Cavity Size 2
(See page 23)
A
300 Box
Standard IDC
Locking
Poke-in
.300
[ 7.62 ]
.135
[ 3.43 ]
.118
[ 3.00 ]
B4
300 Box
Standard IDC w/
Strain Relief Slot
Locking
Poke-In
.300
[ 7.62 ]
.118
[ 3.00 ]
B
Mating5
Tab
Stock
Strip
Thickness Part Number*
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.010
0.25
.010
0.25
.012
0.30
.012
0.30
0.5-0.9
.135 x .020
3.40 x 0.50
.016
0.41
62935-1
20-18
0.5-0.9
20-18
0.5-0.9
0.81
20-18
0.5-0.9
.016
0.41
.016
0.41
.016
0.41
63658-1
0.64-0.81
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
19-17 2
0.91-1.15
20-18
0.5-0.9
30
0.25
20-18
0.5-0.9
29-28
0.29-0.32
20-18
0.5-0.9
28-26
0.32-0.40
20-18
0.5-0.9
27-23
0.36-0.57
20-18
0.5-0.9
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.016
0.41
.012
0.30
.012
0.30
.012
0.30
.016
0.41
34-33
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
30-27
0.25-0.36
20-18
0.5-0.9
27-23
0.36-0.57
20-18
25-22 2
0.45-0.64
22-20 2
20
A
.135
[ 3.43 ]
Copper Magnet Wire Range1 Lead Wire Range3
AWG
mm
AWG
mm2
2
63662-1
62431-1
1217234-1
62429-1
62420-1
63591-1
62833-1
63786-1
1217011-1
1217368-1
63789-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 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 See page 7 for mating tab options.
* Recognized under the Component Program of Underwriters Laboratories, Inc.
Solid Lead Wire
POKE-IN MAGMATE
Terminal
MAGMATE
Terminal
Solid
Lead Wire
SOLID WIRE
SOLID WIRE LOCKS
IN “V” NOTCH
Cavity
Magnet Wire
Cavity
POKE-IN SYSTEM: SOLID WIRE CONNECTION
Stranded
Lead Wire
POKE-IN TAB
Terminal
Stranded
Lead Wire
MAGMATE
Terminal
POKE-IN MAGMATE
Terminal
POKE-IN TAB
Terminal
POKE-IN TAB
Locking
Grooves
Tab locks into
edges of leaf
Magnet Wire
Cavity
Cavity
POKE-IN SYSTEM: STRANDED LEAD WIRE AND POKE-IN TAB CONNECTION
4
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
Type
.118
[ 3.00 ]
A
300 Box
Standard IDC
Non-Locking
Poke-In MKI
A
.300
[ 7.62 ]
.135
[ 3.43 ]
.118
[ 3.00 ]
B
B
300 Box
Standard IDC
Non-Locking
Poke-In MKII
Type
.433
[ 11.00 ]
.135
[ 3.43 ]
.125
[ 3.20 ]
C
.433
[ 11.00 ]
.135
[ 3.43 ]
.125
[ 3.20 ]
C
433 Box
Standard IDC
with Receptacle
for Tabs
.110 x .020
[2.8 mm x 0.5 mm]
or .110 x .032
[2.8 mm x 0.8 mm]
D
433 Box
Standard IDC
with Receptacle
for Tabs
.187 x .020
[4.8 mm x 0.5 mm]
or .187 x .032
[4.8 mm x 0.8 mm]
Copper Magnet Wire Range1
AWG
mm
35-32
0.14-0.20
33-30
0.18-0.265
30-26
0.265-0.40
26-21.5 2
0.40-0.67
21.5-18.5 2
0.67-0.95
19.5-17 2
0.91-1.13
33-30
0.18-0.265
30-26
0.265-0.40
2
26-22
0.40-0.63
22-19.5 2
0.63-0.85
19.5-17 2
0.85-1.12
Copper Magnet Wire Range1
AWG
mm
33-30
0.18-0.265
30-26
0.265-0.40
26-22
22-19.5
0.40-0.63
2
0.63-0.85
Stock
Thickness
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.010
0.25
.010
0.25
.013
0.32
.016
0.41
.016
0.41
.016
0.41
.013
0.32
.013
0.32
.013
0.32
.013
0.32
.135 x .020
3.40 x 0.50
.013
0.32
964341-2
Feature
Stock
Thickness
Strip
Part Number
w/o Dimple
Dimple
w/o Dimple
Dimple
w/o Dimple
Dimple
w/o Dimple
Dimple
.013
0.32
.013
0.32
.013
0.32
.013
0.32
.013
0.32
.013
0.32
.013
0.32
.013
0.32
.013
0.32
0.18-0.265
Dimple
26-23
0.40-0.57
w/o Dimple
22.5 - 20 2
0.60-0.80
w/o Dimple
19-172
0.90-1.13
w/o Dimple
1
0.90-1.12
w/o Dimple
19-17
Strip
Part Number*
Mating Tab3
33-31
Standard MAG-MATE
Terminals
.300
[ 7.62 ]
.135
[ 3.43 ]
969082-1
926850-2
926851-2
926852-2
928770-2
1-928771-4
964337-2
964338-2
964339-2
964340-2
1-964114-1
964114-1
1-964108-1
964108-1
1-928854-1
928854-1
1-964106-1
964106-1
1740574-1
964252-1
964110-1
964111-1
1534234-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only; 22 AWG [0.64 mm] or larger unless otherwise noted.
3 See page 7 for mating tab options.
* Recognized under the Component Program of Underwriters Laboratories, Inc.
D
www.te.com/appliances
5
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
300 Box Poke-In Terminals
(Continued)
Material
Tin plated brass
.300
[7.62]
.300
[ 7.62 ]
.135
[3.43]
Typical Cavity Size 2
B
Type
Note: Special cavity required for
See Application Spec.
114-2046.
.118
[ 3.00 ]
A
(See page 23)
Tri-slot splice terminal.
.455
[ 11.56 ]
.118
[3.00]
A3
300 Box
Standard IDC
w/Strain Relief Slot
Non-Locking
Poke-In
Copper Magnet Wire Range1
Strip
Stock
Mating Tab4 Thickness Part Number
AWG
mm
.016
.135 x .020
27-26
0.36-0.40
1217691-1
0.41
3.40 x 0.50
25.5-24
0.43-0.51
23.5-222
0.54-0.64
2
0.68-0.81
21.5-20
B
300 Box
Standard IDC
Non-Locking
Poke-In
30-27
0.25-0.36
27-23
0.36 -0.57
23-202
0.57-0.81
19-17
0.91-1.15
27-23 2
19-17 2
182
0.36-0.57
0.91-1.15
0.8-0.9
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.135 x .020
3.40 x 0.50
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.016
0.41
1217690-1
.135 x .020
3.40 x 0.50
.016
0.41
63975-1
1217689-1
1217688-1
1217221-1
63632-1
1217533-1
1742347-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only; 22 AWG [0.64 mm] or larger.
3 Strain relief slot for high vibration applications.
4 See page 7 for mating small tab options.
* Recognized under the Component Program of Underwriters Laboratories, Inc.
500 Box Poke-In Terminals
Material
Typical Cavity Size 4
(See page 23)
.281
[ 7.14 ]
(See Type H, Page 7)
.118
[ 3.00 ]
.281
[ 7.14 ]
C
Note: Mating poke-in tab
1217324-1
.505
[ 12.83 ]
.505
[ 12.83 ]
Tin plated brass
Type
C
500 Box
Standard IDC
Non-Locking
Poke-In
D3
500 Box
Standard IDC w/
Strain Relief Slot
Non-Locking
Poke-In
.118
[ 3.00 ]
D
Range1
Copper Magnet Wire
AWG
mm
23-19.5
0.57-0.86
19-17
0.91-1.15
16-15
1.29-1.45
23-21.5
0.57-0.68
21-19.5
0.72-0.86
19-17
0.91-1.15
17-16
1.15-1.29
16-15
1.29-1.45
14-13 2
1.61-1.83
Stock
Thickness
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.016
0.41
Strip
Part Number
1217069-1
1217068-1
1217067-1
1217358-1
1217357-1
1217356-1
1742203-1
1217355-1
1217579-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only.
3 Strain relief slot for high vibration applications.
6
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
Poke-In Tab Terminals
Material
.135
[ 3.43 ]
.312
[ 7.92 ] .275
[ 6.98 ]
.135
[ 3.43 ]
.312
[ 7.92 ] .275
[ 6.98 ]
.255
[ 6.48 ]
.405
[ 10.29 ]
.323
[ 8.20 ]
.203
[ 5.28 ]
B
A
.135
[ 3.43 ]
Standard MAG-MATE
Terminals
.135
[ 3.43 ]
Tin plated brass
Optional Slot for
#20 AWG [0.8 mm] Dia.
Solid Copper Diode Slot
Type
A
90° Up
.255
[ 6.48 ]
B
90° Up
w/Ins. Sup.
.520
[ 13.21 ]
C
Straight
D
.208
[ 5.28 ]
.312
[ 7.92 ]
D
Straight
w/Ins. Sup.
.135
[ 3.43 ]
E
E
90° Down
C
Lead Wire Size1
AWG
mm2
22-18
Stock
Thickness
Strip
Part Number
62895-1*
.060-.100
1.52-2.54
.090-.140
2.29-3.56
.018
0.46
.020
0.51
.018
0.46
.018
0.46
.018
0.46
.020
0.51
.020
0.51
.020
0.51
.020
0.51
Ins. O.D.
0.3-0.9
24
0.2
22-18
0.3-0.9
18-14
0.8-2.0
22-18
0.3-0.9
18-14
0.8-2.0
.040-.060
1.02-1.52
.060-.100
1.52-2.54
.090-.140
2.29-3.56
63410-1
1742828-1
62896-1*
63218-1
62897-1*
63775-1
22-18
0.3-0.9
18-14
0.8-2.0
22-17
0.3-1.0
.118 MAX.
3.00 MAX.
.018
0.45
281622-2
2
22-17
0.3-1.0
.118 MAX.
3.00 MAX.
.018
0.45
281623-2
2
20-17
0.5-1.0
.063-.090
1.60-2.30
.018
0.45
964101-2
3
20-17
0.5-1.0
.063-.090
1.60-2.30
.018
0.45
964290-1
22-18
0.3-0.9
.018
0.46
63364-1
18-14
0.8-2.0
.018
0.46
1742125-1
62898-1*
63397-1
4
1 Stranded, fused stranded or solid lead wire.
Note: All tab terminals accept stranded, fused stranded
or solid lead wire.
2 Can be selectively bent inside applicator. With support flanges,
can only be used in combination with modified cavity IA-84-5157
3 Can be selectively bent inside applicator, Non-locking
4 Can be selectively bent inside applicator. Non-locking;use
with housing
* Recognized under the Component Program of
Underwriters Laboratories, Inc.
7
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
Poke-In Tab Terminals
Material
.340
[ 8.64 ]
Tin plated brass
Pre-Tin plated brass
.245
[ 6.22 ]
.312
[ 7.92 ]
.106
[ 2.70 ]
.315
[ 8.00 ]
.135
[ 3.43 ]
.135
[ 3.43 ]
F
Type
.197
[ 5.00 ]
.135
[ 3.43 ]
.150
[ 3.81 ]
.490
[ 12.45 ]
J
I
Lead Wire Size1
AWG
mm2
Ins. O.D.
Stock
Thickness
.048-.078
1.22-1.98
.060-.100
1.52-2.54
.090-.140
2.29-3.56
Strip
Part Number
1742410-1
K
Bridge Contact
L
PCB Contact
.020
0.51
1217041-1
I
Flag - 300 Box only
J
Flag - 500 Box only
.250
[ 6.35 ]
.540
[ 13.72 ]
.285
.347 [ 7.24 ]
[ 8.81 ]
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
F
90° Down
w/Ins. Sup.
K
.110
.370 [ 2.79 ]
[ 9.40 ]
24-20
0.2-0.5
22-18
0.3-0.9
18-14
0.8-2.0
20-16
0.5-1.4
0.8-2.0
18-14
.080-.120
2.03-3.05
1742211-1
63458-1
1217406-1
1217324-1
1987199-1
Note: All tab terminals accept stranded, fused stranded
or solid lead wire.
.200
[ 30.48 ]
L
MAG-MATE Terminals
with extended leaf-spring
Material
Pre-tinned copper alloy
Type
.55
[ 13.9 ]
.41
[ 10.3 ]
M
Mag-Mate Terminal with
extended Leaf-Spring
*Single magnet wire
.120
[ 3.05 ]
Copper Magnet Wire Range
AWG
mm
33-30
0.18-0.265
30-26
0.265-0.40
26.5-22.5
0.375-0.60
22.5-20
0.60-0.80
19.5-17
0.85-1.12
Stock
Thickness
.013
0.32
.013
0.32
.013
0.32
.013
0.32
.013
0.32
Strip
Part Number
1740603-1
1740698-2
1534110-1
969125-1*
1418686-1
Note: Special cavity is required,contact TE connectivity
for information.
.136
[ 3.45 ]
M
8
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
300 Box Poke-In Terminals
Standard MAG-MATE
Terminals
Material
Tin plated brass
.300 [7.62] Series Box
Typical Cavity Size 2
(See page 23)
.300
[ 7.62 ]
.300
[ 7.62 ]
Note: Special cavity required for
Tri-slot splice terminal.
SPEC 114-2046
.455
[ 11.56 ]
.120
[ 3.05 ]
.135
[ 3.43 ]
See application
A
Type
A
300 Box
Standard IDC
Splice
B
300 Box
Standard IDC
Tri-Slot
Splice
B
Range1
Copper Magnet Wire
AWG
mm
22-20
0.64-0.81
19-17
0.91-1.15
28-24
0.32-0.51
23-20
2
27-23
4
18
19-17 2
25-223
4
18
23.5-20 2
.120
[ 3.05 ]
Stock
Thickness
Strip
Part Number
.016
0.41
.020
0.51
.016
0.41
1217973-1
.016
0.41
1217853-1
.016
0.41
1217613-1
.016
0.41
1217209-1
0.57-0.81
0.36-0.57
0.8-0.9
0.91-1.15
0.45-0.64
0.8-0.9
0.54-0.81
1742159-14
1217858-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only; 22 AWG [0.64 mm] or larger.
3 Single solid or fused stranded lead wire only.
4 Special cavity required for 1742159-1.
Tab Receptacle Terminals
Material
Tin plated phos. bronze
.345
[8.76]
.185
[4.70]
Note: Special cavity required.
Contact TE Engineering for
.110
[2.79]
details.
.070
[1.78]
C
Type
C
185 Box
Standard IDC
Tab Receptacle
Copper Magnet Wire Range1
AWG
mm
32-31
0.20-0.23
30-28
0.25-0.32
29-28
0.29-0.32
28-27
0.32-0.36
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
.070 x .020
1.78 x 0.51
.010
0.25
.010
0.25
.010
0.25
.010
0.25
Strip
Part Number
1217538-1
1217457-1
1217458-1
1742781-1
1 Two magnet wires may be terminated in the same slot if diameters are equal.
www.te.com/appliances
9
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
187 Box F-Crimp Terminals
Material
Tin plated brass
.187 [4.75] Series Box
.187
[ 4.75 ]
.360 .187
[ 9.14 ] [ 4.75 ]
Typical Cavity Size 1
.467
[ 11.86 ]
(See page 23)
.090
[ 2.29 ]
B
A
Copper Magnet Wire Range1
AWG
mm
Type
A
187 Box
Standard IDC
F-Crimp
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
0.51-0.64
26-22
0.12-0.3
0.36-0.46
22-18
0.3-1.0
24-22
B
187 Box F-Crimp
w/Ins Sup.
Lead Wire Range3
AWG
mm2
33-31
2
27-25
.070
[ 1.78 ]
.090
[ 2.29 ]
.070
[ 1.78 ]
Ins. O.D.
Strip
Part Number
Stock
Thickness
.010
0.25
.012
0.30
.012
0.30
.012
0.30
.012
0.30
.071-.088
1.80 -2.23
63039-1
63036-1
62609-1
4
1217146-1
62610-1
.012
0.30
4
63856-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 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.
300 Box F-Crimp Terminals
Material
Type
Tin plated brass
Copper Magnet Wire Range1
AWG
mm
.300 [7.62] Series Box
Typical Cavity Size 2, when
33-31
0.18-0.23
31-28
0.23-0.32
30-27
0.25-0.36
28-24
0.32-0.51
“C” dimension is .120 [3.05]
(See page 23)
Typical Cavity Size 6, when “C”
dimension is .070 [1.78]
(See page 23)
C
300 Box
Standard IDC
F-Crimp
.480
[ 12.19 ]
.300
[ 7.62 ]
27-24
0.36-0.51
27-23
0.36-0.57
25-22
0.45-0.64
2
0.64-0.81
2
0.91-1.15
22-20
19-17
.135
[ 3.43 ]
C
10
Dim.
C
.070
1.78
.120
3.05
.070
1.78
.070
1.78
.120
3.05
.120
3.05
.070
1.78
.120
3.05
.070
1.78
.120
3.05
.120
3.05
Lead Wire Range3
AWG
mm 2
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
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
22-18
0.3-1.0
Stock
Thickness
.012
0.30
.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
.016
0.41
Strip
Part Number
63235-1
63420-1
63236-1
1742614-1
62992-1
63641-1
63237-1
62459-1
63690-1
62458-1
63504-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only; 22 AWG [0.64 mm] or larger.
3 Stranded, fused stranded or solid lead wire.
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
300 Box Posted PCB
Terminals
L
Material
.300
[ 7.62 ]
Tin over Copper Alloy
Cavity Size
.132
[ 3.35 ]
Application Spec.
114-74109 with 114-74109-5
Type
A
Multi-Spring
Solderless PCB
Tab Terminal
Standa rd MAG-MATE
Terminals
Multi-Spring
Solderless Terminal
A
Copper Magnet Wire Range1
AWG
mm
33-29.5
0.18-0.265
29.5-26
0.265-0.40
26-22.5
22.5-19.5
19.5-17
.120
[ 3.05 ]
2
.583
14.80
.583
14.80
.583
14.80
.583
14.80
.583
14.80
0.40-0.63
2
Stock Thickness
Tab Section
Mag Wire Section
.013
.031
0.32
0.80
.013
.031
0.32
0.80
.013
.031
0.32
0.80
.031
.013
0.80
0.32
.031
.013
0.80
0.32
Dim
L
0.63-0.85
0.85-1.12
Strip
Part Number
1247000-2
1247001-2
1247002-2
1247003-2
1247004-2
Note: PC Board hole size .057 [1.45].
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only. 22 awg [0.63 mm] and larger.
300 Box Posted PCB
Terminals
Solder Terminal
.042
[ 1.07 ]
L
Material
.300
[ 7.62 ]
Tin over copper plated brass
Typical Cavity Size
(See page 23)
.135
[ 3.43 ]
Type C—Cavity Size 2
Type D—Cavity Size 6
L
.300
[ 7.62 ]
B
Type
B
300 Box
Standard IDC
PCB Post
C
PCB Post
Shallow Box
Copper Magnet Wire Range1
AWG
mm
C
Dim.
L
22-20
2
0.64-0.81
19-17
2
0.91-1.15
19-17
2
0.91-1.15
.540
13.72
.540
13.72
.540
13.72
.460
11.68
.460
11.68
.460
11.68
.570
14.48
0.18-0.23
.475
12.07
33-31
0.18-0.23
31-28
0.23-0.32
29-26
0.29-0.40
27-23
0.36-0.57
33-31
.070
[ 1.78 ]
.135
[ 3.43 ]
.120
[ 3.05 ]
Stock Thickness
Tab Section
Mag Wire
.010
0.25
.010
0.25
.012
0.30
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.010
0.25
.010
0.25
.012
0.30
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.020
0.51
.012
0.30
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.
Strip
Part Number
63253-1
62928-1*
62958-1*
63659-1
63660-1
63661-1
1742708-1
1217302-1
Note: PC Board hole size .050 [1.27].
www.te.com/appliances
11
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
MAG-MATE
Edge Leaf Terminal
Material
Pre-tinned brass
Brass
Cavity
411-18517
Copper Magnet Wire Range
AWG
mm
16.2
A
MAG-MATE
Contact RAST 5D
7.6
3
A
Cavity Size
33-30
0.18-0.265
2
30-26
0.265-0.40
2
26-22
0.40-0.63
2
22-20
0.63-0.80
2
20-17
0.85-1.12
2
Stock
Thickness
.013
0.32
.013
0.32
.013
0.32
.013
0.32
.013
0.32
Strip
Part Number
1394429-2
1394430-2
1394431-2
1394432-2
1394433-2
Note: Special cavity required. Contact
TE Connectivity for information
3.15
Material
Unplated brass
Cavity
411-18517
Type
B
MAG-MATE
Edge Leaf Contact
.64
[ 16.2 ]
Copper Magnet Wire Range
AWG
mm
33-30
0.18-0.265
Cavity Size
Stock
Thickness
Strip
Part Number
2
.013
0.32
1-1987143-1
Note: Special cavity required. Contact
TE Connectivity for information
.31
[ 7.8 ]
.12
[ 3.0 ]
12
B
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
187 Box Posted PCB
Terminals
Tin plated brass
Copper Magnet Wire Range1
AWG
mm
33-31
Dim.
L
.267
6.78
0.18-0.23
(See page 23)
.050
[ 1.27 ]
L
A
185 Box
Standard IDC
PCB Post
.187
[ 4.75 ]
30-28
0.25-0.32
27-25
0.36-0.46
24-222
0.51-0.64
.010
0.25
.010
0.25
.330
8.38
.267
6.78
.287
7.29
.330
8.38
.330
8.38
.287
7.29
.330
8.38
Typical Cavity Size 1
Strip
Part Number
Stock Thickness
Standard MAG-MATE
Terminals
Material
Type
63565-1
62938-1
.012
0.30
.012
0.30
.012
0.30
.012
0.30
.012
0.30
.012
0.30
63160-1
63818-1
62430-1
62438-1
63819-1
62439-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only.
.090
[ 2.29 ]
.070
[ 1.78 ]
A
187 Box Tab Terminals
Material
Tin plated brass
Typical Cavity Size 1
Type
(See page 23)
Dim.
L
Tab Size
0.25-0.32
.432
10.97
.110 x .020
2.79 x 0.51
.020
0.51
.012
0.30
63702-1
29-27
0.29-0.36
0.25-0.32
27-25
0.25-0.32
24-22
0.25-0.32
30
0.25
29-27
0.29-0.36
25-222
0.46-0.64
.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
.071 x .025
1.80 x 0.63
.059 x .032
1.50 x 0.81
.059 x .032
1.50 x 0.81
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.025
0.63
.032
0.81
.032
0.81
.012
0.30
.012
0.30
.012
0.30
.012
0.30
.012
0.30
.012
0.30
.012
0.30
1217196-1
30-28
.432
10.97
.512
13.00
.512
13.00
.512
13.00
.550
14.00
.700
17.78
.700
17.78
Copper Magnet Wire Range1
AWG
mm
30-28
B
187 Box
Standard IDC
F-Crimp
L
.187
[ 4.75 ]
.090
[ 2.29 ]
.070
[ 1.78 ]
Stock Thickness
Tab Section Mag Wire
Strip
Part Number
160810-2
160809-2
160897-2
1217405-1
1742605-1
1217013-1
1 Two magnet wires may be terminated in the same terminal if diameters are equal.
2 Single magnet wire only.
B
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13
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
300 Box Tab Terminals
Material
Tin plated brass
.870
[ 22.1 ]
L
Typical Cavity Size 2
(See page 23)
.300
[ 7.62 ]
.135
[ 3.43 ]
.300
[ 7.62 ]
.120
[ 3.05 ]
.135
[ 1.78 ]
C
B
A
Type
A
300 Box
Standard IDC
Straight Tab
Copper Magnet Wire Range1
AWG
mm
20
0.79
31
0.23
Dim.
L
Tab Size
.750
19.05
.895
22.73
.870
22.10
.063 x .025
1.60 x 0.63
.063 x .025
1.60 x 0.63
.062 x .032
1.57 x 0.81
Stock Thickness
Tab Section
Mag Wire
.025
.016
0.63
0.41
.025
.016
0.63
0.41
.010
.032
0.81
0.25
Strip
Part Number
63965-12
1217595-1
2
63810-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Tinsel wire only.
Typical Cavity Size 2
when “C” dimension is.120[3.05]
(See page 23)
Typical Cavity Size 6
when “C” dimension is.070[1.78]
(See page 23)
Type
B
300 Box
Standard IDC
Twisted Tab
Copper Magnet Wire Range1
AWG
mm
33-31
0.18-0.23
31-28
0.23-0.32
27-24
0.36-0.50
212
0.72
2
19.5
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
0.51
.020
0.51
.020
0.51
.030
0.76
.030
0.76
.012
0.30
.012
0.30
.012
0.30
.016
0.41
.016
0.41
Strip
Part Number
63806-1
63807-1
63808-1
63463-1
63216-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only.
Material
Type
Tin plated brass
Typical Cavity Size 2
(See page 23)
L
.300
[ 7.62 ]
.120
[ 3.05 ]
.132
[ 3.35 ]
C
14
C
300 Box
Standard IDC
Timer Tab
Copper Magnet Wire Range1
AWG
mm
33-31
0.18-0.23
30 -28
0.25-0.32
27-23
0.36-0.57
25-222
0.45-0.64
2
23.5-21.5
0.54-0.68
27-23
0.36-0.57
23-202
0.57-0.81
19-172
0.91-1.15
18 Lead
1.02
Dim.
L
Tab Size
.585
14.86
.585
14.86
.585
14.86
.585
14.86
.585
14.86
.585
14.86
.775
19.68
.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
3.17 x 0.51
.118 x .020
3.00 x 0.51
.118 x .020
3.00 x 0.51
.125 x .020
3.17 x 0.51
.125 x .020
3.17 x 0.51
.118 x .020
3.00 x 0.51
.118 x .020
3.00 x 0.51
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
.016
.020
0.41
0.51
.016
.020
0.41
0.51
.016
.020
0.41
0.51
.020
.016
0.51
0.41
.016
.020
0.41
0.51
Strip
Part Number
1217746-1
1217745-1
63973-1
63489-1
1217596-1
1217593-1
1742167-1
63899-1
63972-1
63974-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only; 22 AWG [0.64 mm] or larger.
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
Pin Receptacle Terminals
A: Tin plated brass
B: Unplated brass
.75
[ 19 ]
.748
[ 19 ]
Typical Cavity Size 2
.30
[ 7.6 ]
.300
[ 7.62 ]
(See page 23)
.132
[ 3.35 ]
.120
[ 3.05 ]
.12
[ 3.0 ]
A
Type
A
Pin
Receptacle
Copper Magnet Wire Range1
AWG
mm
30-27
0.25-0.36
26-23
0.40-0.57
2
0.72-1.00
26-23
0.40-0.57
2
0.72-1.00
21-18
21-18
30-27
B
Pin
Receptacle
Standard MAG-MATE
Terminals
Material
0.25-0.36
26-23
0.40-0.57
3
0.72-1.00
21-18
B
.138
[ 3.5 ]
Mating Pin Dia.
Stock Thickness
.079
2.00
.079
2.00
.079
2.00
.150
3.80
.150
3.80
.150
3.80
.013
0.32
.013
0.32
.013
0.32
.013
0.32
.013
0.32
.013
0.32
.150
3.80
.150
3.80
.013
0.32
.013
0.32
Strip
Part Number
1394403-1
1394475-1
1394476-1
1394638-1
1394639-1
1740417-1
1740418-1
1740419-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only; 20.5 AWG [0.76 mm] or larger.
3 Single magnet wire only
www.te.com/appliances
15
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
Pin I/O Terminals
Material
Tin plated brass
.300 [7.62] Series Box
.048
[ 1.22 ]
.060
[ 1.52 ]
Styles A, B and C
Typical Cavity Size 2
(See page 23)
.789
[ 20.29 ]
.300
[ 7.62 ]
.500 [12.7] Series Box
Style D
Typical Cavity Size 4
(See page 23)
.668
[ 16.76 ]
.300
[ 7.62 ]
.120
[ 3.05 ]
.135
[ 3.43 ]
.120
[ 3.05 ]
.120
[ 3.05 ]
A
B
.090
[ 2.29 ]
.048
[ 1.22 ]
.660
[ 16.76 ]
.300
[ 7.62 ]
.500
[ 17.7 ]
.120
[ 3.05 ]
.860
[ 21.84 ]
.280
[ 7.11 ]
.120
[ 3.05 ]
.120
[ 3.05 ]
C
Type
D
Copper Magnet Wire Range1
AWG
mm
Pin
Dia.
Stock Thickness
I/O
Mag Wire
Strip
Part Number
A
300 Box
Straight Pin
27-23
0.36-0.57
.060
1.52
.010
0.25
.010
0.25
63722-1
B
300 Box
Offset Pin-R.H.
33-31
0.18-0.23
.048
1.22
.010
0.25
.010
0.25
63443-1
33-31
0.18-0.23
0.23-0.32
.010
0.25
.010
0.25
.048
1.22
.048
1.22
.010
0.25
.010
0.25
.010
0.25
.010
0.25
63444-1
31-28
.048
1.22
.048
1.22
.016
0.25
.016
0.41
63570-1
.090
2.29
.090
2.29
.016
0.41
.016
0.41
.016
0.41
.016
0.41
63278-1
C
300 Box
Offset Pin-L.H.
D
500 Box
Straight Pin
27-23
0.36-0.57
25-222
0.45-0.64
27-23
0.86-1.15
22-20
0.64-0.81
63569-1
63788-1
63277-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only; 22 AWG [0.64 mm] or larger.
16
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
110 Series
FASTON Tab Terminals
Standard MAG-MATE
Terminals
Material
Tin plated brass
Typical Cavity Size 2
(See page 23)
.300
[ 7.62 ]
.310
[ 7.87 ]
Note:.110 [2.79] Tab Terminals
Request Catalog 82004.
.300
[ 7.62 ]
.135
[ 3.43 ]
mate with compatible
FASTON receptacles.
.660
[ 16.76 ]
.625
[ 15.88 ]
.625
[ 15.88 ]
.135
[ 3.43 ]
.120
[ 3.05 ]
.120
[ 3.05 ]
B
A
Type
A4
300 Box
Standard IDC
.110[2.79]
FASTON Tab
B 4.5
300 Box
Single IDC w/
Strain Relief Slot
C 3.4
Poke-In
Combination Tab
.135
[ 3.43 ]
Copper Magnet Wire Range1
AWG
mm
30-27
0.25-0.36
27-23
0.36-0.57
23-20
2
0.45-0.64
19-17
0.91-1.15
27-23
0.36-0.57
3.5-202
0.54-0.81
28-24
0.32-0.51
2
0.45-0.64
25-22
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
.120
[ 3.05 ]
C
Stock Thickness
Tab
Mag Wire
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.012
0.30
.016
0.41
.016
0.41
.020
0.51
.016
0.41
.016
0.41
.012
0.30
.012
0.30
Strip
Part Number
63777-1
63746-1
63486-1
63145-1
63827-1
1217783-1
63062-1
63063-2
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only; 22 AWG [0.64 mm] or larger.
3 Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] Solid or overcoated stranded lead wire or 90° Poke-In tab.
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 Strain relief slot for high vibration applications.
www.te.com/appliances
17
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
187 Series
FASTON Tab Terminals
Type
Copper Magnet
Wire Range1
Dim.
L
Tab
Feature
Dimple
AWG
mm
Tin plated brass
33-31
0.18-0.23
.630
16.00
.660
16.76
Typical Cavity Size
30-27
0.25-0.36
.630
16.00
Material
(See page 23)
Type A—Cavity Size 2
Dimple
Dimple
Dimple
27-23
Hole or
Dimple
0.36-0.57
3
A
300 Box
Standard IDC
.187 [4.75]
FASTON
Tab
L
.300
[ 7.62 ]
23
0.57
.630
16.00
.660
16.76
.630
16.00
0.64-0.81
Hole
2
Tin plated brass
Hole
Dimple
A
Material
Hole
.630
16.00
.120
[ 3.05 ]
187 Series
Combination Poke-In
FASTON Terminals
Hole
Dimple
22-202
.135
[ 3.43 ]
Hole
.630
16.00
20-18
0.81-1.02
19-17
0.91-1.15 .630
16.00
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
Stock Thickness
Tab
Mag. Wire
Section
Section
.020
.010
0.51
0.25
.020
.012
0.51
0.30
.020
.012
0.51
0.30
.032
.012
0.81
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
.032
.016
0.81
0.41
.032
.016
0.81
0.41
.020
.020
0.51
0.51
.020
.020
0.51
0.51
.020
.020
0.51
0.51
.020
.020
0.51
0.51
Strip
Part Number
62513-1*
63584-1
62512-1*
62678-1†*
62514-1*
63664-1
63461-1
63585-1
63776-1
62511-1*
63663-1
1217065-1
1217128-1
4
62904-1
63670-1
63273-12
1742160-11
63665-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 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 Single bare copper wire only.
* Recognized under the Component Program of Underwriters Laboratories, Inc.
† These part numbers are available upon special request; contact TE Engineering for details.
Typical Cavity Size
(See page 23)
Type
Type B—Cavity Size 2
B 3.4
Poke-In
Combination
Tab
.310
[ 7.87 ]
.120
[ 3.05 ]
.135
[ 3.43 ]
Copper Magnet
Wire Range1
mm
AWG
33-31
0.81-0.23
27-222
0.35-0.63
22-19
2
0.64-0.89
19-17
2
0.90-1.15
17-16
2
1.20-1.30
Dim.
L
.630
16.00
.630
16.00
.630
16.00
.630
16.00
.630
16.00
Tab
Feature
Hole
Hole
w/o Hole
Hole
w/o Hole
Hole
w/o Hole
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 .020
4.75 x 0.51
.187 x .020
4.75 x 0.51
Stock Thickness
Tab
Mag. Wire
Section
Section
.020
.010
0.51
0.25
.020
.016
0.51
0.41
.020
.016
0.51
0.41
.016
.020
0.41
0.51
.020
.016
0.51
0.41
Strip
Part Number
63018-1
316300-4
2-316300-7
316300-5
2-316300-8
316300-6
2-316300-9
6-316300-7
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only; 22 AWG [0.64 mm] or larger.
3 Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] solid, fused stranded lead wire or 90° poke-in tab terminal.
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.
B
Note:.187 [4.75] Tab Terminals
mate with compatible FASTON
receptacles. Request
Catalog 82004.
Chart continued on next page
18
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
187 Series
FASTON Tab Terminals
.187
[ 4.75 ]
Hole or
Dimple
Material
Standard MAG-MATE
Terminals
(Continued)
Dimple
L
Tin plated brass
.300
[ 7.62 ]
.300
[ 7.62 ]
Typical Cavity Size
(See page 23)
.120
[ 3.05 ]
Type A—Cavity Size 5
Type B—Cavity Size 5
.135
[ 3.43 ]
.120
[ 3.05 ]
.135
[ 3.43 ]
A
Type
A
300 Box
Standard IDC
Narrow Body
Latch Type
Copper Magnet
Wire Range1
mm
AWG
33-31
0.18-0.23
31-28
0.23-0.32
30-27
0.25-0.36
27-23
0.36-0.57
2
0.57-0.81
22-202
0.64-0.81
19-172
0.91-1.15
23-20
2
18 lead 0.80-0.92
B3
Narrow Body
2
Latch Type w/ 23.5-20
Strain Relief Slot
mm 2
0.54-0.81
B
Dim.
L
Tab
Feature
.630
16.00
.630
16.00
.630
16.00
Dimple
.630
16.00
.630
16.00
.630
16.00
.630
16.00
Dimple
Dimple
Dimple
Dimple
Dimple
Dimple
Dimple
Hole
.630
16.00
.630
16.00
Dimple
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 .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
Tab
Mag. Wire
Section
Section
.010
.020
0.25
0.51
.010
.020
0.25
0.51
.012
.020
0.30
0.51
.016
.020
0.41
0.51
.016
.020
0.41
0.51
.016
.020
0.41
0.51
.016
.020
0.41
0.51
.016
.020
0.41
0.51
.016
.020
0.41
0.51
.016
.020
0.41
0.51
.020
0.51
.016
0.41
Strip
Part Number
63108-1†
62743-1†
63109-1†
63107-1
1217493-1
63340-1
63429-1
62888-1
63782-1
1217592-1†
1217004-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only; 22 AWG [0.64 mm] or larger.
3 Strain relief slot for high vibration applications.
† These part numbers are available upon special request; contact TE Engineering for details.
Chart continued on next page
www.te.com/appliances
19
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
187 Series
FASTON Tab Terminals
(Continued)
Material
Tin plated brass
Typical Cavity Size
(See page 23)
Type A—Cavity Size 4
Type B—Cavity Size 4
Type
Hole or
Dimple
Copper Magnet
Wire Range1
mm
AWG
22-20
0.64-0.81
19-17
0.91-1.15
Dim.
L
Tab
Feature
.830
21.08
.830
21.08
Hole
Hole
Hole
.505
[ 12.83 ]
17.5-16
.120
[ 3.05 ]
1.09-1.29
A3
500 Box
Standard IDC
Hole
1.29-1.45
.830
21.08
14.5-13
1.54-1.83
27-23
0.36-0.57
.830
21.08
.830
21.08
22-20
0.64-0.81
.830
21.08
19-17
0.91-1.15
.830
21.08
16-15
.187
[ 4.75 ]
3.4
Hole
.505
[ 12.83 ]
.281
[ 7.14 ]
.120
[ 3.05 ]
B
Hole
Dimple
2
L
Hole
Hole
.280
[ 7.11 ]
A
.830
21.08
B
500 Box
Single IDC w/
Strain Relief Slot
16-15
1.29-1.45
.830
21.08
Hole
Hole
Hole
Hole
Hole
Hole
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 .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
Stock Thickness
Tab
Mag. Wire
Section
Section
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.032
0.81
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.032
0.81
.020
0.51
.032
0.81
.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
Strip
Part Number
1742819-1
1742820-1
63667-1
63427-1
1217075-1
63666-1
63762-1
63353-1
1217902-1
1217042-1
63983-1
1217339-1
63995-1
1217090-1
63996-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 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 Strain relief slot for high vibration applications.
20
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
250 Series
FASTON Tab Terminals
Tin plated brass
Typical Cavity Size
(See page 23)
Type A—Cavity Size 2
Type B—Cavity Size 5
Type C—Cavity Size 3
receptacles. Request
Catalog 82004.
L
.135
[ 3.43 ]
.120
[ 3.05 ]
A
3
A
300 Box
Standard IDC
.250 [6.35]
FASTON
Tab
B
Narrow
Body
Latch Type
33-31
0.18-0.23
30-27
0.25-0.36
28-24
0.32-0.51
27-23
0.36-0.57
22-20
0.64-0.81
19-17
0.91-1.15
33-31
1
1
30-27
0.25-0.36
27-23
0.36-0.57
23-20
C
Wide Body
Latch Type
0.18-0.23
2
0.57-0.81
33-31
0.18-0.23
31-28
0.23-0.32
30-28
0.25-0.32
30-27
0.25-0.36
27-23
0.36-0.57
22-20
2
0.64-0.81
19-17
2
0.91-1.15
Dim.
L
Tab
Feature
.750
19.05
.750
19.05
.750
19.05
.750
19.05
.750
19.05
.750
19.05
.750
19.05
.750
19.05
.750
19.05
.750
19.05
.750
19.05
.750
19.05
.750
19.05
.750
19.05
.750
19.05
.750
19.05
.750
19.05
Dimple
Dimple
Hole
Dimple
Dimple
Dimple
Dimple
Dimple
Dimple
Dimple
Hole
Dimple
Hole
Dimple
Hole
Hole
Dimple
Dimple
Hole
1 Two magnet wires may be terminated in the same
terminal slot if diameters are equal.
2 Single magnet wire only; 22 AWG [0.64 mm] or larger.
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.
Locking
Latch
(2)
.135
[ 3.43 ]
.120
[ 3.05 ]
.120
[ 3.05 ]
B
Copper Magnet
Wire Range1
mm
AWG
L
.300
[ 7.62 ]
.300
[ 7.62 ]
.135
[ 3.43 ]
Type
Hole or
Dimple
L
.300
[ 7.62 ]
Note:.250 [6.35] tab terminals
mate with compatible FASTON
Dimple
Standard MAG-MATE
Terminals
Material
Hole or
Dimple
C
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
.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
.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
Strip
Tab
Mag. Wire Part Number
Section
Section
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.010
0.25
.012
0.30
.016
0.41
.016
0.41
.016
0.41
.020
0.51
.010
0.25
.012
0.30
.016
0.41
.016
0.41
.010
0.25
.012
0.30
.012
0.30
.012
0.30
.016
0.41
.016
0.41
.016
0.41
62600-1*
62651-1*
63607-1
62652-1*
1217924-1
1742398-1
63026-1
63027-1.
1217860-1
1217870-1
63309-1
63403-2
1217152-1
63132-1
63499-1
63571-1
63128-1
63601-2
63614-1
* Recognized under the Component Program of
Underwriters Laboratories, Inc.
Chart continued on next page
21
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
250 Series
FASTON Tab Terminals
(Continued)
Hole or
Dimple
Hole or
Dimple
Material
Tin plated brass
L
L
.500
[ 12.7 ]
Typical Cavity Size
.500
[ 12.7 ]
(See page 23)
.120
[ 3.05 ]
Type A—Cavity Size 4
Type B—Cavity Size 4
.120
[ 3.05 ]
.280
[ 7.11 ]
.280
[ 7.11 ]
A
Type
A3
500 Box
Standard IDC
Wide Neck
3
B
500 Box
Standard IDC
Narrow Neck
Copper Magnet
Wire Range1
B
Dim.
L
Tab
Feature
.952
24.18
.952
24.18
.952
24.18
Hole
AWG
mm
22-20
0.64-0.81
19-17
0.91-1.15
16-15
1.29-1.45
14-13 2
1.61-1.83
.952
24.18
22-20
0.64-0.81
19-17
0.91-1.15
16-15
1.29-1.45
2
1.61-1.83
.952
24.18
.952
24.18
.952
24.18
.952
24.18
.952
24.18
14-13
12
2
2.05
Hole
Hole
Dimple
Hole
Dimple
Dimple
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
.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
Strip
Tab
Mag. Wire Part Number
Section
Section
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.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
63495-1
63464-3
63459-2
63460-1
63816-1
63155-1
62923-1
63064-1
63465-1
63425-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 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.
22
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
Typical Plastic Cavity
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
.355
[ 9.08 ]
Min.
.235
[ 5.97 ]
Min.
.175
[ 4.45 ]
Min.
.150
[ 3.81 ]
Min.
Cavity Size 1
187 [4.75] Box
MAG-MATE
(Application Spec. 114-2069)
.215
[ 5.46 ]
Min.
Cavity Size 2
.300 [7.62] Box
MAG-MATE
(Application Spec. 114-2046)
.550
[ 13.97 ]
Min.
.375
[ 9.53 ]
Min.
.300
[ 7.62 ]
Min.
Cavity Size 4
.500 [12.70] Box
MAG-MATE
(Application Spec. 114-2066)
Note: The MAG-MATE
typical plastic cavities shown
above are for reference only.
They are not a purchased
item. Refer to appropriate TE
application specification for
details.
Plastic cavities, designed to
TE 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, either manually or by
coil winding equipment.
.355
[ 9.08 ]
Min.
.355
[ 9.08 ]
Min.
.205
[ 5.21 ]
Min.
.235
[ 5.97 ]
Min.
.235
[ 5.97 ]
Min.
Cavity Size 3
.300 [7.62] Box
Latch-In MAG-MATE Wide Body
(Application Spec. 114-2094)
.355
[ 9.08 ]
Min.
.215
[ 5.46 ]
Min.
.355
[ 9.08 ]
Min.
.215
[ 5.46 ]
Min.
.150
[ 3.81 ]
Min.
Cavity Size 5
.300 [7.62] Box
Latch-In MAG-MATE,
Narrow Body
(Application Spec. 114-2067)
Cavity Size 6
.300 [7.62] Box
MAG-MATE
(Application Spec. 114-2046)
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 quick
disconnect FASTON tab
terminals.
Standard MAG-MATE
Terminals
Illustrations shown are for
reference only. They are not
a purchased item.
Manufacture only according
to TE Specification.
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.
TE will provide design
and mold engineering
resources to manufacture any specifically
designed MAG-MATE
cavity housing.
www.te.com/appliances
23
Magnet Wire Terminals and Termination Systems
Catalog 82221
Standard MAG-MATE Terminals (Continued)
Typical Plastic Cavities
Illustrations shown are for
reference only. They are not
a purchased item.
Manufacture only according
to TE Specification.
.375
[ 9.53 ]
Min.
.270
[ 6.86 ]
Min.
.115
[ 2.92 ]
Min.
Slim Line MAG - MATE
Reference Application
Spec. 114-2147
24
.375
[ 9.53 ]
Min.
.250
[ 6.35 ]
Min.
.225
[ 5.71 ]
Min.
Mini MAG - MATE
Reference Application
Spec. 114-2047
Technical Documents
Application Specifications
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.
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
114-2047—Mini MAG-MATE
Terminals
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Slim Line MAG-MATE Terminals
Product Facts
Slim Line MAG-MATE
Terminals
Terminates all magnet wire
film insulations
Eliminates need for
pre-stripping conductors
Eliminates need to
post-insulate terminations
Excess magnet wire is
automatically trimmed during
the termination process
187 and 250 Series Faston
Tab and posted PCB 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 [0.18-0.57
mm ]
Available in strip form for
semi-automatic or fully
automatic insertions
High speed, fully automated
integrated systems provide
uniform terminations
reliably 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
TE offers a full selection of
187 and 250 Series Faston
and posted PCB Slim Line
MAG-MATE Tab insulation
displacement (IDC) terminals for magnet wire
terminations.
Slim Line MAG-MATE
terminals with a single IDC
slot terminate 33-17 AWG
[0.18 to 1.15 mm].
Each IDC slot terminates
a range of up to four
consecutive magnet wire
sizes.
Two magnet wires with the
same diameter can be
terminated in one terminal.
Except as noted.
MAG-MATE cavities are
either integrated into coil
bodies or especially
designed cavity housings.
The magnet wires are
precisely positioned in the
plastic cavity slots.
The MAG-MATE Inserter
cuts the terminals from the
strip and places the terminals over the magnet wire
into the plastic cavities.
This constant pressure
results in an intimate
metal-to-metal interface,
providing a reliable, longterm connection.
During this operation, small
stripping shoulders in the
IDC slot remove the film
insulation from the magnet
wire.
The MAG-MATE
Inserter may be used as a
semi-automatic bench
machine or integrated in
production lines for
fully-automatic applications.
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.
Residual spring energy in
the terminal causes the side
walls of each IDC slot to
function as opposing
cantilever beams.
Power Supplies
www.te.com/appliances
25
Magnet Wire Terminals and Termination Systems
Catalog 82221
Slim Line MAG-MATE Terminals (Continued)
187 Series
FASTON Tab Terminals
Material
Tin plated brass
Type
.187
[ 4.75 ]
.020
[ 0.51 ]
Copper Magnet
Wire Range1
mm
AWG
0.18-0.23
.630
16.00
30-28
0.25-0.32
27-24
0.36-0.51
.630
16.00
.630
16.00
.760
19.31
23-202
0.57-0.81
.630
16.00
0.91-1.15
.630
16.00
33-31
Hole or
Dimple
L
A
.187 [4.75]
FASTON Tab
.135
[ 3.43 ]
.016
[ 0.41 ]
2
19-17
A
Dim.
L
Tab
Feature
Tab Size
Hole
Dimple
.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
Hole
Hole
Dimple
Hole
Dimple
Plain
Hole
Dimple
Hole
Hole
Dimple
Stock Thickness
Tab Mag.Wire
Section Section
.020
.012
0.51
0.30
.032
.012
0.81
0.30
.020
.012
0.51
0.30
.020
.016
0.51
0.41
.020
.016
0.51
0.41
.020
.016
0.51
0.41
.032
.016
0.81
0.41
.020
.016
0.51
0.41
Strip
Part Number
63710-2
63738-2
1217666-1
63711-2
63737-2
63712-2
63736-2
1217497-1
63713-2
63735-2
1217516-1
63714-2
63734-2
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only; 22 AWG [0.64] or larger.
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
L
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
2
0.91-1.15
19-17
.135
[ 3.43 ]
.016
[ 0.41 ]
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
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only; 22 AWG [0.64] or larger.
B
Posted PCB
SOLDER Terminal
Material
Type
Tin plated brass
.0322
[ 8.20 ]
.0125
[ 0.32 ]
.132
[ 3.45 ]
C
26
C
.040 [1.00]
PCB Tab
Copper Magnet
Wire Range1
AWG
mm
33.5-30
0.17-0.25
29.5-26
0.27-0.40
26-22
0.40-0.63
22-20
0.63-0.81
21.5-19.5
0.67-0.85
Dim.
L
Tab
Feature
.323
8.20 Embossment
.323
8.20
.323
8.20
.323
8.20
.323
8.20
Embossment
Embossment
Embossment
Embossment
Stock Thickness
Tab Mag.Wire
Section Section
.024
.013
.040 x .024
0.32
1.00 x 0.60 0.60
.024
.013
.040 x .024
0.60
0.32
1.00 x 0.60
.024
.013
.040 x .024
0.60
0.32
1.00 x 0.60
.040 x .024
.024
.013
1.00 x 0.60
0.60
0.32
.040 x .024
.024
.013
1.00 x 0.60 0.60
0.32
Tab Size
Strip
Part Number
1534684-1
1534685-1
1534686-1
1740829-1
1534687-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
2 Single magnet wire only; 22 AWG [0.64] or larger.
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Slim Line MAG-MATE Terminals (Continued)
Offset Tab Terminals
Slim Line MAG-MATE
Terminals
Mater
l
ial
Tin Plated Brass
Applications where I/O Tab
spacing must be less than
IDC connection spacing
Example: automotive
accessory coils
.139
[ 3.53 ]
.032
[ 0.81 ]
.059
[ 1.50 ]
.135
[ 3.43 ]
Type
L
A
Combination
Diode Slot/Tab
.220
[ 5.59 ]
.013
[ 0.33 ]
Copper Magnet
Wire Range1
mm
AWG
33-31
0.18-0.23
33-31
0.18-0.23
Dim.
L
Diode
Size
Tab Size
.725
18.42
.725
18.42
#20
0.8
#22.5
0.6
.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
Strip
Part Number
63888-1
63903-1
1 Two magnet wires may be terminated in the same terminal slot if diameters are equal.
A
Posted PCB Terminals
Multi-Spring Solderless
Terminal
Material
Tin Plated Copper Alloy
Cavity Size
Application Spec.
Contact TE Engineering
Type
L
.289
[ 9.33 ]
.132
[ 3.35 ]
.013
[ 0.32 ]
B
Multi-Spring
Solderless PCB
Tab Terminal
Copper Magnet
Wire Range1
AWG
mm
33-29.5
0.18-0.265
29.5-26
0.265-0.40
26-22.5
0.40-0.63
22.5-19.5 2
0.63-0.85
19.5-17 2
0.85-1.12
Dim.
L
.583
14.80
.583
14.80
.583
14.80
.583
14.80
.583
14.80
1 Two magnet wires may be terminated in the same terminal slot
if diameters are equal.
2 Single magnet wire only. 22 awg [0.63 mm] and larger.
Stock Thickness
Tab
Mag.Wire
Section
Section
.031
.013
0.81
0.32
.031
.013
0.81
0.32
.031
.013
0.81
0.32
.031
.013
0.81
0.32
.031
.013
0.81
0.32
Strip
Part Number
2120743-2
2120744-2
2120745-2
2120746-2
2120747-2
Note: PC Board hole size .057 [1.45]
B
www.te.com/appliances
27
Magnet Wire Terminals and Termination Systems
Catalog 82221
Slim Line MAG-MATE Terminals (Continued)
Posted PCB
Solder Terminals
Material
Unplated brass
Type
A
MAG-MATE
Terminal
with MQS Pins
A
Copper Magnet Wire Range
AWG
mm
0.256-0.40
33-30
0.40-0.561
331
30-26
0.256-0.40
30-261
0.40-0.561
26-22
0.40-0.63
26-231
0.40-0.561
22-20
0.63-0.80
20-17
0.85-1.12
Stock
Thickness
Strip
Part Number
Varied
thickness
Varied
thickness
Varied
thickness
Varied
thickness
Varied
thickness
1-1987222-1
1-1987223-1
1-1987224-1
1-1987225-1
1-1987226-1
1 For double magnet wires
28
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Mini MAG-MATE Terminals
Product Facts
Mini MAG-MATE
Terminals
Terminates all fine gauge
magnet wire film
insulations
Eliminates need to pre-strip
conductors
Eliminates need to post
insulate terminations
Terminates 52-30 AWG
[0.02-0.25 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
High speed, fully automated
integrated systems provide
uniform terminations and
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
TE offers 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 [0.02-0.25 mm]
diameter copper magnet
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.
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.
The Mini MAG-MATE
Inserter shears the terminal
from the carrier strip and
inserts the terminal into the
cavity by a dual ram
The terminal design uses the insertion mechanism.
AMPLIVAR serrated burr
technology to penetrate the As the unexpanded terminal
approaches the bottom of
film insulation of copper
the cavity, the upper ram
magnet wire.
stops. The lower ram
continues to push to a
Mini MAG-MATE cavity
prescribed depth to expand
pockets, designed to TE
specifications, include a wire the terminal and complete
Poke-in leaf terminals accept
22-18 AWG [0.3-0.9 mm2]
overcoated stranded or solid
lead wire.
www.te.com/appliances
29
Magnet Wire Terminals and Termination Systems
Catalog 82221
Mini MAG-MATE Terminals (Continued)
Wire
Split ram
Wire tie-off post
Wire
Upper ram stops
Lower ram continues
Sheared post and excess
wire to scrap chute
Lower ram stops
Termination Complete
Poke-In Terminal
Material
.010 [0.25] tin plated brass
.138
[ 3.51 ]
.345
[ 8.76 ]
.060
[ 1.52 ]
A
Lead
Wire
Poke-In
A
.138
[ 3.51 ]
B
.345
[ 8.76 ]
.060
[ 1.52 ]
.047
[ 1.20 ]
L
.345
[ 8.76 ]
Type
B
Tab
Poke-In
Stock Thickness
Mating
Strip
Tab
Poke-In Beam Mag Wire Part Number
0.010
0.010
—
62781-1
0.3-0.9
0.25
0.25
0.010
0.010
—
62780-1
0.3-0.9
0.25
0.25
0.010
0.010
—
62606-1
0.3-0.9
0.25
0.25
.060
x
.020
0.010
0.010
—
63613-1
1.52 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
.060 x .020
0.010
0.010
—
63844-22
1.52 x 0.51
0.25
0.25
.040 x .020
0.010
0.010
—
1718165-1
1.00 x 0.51
0.25
0.25
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
—
0.08-0.15
—
C
Skinny Mini 40-34.5
1 Solid or overcoated stranded lead wire only.
2 Radius on beam leaf tip.
C
30
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Mini MAG-MATE Terminals (Continued)
Posted Terminal
Mini MAG-MATE
Terminals
Material
Tin over premilled brass
.138
[ 3.51 ]
.060
[ 1.52 ]
.169
[ 4.29 ]
Copper Magnet Wire Range
AWG
mm
Type
.540
[ 13.72 ]
A
PCB Post
38-30
0.10-0.25
Post Size
.024 x .020
0.62 x 0.51
Stock Thickness
Post
Mag Wire
0.020
0.010
0.51
0.25
Strip
Part Number
Stock Thickness
Post
Mag Wire
.020
.010
0.51
0.25
.020
.010
0.51
0.25
Strip
Part Number
63675-4
A
FASTON Tab Terminals
Material
Tin over premilled brass
.138
[ 3.51 ]
.690
[ 17.53 ]
.060
[ 1.52 ]
Copper Magnet Wire Range
G
W
A m
m
Type
B
.187 [4.75]
FASTON Tab
B
44-36
0.05-0.13
38-30
0.10-0.25
Tab Size
.187 x .020
4.75 x 0.51
.187 x .020
4.75 x 0.51
63778-1
1217529-1
Crimp Wire Barrel Terminal
Material
Tin plated brass
.060
[ 1.52 ]
.138
[ 3.51 ]
.620
[ 15.75 ]
Type
C
Crimp Wire
Barrel
Copper Magnet Wire Range
AWG
mm
38-30
0.10-0.25
Lead Wire Range
AWG
mm2
22-18
0.3-0.9
Stock Thickness
Crimp Barrel
Mag Wire
0.010
0.25
0.010
0.25
Strip
Part Number
63199-11
1 Wire and insulation barrel reversed so lead wire exits over magnet wire termination area.
C
www.te.com/appliances
31
Magnet Wire Terminals and Termination Systems
Catalog 82221
SIAMEZE Terminals
Product Facts
Terminates all copper
magnet wire film insulations
Eliminates need for
pre-stripping conductors
Moving Beam contact
design connects a wide
range of magnet wire sizes
with a single terminal
Standard range terminals
connect 34-18 AWG
[0.16-1.0 mm ] magnet wire
Fine range terminals
connect 36-27 AWG
[0.13-0.38 mm ] magnet wire
Medium range terminals
connect 23-12 AWG
[0.56-2.03 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 manual 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
R
Applications
Motor windings and
connections
Coil connections
Transformer windings and
connections
Ballasts
Power supplies
Solenoids
Actuators
TE offers a full selection of
SIAMEZE insulation
displacement (IDC)
terminals for interconnecting copper magnet wires,
lead wires, and other
components.
The SIAMEZE
insulation displacement
(IDC) terminal 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.
Available with either Moving
Beam contacts whereby a
single terminal connects toa
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.
Tab terminals are available
with single barbs or multiple
retention barbs for higher
retention.
According to TE 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 terminal
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 the IDC slot
to function as opposing
cantilever beams.
This constant pressure
results in an intimate
metal-to-metal interface,
providing a reliable,
long-term connection.
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 SIAMEZE terminal
Inserter may be used as a
semi-automatic bench
machine or integrated in
production lines for
fully-automatic applications.
32
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Magnet Wire Terminals and Termination Systems
Catalog 82221
SIAMEZE Terminals (Continued)
Lead Lok Terminals
Product Facts
SIAMEZE Terminals
Provides perpendicular and
parallel lead wire strain
relief retention forces in
excess of 20 lbs ( 90 N ) .
Inserter automatically
positions and secures lead
wire during insertion
Manual, semi-automated,
fully automated systems
allow for lead wire termination
Accepts #18 - #22 [0.3mm
2-0.8 mm2 ] AWG solid or
stranded lead wire with
.115 [2.92 ] max.insulation
diameter
No lead wire stripping
required
TE features the 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 SIAMEZE wire-towire terminals into TE
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 Lead Lok Inserter
cuts the Lead Lok terminals
from the strip and places
the terminal over the lead
wire in the plastic cavities.
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.
Residual spring energy in the
terminal causes the side
walls of the IDC slot to
function as opposing
cantilever beams.
This constant pressure
results in an intimate
metal-to-metal interface,
providing a reliable, longtermconnection.
Perpendicular and parallel
lead wire strain relief retention
forces in excess of 20 lbs are
achieved.
The Lead Lok Inserter
may be a secondary station in
the SIAMEZE Wire-toWire semi-automatic bench
machine.
Information regarding terminal
insertion equipment may be
found in Magnet Wire Termination Overview #138516.
TECHNICAL DOCUMENTS
Cavity Specifications - Provide dimensional design guidelines & criteria for a cavity to be used with a
SIAMEZE IDC terminal. The appropriate Cavity Specification number is shown on the following pages
adjacent to the terminal number. As a general reference, overall dimensions are shown at the end of this
section.
Product Specifications ( These describe the performance characteristics and verification tests )
108-2085
Standard Range SIAMEZE Insulation Displacement
108-2293
High Temperature Standard Range SIAMEZE Insulation Displacement
108-2244
Fine Range SIAMEZE Insulation Displacement
108-2239
Medium Range SIAMEZE Insulation Displacement
108-2316
Heavy Range SIAMEZE Insulation Displacement
Application Specifications ( These describe the requirements for using the product in its intended
application )
114-13166
Standard and Fine Range SIAMEZE Insulation Displacement
114-13210
Medium and Heavy Range SIAMEZE Insulation Displacement
33
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
SIAMEZE Terminals (Continued)
SIAMEZE
Interconnection System
How the System Operates
Magnet Wire
The magnet wire is
positioned in “U” slot
manually or automatically
by coil winding equipment.
Plastic Cavity
Design must comply with
TE connectivity
specifications(for cavity
drawing numbers see
tables). ConsultingTE is
required for design in.
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.
Cavity Slot for Wire
The width has to be in
accord ance with the wire
size (see cavity drawings).
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.
Contact
Various wire attachments in
standard, fine, mediumand
heavy duty terminals are
available (See tables).
IDC Slot
The IDC slot in the terminal
will terminate a wide range
of magnet wire sizes.
Stripping Burrs
During the insertion
process, these burrsstrip
the film insulation from the
magnet wire.
Retention Barbs
Terminal retention is
provided in the cavity by
single or multiple locking
barbs.
Test Results
SIAMEZE products have
been submitted to the
following tests without
significant millivolt increase:
Trim Blade
The trim blade cuts the
excess magnet wire and
the wire cutoff block at the
front of the cavity.
11
Terminal Insertion
Complete
The magnet wire termination is complete when the
terminal is fully seated in
the cavity.
Current Cycling—
250 cycles with each cycle
consisting of 15 minutes
11
“ON” followed by 15 minutes
“OFF”
Thermal Shock—
25 Cycles -40°C to +125°C,
25 Cycles -40°C to +175°C
for High Temperature
terminals
Humidity—
Temperature Cycling
10 cycles between 25°C and
65°C at 80 to 100% RH
34
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
SIAMEZE Terminals (Continued)
Lead Lok
Interconnection System
How the System Operates
SIAMEZE Terminals
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.
Lead Lok Terminal
The Lead Lok terminal
provides maximum lead
wire retention in the cavity.
Retention Barbs
The Lead Lok multiple
barbs provide retention in
the cavity.
Lead Wire
Stranded, solid and bonded
lead wire with 105°C PVC
insulation can be used.
Contact TE Engineering for
other lead wires and
insulation under consideration.
IDC Slot
The IDC slot will pierce the
lead wire during insertion.
Lead Wire Insertion
Complete
The lead wire termination is
complete when the Lead
Lok is fully seated in the
cavity.
HOW TO CONNECT MULTIPLE MAGNET WIRES OR OTHER COMPONENTS
Bussed High Carrier
Terminals
Bridging of two SIAMEZE
terminals that is accomplished by leaving the
carrier strip between two
adjacent terminals intact.
Bussed High Carry
SIAMEZE Plastic Cavity
Bussed cavity pocket
designs are available for
double or triple bussed
terminals.
Magnet Wire
Magnet wire may be equal
or differ in size for bi-filar
applications.
35
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Magnet Wire Terminals and Termination Systems
Catalog 82221
SIAMEZE Terminals (Continued)
Wire-to-Wire Terminals
Material
Brass
.300
[ 7.62 ]
.300
[ 7.62 ]
.146
[ 3.71 ]
.146
[ 3.71 ]
A
.300
[ 7.62 ]
.146
[ 3.71 ]
.020
[ 0.51 ]
.020
[ 0.51 ]
B
C
.020
[ 0.51 ]
.250
[ 6.35 ]
.550
[ 13.97 ]
.300
[ 7.62 ]
.146
[ 3.71 ]
.020
[ 0.51 ]
D
E
F
Lead Wire
Range
AWG
mm2
18-34
1.02-0.16
18-226
0.8-0.3
27–36
0.36–0.13
18-226
0.8-0.3
18-34
1.02–0.16
20
0.5
18-34
1.02-0.16
18
0.8
1601433
1601440
18-34
1.02-0.16
18-226
0.8-0.3
1601046-1
2-1601046-11
4-1601046-12
6-1601046-13
8-1601046-14
1601433
27–36
0.36-0.13
20
0.5
1601237-1
2-1601237-11
4-1601237-12
6-1601237-13
1601436
12-23
2.06-0.56
16-20
1.3-0.5
1601136-1
2-1601136-11
4-1601136-12
6-1601136-13
18-22
0.8-0.3
1601140-1
2-1601140-11
4-1601140-1
Recommended
Pocket7
A
Moving
Beam
1601421
B
Wire
Specific 8
1601421
C
High Carrier
F
Lead Lok
.032
[ 0.81 ]
.025
[ 0.46 ]
Copper Magnet
Wire Range
AWG
mm
Type
D
High Carrier
Specific8
E
Medium
Range
.150
[ 3.81 ]
.280
[ 7.11 ]
1601421
1601433
1601440
Part Number
Reeled
Loose
1601000-1
1601000-25
1601117-1
2-1601117-11
1601056-1
2-1601056-11
1601074-1
2-1601074-11
4-1601000-12
4-1601000-22,5
4-1601117-12
4-1601056-12
4-1601074-12
1 Reversed Reeled—Consult TE drawing for orientation.
2 Loose Single.
3 Loose Bussed (Bridged) Double.
4 Loose Bussed (Bridged) Triple.
5 Finish is Post Plated Tin over Copper (Consult TE drawing for specifics).
6 Lead wire may be stranded, solid or bonded with 105°C PVC insulation. Contact TE 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.
8 Wire Specific terminals have a top contact designed to penetrate difficult Lead Wire Insulation (e.g Irradiated types).
36
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Magnet Wire Terminals and Termination Systems
Catalog 82221
SIAMEZE Terminals (Continued)
Receptacle Terminals
(Wire to Blade)
Material
Brass
.146
[ 3.71 ]
.550
[ 13.97 ]
.146
[ 3.71 ]
.020
[ 0.51 ]
.020
[ 0.51 ]
A
.280
[ 7.11 ]
B
.310
[ 7.87 ]
.480
[ 12.19 ]
.032
[ 0.81 ]
.032
[ 0.81 ]
C
D
L
Dim.
Mating
Tab Size
1.02-0.16
.300
7.62
.020
0.51
18-34
1.02-0.16
.300
7.62
.020
0.51
Part Number
Reeled
Loose
1601075-12,1
4-1601075-12
2-1601075-11
6
1601075-2
4-1601075-22,6
2-1601075-21,6
–
2-1601075-31,7
4-1601196-12
1601196-1
6-1601196-13
2-1601196-11
8-1601196-14
1601436
15-23
1.47-0.56
.550
13.97
.032
0.81
1601232-27
2-1601232-21,7
4-1601232-22,7
1601437
15-23
1.47-0.56
.310
7.87
.032
0.81
1601137-2 6
2-1601137-21,6
4-1601137-22,6
Copper Magnet Wire Range
AWG
mm
Type
Recommended
Pocket 5
A
Wire2Blade In Line
1601425
18-34
1601426
B
Wire2Blade
High Carrier In Line
C
Wire2Blade
In Line Medium Range
D
Wire2Blade
Off Line Medium Range
SIAMEZE Terminals
.300
[ 7.62 ]
.300
[ 7.62 ]
1 Reverse Reeled –Consult TE drawing for orientation.
3 Loose Bussed (Bridged) Double.
5 Magnet wire 30 AWG [0.25] and smaller also requires a wrap post per Specification
1601447.
7 Finish is Post Plated Tin over Nickel (Consult TE drawing for specifics).
8
2 Loose Single.
4 Loose Bussed (Bridged) Triple.
6 Finish is Pre Plated Tin (Consult TE drawing for specifics).
8 Overall Height of terminal does not include inserted Blade (Tab).
Pin Terminals
Dia.
[ 2.13 ]
Material
Brass
L
.
[ 0.51 ]
[ 3.71 ]
E
Type
Recommended
Pocket 2
E
Round Pin
1601424
Copper Magnet Wire Range
AWG
mm
18-34
1.02-0.16
L
Dim.
Pin Dia.
.718
18.24
.084
2.13
Part Number
Loose
Reeled
1601077-1
3
4-1601077-1
2-1601077-11
1 Reverse Reeled –Consult TE drawing for orientation.
2 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447.
3 Loose piece single.
37
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Magnet Wire Terminals and Termination Systems
Catalog 82221
SIAMEZE Terminals (Continued)
Post Terminals
Material
Brass
L
L
L
L
L
L
.146
[ 3.71 ]
.020
[ 0.51 ]
A
Type
A
PC Tab
B
Extended
PC Tab
C
Long Narrow
Blade
D
Long Narrow
Blade
Mult-Barb
.146
[ 3.71 ]
.020
[ 0.51 ]
.146
[ 3.71 ]
B
Recommended
Pocket7
1601424
1601425
1601431
1601425
E
Medium
Width Blade
Mult-Barb
1601475
F
Medium
Width Blade
Medium wire range
1601438
.020
[ 0.51 ]
.146
[ 3.71 ]
C
18-34
1.02-0.16
29**
0.29
27-36
0.36-0.13
18-34
1.02-0.16
27-36
0.36-0.13
1.02-0.16
18-34
1.02-0.16
18-34
1.02-0.16
27-36
0.36-0.13
12-23
0.56-2.06
1 Reverse Reeled –Consult TE drawing for orientation.
3 Finish is Post Plated Tin (Consult TE drawing for specifics).
5 Finish is Post Plated Tin over Nickel (Consult TE drawing for specifics).
7 Magnet wire 30 AWG [0.25] and smaller also requires a wrap post per
Specification 1601447
38
.146
[ 3.71 ]
D
Copper Magnet Wire Range
AWG
mm
18-34
.020
[ 0.51 ]
.280
[ 7.11 ]
.020
[ 0.51 ]
E
.032
[ 0.81 ]
F
Part Number
Tab Size
L
Dim.
.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
.345
8.76
.405
10.29
.345
8.76
.345
8.76
.456
11.57
.485
12.32
.485
12.32
.754
19.16
.669
17.00
.756
19.21
.904
22.96
1.005
25.53
.974
24.74
Reeled
1601009-45
2-1601009-41,5
1601214-2 5
2-1601214-21,5
1601155-35
2-1601155-31,5
1601120-45
2-1601120-41,5
1601095-2 4
2-1601095-22,4
1601041-35
2-1601041-31,5
1601128-3 5
2-1601128-3 1,5
1601110-2 6
2-1601110-21,6
1601099-2 5
2-1601099-21,5
1601063-2 6
2-1601063-21,6
1601037-2 6
2-1601037-21,6
1601066-2 6
2-1601066-2 1,6
1601104-2 6
2-1601104-21,6
.059 x .032
1.50 x 0.81
.805
20.45
293214-1
2-293214-11
—
.
.118 x .020
3.00 x 0.51
.118 x .025
3.00 x 0.64
.533
13.54
.952
24.18
1601243-2 3
2-1601243-21,3
1601119-2 6
2-1601119-21,6
4-1601243-2 2,3
.130 x .032
3.30 x 0.81
.872
22.15
1601138-1
2-1601138-11
4-1601138-12
Loose
4-1601009-4 2,5
4-1601214-2 2,5
4-1601155-3 2,5
4-1601120-4 2,5
4-1601095-2 2,4
4-1601041-3 2,5
4-1601128-3 2,5
4-1601110-2 2,5
4-1601099-2 2,5
4-1601063-2 2,6
4-1601037-2 2,6
4-1601066-2 2,6
4-1601104-2 2,6
4-1601119-2 2,6
2 Loose Piece Single.
4 Finish is Post Plated Tin over Copper (Consult TE drawing for specifics).
6 Finish is Pre Plated Tin (Consult TE drawing for specifics)
** Compliant contact can connect 2 wires of the same diameter.
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
SIAMEZE Terminals (Continued)
110 Series (2.8 mm wide)
FASTON Tab Terminals
Material
Brass
SIAMEZE Terminals
L
L
L
.146
[ 3.71 ]
A
Type
A
Single Barb
B
Single Barb
Low Transition
C
Multi-Barb
Recommended
Pocket 8
1601425
1601431
1601425
.020
[ 0.51 ]
Copper Magnet Wire Range
AWG
mm
18-34
18-34
18-34
27-36
1.02-0.16
1.02-0.16
1.02-0.16
0.36-0.13
.146
[ 3.71 ]
B
.146
[ 3.71 ]
.020
[ 0.51 ]
C
Thickness
L
Dim.
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.032
0.81
.032
0.81
.020
0.51
.020
0.51
.032
0.81
.032
0.81
.032
0.81
.640
16.26
.640
16.26
.846
21.49
.846
21.49
.925
23.50
.945
24.00
1.195
30.35
.655
16.63
.655
16.63
.630
15.99
1.240
31.50
1.240
31.50
.020
[ 0.51 ]
Part Number
Reeled
Loose
1601005-1
4-1601005-1 2
1
2-1601005-1
1601204-26,7
4-1601204-2 2,6,7
2-1601204-21,6,7
1601045-1
4-1601045-1 2
2-1601045-11
1601059-17
2-1601059-11,7
1601073-1
2-1601073-11
1601097-36,7
2-1601097-31,6,7
1601194-23,7
2-1601194-21,3,7
1601039-1
2-1601039-11
1601039-26
2-1601039-21,6
1601064-17
2-1601064-11,7
1601112-2 6,7
2-1601112-21,6,7
1601133-2 6,7
2-1601133-21,6,7
4-1601059-12,7
4-1601073-1 2
4-1601097-3 2,6,7
4-1601194-2 2,3,7
4-1601039-1 2
4-1601039-2 2,6
4-1601064-1 2,7
4-1601112-2 2,6,7
4-1601133-2 2,6,7
1 Reverse Reeled-Consult TE drawing for orientation.
2 Loose Piece Single.
3 Finish is Post Plated Tin over Nickel (Consult TE drawing for specifics).
4 Finish is Post Plated Tin (Consult TE drawing for specifics).
5 Finish is Pre-Plated Tin over Copper (Consult TE drawing for specifics).
6 Finish is Pre-Plated Tin (Consult TE drawing for specifics).
7 No hole in Tab.
8 Magnet wire 30 AWG [0.25] and smaller also requires a wrap post per Specification 1601447.
39
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
SIAMEZE Terminals (Continued)
187 Series (4.75 mm wide)
FASTON Tab Terminals
Material
Brass
(except High Temp listed below)
L
L
L
L
L
.146
[ 3.71 ]
.020
[ 0.51 ]
.146
[ 3.71 ]
A
Type
Recommended
Pocket 8
A
Single Barb
1601425
B
Single Barb
Short Pocket
C
Multi-Barb
D
Multi-Barb
Short Profile
E
Multi-Barb
.187/.250 Profile
1601427
1601425
1601434
1601425
B
Copper Magnet Wire Range
AWG
mm
18-34
18-34
18-34
.020
[ 0.51 ]
.146
[ 3.71 ]
1.02-0.16
1.02-0.16
1.02-0.16
20-23**
0.58-0.81
18-34
1.02-0.16
18-34
1.02-0.16
18-34
1.02-0.16
1 Reverse Reeled-Consult TE drawing for orientation.
3 High Temperature Copper Alloy.
5 Finish is Pre Plated Tin (Consult TE drawing for specifics).
7 Extra Short Tab-Does not meet UL & NEMA length requirements.
** Compliant contact can connect 2 wires of the same diameter
.020
[ 0.51 ]
C
Thickness
L
Dim.
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.020
0.51
.032
0.81
.032
0.81
.032
0.81
.032
0.81
.020
0.51
.032
0.81
.032
0.81
.020
0.51
.020
0.51
.020
0.51
.605
15.37
.505
12.83
.590
14.99
.985
25.02
.618
15.70
.655
16.64
.791
20.09
0.832
21.14
.625
15.88
.655
16.64
.655
16.64
.745
18.92
.655
16.64
0.492
12.50
0.571
14.50
.655
16.64
.655
16.64
.805
20.45
.146
[ 3.71 ]
.020
[ 0.51 ]
.146
[ 3.71 ]
.020
[ 0.51 ]
D
E
Part Number
Reeled
1601006-25
2-1601006-21,5
1601011-1
2-1601011-11
1601018-2 5,6
2-1601018-21,5,6
1601033-25,6
2-1601033-21,5,6
1601021-25,6
2-1601021-21,5,6
6
1601013-1
2-1601013-11
Loose
4-1601006-2 2,5
4-1601011-12
4-1601018-22,5,6
4-1601033-2 2,5,6
4-1601021-2 2,5,6
4-1601013-12
3-1601072-25,6
4-1601072-22,5,6
1601068-25,6
2-1601068-21,5,6
4-1601068-22,5,6
1601174-25,6
2-1601174-21,5,6
1601035-1
2-1601035-11
1601035-25
2-1601035-21,5
293029-1 5
2-293029-11,5
1601142-1
2-1601142-11
1601058-25,7
2-1601058-21,5,7
1601226-13,6
2-1601226-11,3,6
1601020-1
2-1601020-11
1601020-2 5
2-1601020-21,5
1601049-2 5
2-1601049-21,5
4-1601174-22,5,6
4-1601035-12
4-1601035-22,5
_
4-1601142-12
4-1601058-22,5,7
4-1601226-12,3,6
4-1601020-12
4-1601020-22,5
4-1601049-2 2,5
2 Loose Piece Single.
4 Finish is Post Plated Tin (Consult TE drawing for specifics).
6 No hole in Tab.,
8 Magnet wire 30 AWG [0.25] and smaller also requires a wrap post per Specification
1601447.
40
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
SIAMEZE Terminals (Continued)
250 Series (6.3 mm wide)
FASTON Tab Terminals
Material
Brass
SIAMEZE Terminals
L
L
L
.146
[ 3.71 ]
.280
[ 7.12 ]
.020
[ 0.51 ]
A
Type
Recommended Copper Magnet Wire Range
Pocket 6
AWG
mm
27-36
A
Multi-Barb
B
Single Barb
Medium Range
C
Single Barb
Heavy Range
1601425
1601438
1601435
18-34
0.36-0.13
1.02-0.16
.032
[ 0.81 ]
B
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
Part Number
Loose
Reeled
1601118-23
3
4-1601118-2
2-1601118-21,3
3
1601002-2
4-1601002-23
2-1601002-21,3
1601028-23
4-1601028-23
2-1601028-21,3
1601028-1
4-1601028-1
2-1601028-11
7
284937-1
—
2-284937-11,7
3
1601061-2
4-1601061-23
2-1601061-21,3
2,4
1601052-2
4-1601052-2 2
2-1601052-21,2,4
Tab
Feature
Tab Size
.745
18.92
.745
18.92
Hole
.250 x .032
6.35 x 0.81
.250 x .032
6.35 x 0.81
Hole
1.281
32.53
Hole
12-23
2.03-0.56
.778
19.76
—
.250 x .032
6.35 x 0.81
1601139-23
2-1601139-21,3
12-20
2.03-0.8
Hole
16-175
1.27-1.15
5
1.60-1.40
.885
22.48
.885
22.48
.885
22.48
.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
14-15
.032
[ 0.81 ]
C
L
Dim.
.805
20.45
.315
[ 8.00 ]
Hole
Hole
4-1601139-23
4-1601115-1
4-1601159-1
4-1601161-1
1 Reverse Reeled –Consult TE drawing for orientation.
2 Finish is Pre-Plated Tin over Copper (Consult TE drawing for specifics).
3 Finish is Pre-Plated Tin (Consult TE 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.
7 Hole size and position complies with DIN standard.
41
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
SIAMEZE Terminals (Continued)
Typical Plastic Cavity
Pockets
Note:The overall dimensions shown
on these pages are for general
reference only. For design
purposes refer to the TE
Cavity Specification.
Plastic cavities, designed to
TE 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
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 wrap post.
Excess magnet wire is
trimmed flush with the outside
of the plastic cavity by a shear
blade traveling with the
During insertion, the insulation terminal insertion ram.
displacing terminal slot strip
TE can provide design and
the film insulation from the
magnet wire producing a
mold engineering resources
stable electrical termination.
to manufacture most
Terminal retention is retained specifically designed
in the plastic cavities by single SIAMEZE cavity housings.
or multiple barbs (Refer to
Product Spec for force
requirements).
.380
[ 9.65 ]
Min.
.276
[ 7.01 ]
Min.
.380
[ 9.65 ]
Min.
.270
[ 6.86 ]
Min.
.276
[ 7.01 ]
Min.
.204
[ 5.18 ]
Min.*
Cavity Specification 1601421
Cavity Specification 1601424
.380
[ 9.65 ]
Min.
.496
[ 12.60 ]
Min.
.104
[ 2.63 ]
Min.
Cavity Specification 1601426
.104
[ 2.63 ]
Min.
.276
[ 7.01 ]
Min.
.104
[ 2.63 ]
Min.
Cavity Specification 1601425
[ 8.38 ]
Min.
[ 7.75 ]
Min.
[ 7.01 ]
Min.
[ 2.63 ]
Min.
Cavity Specification 1601427
[ 7.01 ]
Min.
[ 2.95 ]
Min.
Cavity Specification 1601431
* Minimum dimension with Lead Lok slot.
42
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
SIAMEZE Terminals (Continued)
Typical Plastic Cavity
Pockets (Continued)
.380
[ 9.65 ]
Min.
.473
[ 12.01 ]
Min.
.116
[ 2.95 ]
Min.
Cavity Specification 1601432
.490
[ 12.60 ]
Min.
.446
[ 11.33 ]
Min.
.135
[ 3.44 ]
Min.
Cavity Specification 1601435
.410
[ 10.41 ]
Min.
.350
[ 8.89 ]
Min.
.580
[ 14.72 ]
Min.
.135
[ 3.44 ]
Min.
Cavity Specification 1601436
.380
[ 9.65 ]
Min.
.716
[ 18.19 ]
Min.
.135
[ 3.44 ]
Min.
Cavity Specification 1601438
Cavity Specification 1601434
.630
[ 16.00 ]
Min.
.520
[ 13.21 ]
Min.
.410
[ 10.41 ]
Min.
.104
[ 2.63 ]
Min.
.276
[ 7.01 ]
Min.
.204
[ 5.18 ]
Min.*
Cavity Specification 1601433
.535
[ 13.59 ]
Min.
.293
[ 7.44 ]
Min.
.204
[ 5.18 ]
Min.*
SIAMEZE Terminals
.380
[ 9.65 ]
Min.
Cavity Specification 1601440
.135
[ 3.44 ]
Cavity Specification 1601437
.050
[ 1.27 ]
.050
[ 1.27 ]
Min.
Wrap Post Specification 1601447
.353
[ 8.97 ]
Min.
.276
[ 7.01 ]
Min.
.116
[ 2.95 ]
Min.
Cavity Specification 1601475
* Minimum dimension with Lead Lok slot.
www.te.com/appliances
43
Magnet Wire Terminals and Termination Systems
Catalog 82221
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
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
TE Connectivity offers a
full selection of 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.
The resulting termination
produces a high tensile
strength, air-sealed
connection that is as
resistant to corrosion as the
insulated conductor.
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
be combined with standard,
pre-stripped solid or
stranded lead wires.
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.
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
44
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
AMPLIVAR Splices (Continued)
Technical Features
Test Results
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
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
45
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
AMPLIVAR Splices (Continued)
General Application Guidelines
Suggested Splice Selection Procedure
To assist you in obtaining the optimum AMPLIVAR product
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.
5. Calculate the total
magnet wire diameters
(see pages 90 and 91).
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.
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
TE for special wide tooling
recommendations.
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 TE for splice
and terminal selection
and recommendations
for all non-standard
applications.
2. Use 9-serration splices
for hermetic and severe
environment applications.
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
90–91).
Example:
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.
114-2002
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
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.
Technical Documents
6. Select a splice for trial
calculations. It should
have the proper CMA
range. Plating finish
should be considered at
this time.
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
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]
CMA range
Stock thickness
Crimp width
= 600–3000
= .016 [0.41]
= .110 [2.79]
Calculate the sum of the magnet wire diameters (Procedure 5):
Select a terminal for trial calculations. Splice No. 62305-2,
page 47 (Procedure 6):
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.
46
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
AMPLIVAR Splices (Continued)
9 Serrations —
Pigtail Type
Product Facts
(Plus All 7 Serration Facts)
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
Additional serrations
enhance stability of crimp
7 Serrations —
Pigtail Type
Product 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
10-8
4.90-8.60
.
9-6.5
7.07-9.45
.
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])
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 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
7000-14,000
2.10-2.85
0.64
.098-.130
.030
10,000-17,000
2.50-3.31
0.76
.118-.137
.030
14,000-22,000
3.00-3.47
0.76
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
.250
6.35
.250
6.35
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
.340
8.64
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
62311-2 *
Tin Plated Brass
1742898-1
AMPLIVAR Splices
Splice length is increased
on larger CMA splices for
improved performance
*These splices are recommended for applications using wire size 28 AWG [0.32 mm] or smaller.
Special high force application equipment required.
1
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
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.
1 Flat bottom.
www.te.com/appliances
47
Magnet Wire Terminals and Termination Systems
Catalog 82221
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 splice s
Serrations centered in splic e
to achieve optimu m
electrical and mechanica l
performance in a thru splic e
Type
A
CMA range accepts a wid e
variety of wire sizes an d
combination s
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.
2 Increased U-diameter.
1
48
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
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.
1 Flat bottom.
AMPLIVAR Splice
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
49
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
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 TE 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 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
50
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
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
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
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
Wire Size Range 23–19 AWG [0.574–0.912 mm]
Type
B
B
A
B
A
Insulation
Dia. Range
Hole
Dia.
.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
Stud
Size
8
8
10
10
Stock
Thk.
.020
0.51
.020
0.51
.020
0.51
.020
0.51
Material
Tin Plated Brass
Tin Plated Brass
Tin Plated Brass
Tin Plated Brass
Wire Size Range 22–18 AWG [0.643–1.024 mm]
C
Type
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
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
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
63399-1
Part
Number
60321-2
60323-2
60319-2
60325-2
Part
Number
63612-1
63649-1
AMPLIVAR Terminals
W
.342
8.69
62835-1
63446-1
63446-2
Part
Number
060322-2
505071-1
505075-1
505072-1
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
F
G
Insulation
Dia. Range
Hole
Dia.
Stud
Size
—
—
8
—
—
8
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
www.te.com/appliances
51
Magnet Wire Terminals and Termination Systems
Catalog 82221
AMPLIVAR Terminals (Continued)
Stud Retaining Terminals
H
45°
J
Wire Size Range 13–11 AWG [1.83–2.3 mm]
Type
Insulation
Dia. Range
Hole
Dia.
A
.085-.150
2.16-3.81
.180
4.57
.180
4.57
.197
5.00
C
—
—
Stud
Size
8
8
10
Stock
Thk.
.025
0.64
.025
0.64
.025
0.64
Material
Brass
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
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
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
Part
Number
061710-1
350571-1
640212-1
Part
Number
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]
M
Type
Insulation
Dia. Range
Hole
Dia.
Stud
Size
Stock
Thk.
Material
K
—
—
10
.020
0.51
Brass
Stock
Thk.
Material
Wire Range 14.5 AWG [1.539 mm]
Type
N
Insulation
Dia. Range
Hole
Dia.
Stud
Size
—
—
2
—
—
2
.025
0.64
.025
0.64
Tin Plated Brass
Brass
Wire Range (2) 13 AWG [1.83 mm]
Alternator Eyelet Terminal
N
52
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
505079-1
Part
Number
505036-1
505036-3
Part
Number
63864-1
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
AMPLIVAR Terminals (Continued)
A
125 Series Blade
B
Stock Thickness
.330
[8.38]
.125
[3.18]
A = .013 [0.33]
B = .020 [0.51]
.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 TE engineering for
housing options available
24-18
18.5-13.5
27-20.5
B
24-18
18.5-13.5
.125
[3.18]
.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
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
Material
Thickness
.013
0.33
.013
0.33
.016
0.41
.013
0.33
.020
0.51
.020
0.51
Part
Number
63871-1
63889-1
63870
1217072-1
1217029-1
1217073-1
AMPLIVAR Terminals
A
187 Series FASTON Tabs1
Material
CMA
.940
[23.88]
.370
[9.40]
B
Board Thickness
A = .062–.072 [1.57–1.83]
Stock Thickness
A = .020 [0.51]
B = .032 [0.81]
Type
B
A
2
†
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
Part
Number
63484-12
61440-3†
62447-1
61442-3†
62445-1
Varnish resist coating.
These part numbers are available upon special request, contact TE engineering for details.
250 Series FASTON Tabs1
Stock Thickness
.032 [0.81]
Wire Range
AWG
mm2
14-12
2.0-3.0
1Mates with FASTON receptacles.
See Catalog 82004.
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 TE.
2
53
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
AMPLIVAR Terminals (Continued)
250 Series FASTON Tabs1
(Continued)
Stock Thickness
.032 [0.81]
Mates with FASTON receptacles.
See 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]
.290
[7.37]
Mates with FASTON tabs.
See 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
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
.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
54
1.02-1.71
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
.020
0.51
.020
0.51
Brass
Brass
.016
0.41
.016
0.41
.016
0.41
Low insertion force
Quick-change applicator for AMP-O-LECTRIC machine 565435-5.
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
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
Mating
Tab Thk.
.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
Material
Tin Plated Brass
Tin Plated Brass
Tin Plated Brass
Tin Plated Brass
Tin Plated Brass
Material
Thickness
Part
Number
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.016
0.41
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 AMP-O-LECTRIC Model G splice terminator No. 356462-2.
Quick-change applicator for AMP-O-LECTRIC Model G splice terminator No. 356462-1.
AMPLIVAR Terminals
2
500-960
Insulation
Diameter
.4.35
[11.05]
250 Series FASTON Flag
Receptacles
Stock Thickness
.018 [0.45]
.070
[1.78]
.600
[15.24]
.305
[7.75]
.125
[3.16]
.31 8
[8.09]
.300
[7.62]
Magnet wire range
CMA
mm2 Dia.
1
Pin Receptacles
500-1900
—
1000-2700
—
1500-4220
—
4000-8500
—
.530
[13.46]
.305
[7.75]
Insulation
Diameter
.100-.120
2.54-3.05
.100-.120
2.54-3.05
.075-.125
1.90-3.18
.110-.150
2.79-3.81
Material
Thickness
0.0157
0.4
0.0157
0.4
0.0157
0.4
0.0157
0.4
Mating Tab
Thk.
6.35
0.81
6.35
0.81
6.35
0.81
6.35
0.81
Part
Number
Applicator
No.
1742881-1
1855633
1742882-1
1855634
1742977-1
1855680
1742979-1
1855681
Quick-change applicator for AMP-O-LECTRIC Model 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
www.te.com/appliances
55
Magnet Wire Terminals and Termination Systems
Catalog 82221
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
0.10-0.3
0.35-0.66 200-700
.028-.060
0.4-1.6
0.71-1.52 800-3600
.053-.086
0.3-1.5
1.35-2.18 2800-7400
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]
Stator Terminal with
Receptacle .250 x .032
[6.35 x 0.81]
Plastic Cavity
Production only
according to
TE Specifications
(contact TE
engineering for details).
For design and
material selection
TE engineering
has to be contacted
before decision.
The terminal is
separated from the strip
and placed automatically into the cavity.
Wire Clamping Barrel
AMPLIVAR Terminal Crimp
The magnet wire is
positioned via posts
into the AMPLIVAR
crimp barrel and fixed
inside clamping barrel.
The application
equipment crimps the
AMPLIVAR product
connection and cuts the
extending clamping barrel
in one operation.
Additional versions
upon request.
Application tooling
for production line
integrating available
upon request.
56
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Cluster Blocks
Product Facts
Connects to sealed hermetic
headers
Versions available to accept
2.29 [.090] and 3.18 [.125 ]
header pins
Accepts Lead wire range
18–16 AWG [0.8–1.4 mm 2] and
14–12 AWG [2.0–3.0 mm 2]
AMPLIVAR product versions
accept up to 3 copper or
aluminum magnet wires
without the need to remove
insulation
Impervious to many oils and
refrigerants
Insulation compatibility
High-performance electrical
and mechanical contact
High-impact resistant
Assemblies accept pins
from one side only to
prevent reversed polarity
High-speed application of
pin receptacle terminals
with automatic
terminating machines and
quick-change applicators for
high volume production
rates at the lowest
installed cost
Recognized under the
Component Program of
Underwriters
Laboratories Inc.,
File No. E28476
R
TE features 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 2.29 [.090] and
3.18 [.125] diameter pin
sizes in either standard or
reverse pin layouts.
Housings accept both lead
wire and AMPLIVAR direct
connect pin receptacle
Cluster Blocks
Housings available to
accept standard and
reversed header p in layouts
Housing versions available for
compressor interior and
exterior
terminals. These are
precision formed and
available on reels for
highspeed application.
High retention pin receptacle terminals are available
to provide optimum
terminal retention housings.
Pin Receptacle Terminal
(Crimped to Wire)
PRODUCT SPECIFICATIONS:
108-2008,108-5205 &108-5541
APPLICATION SPECIFICATIONS:
114-2019 & 114-5235
Typical Assembly
www.te.com/appliances
57
Magnet Wire Terminals and Termination Systems
Catalog 82221
Cluster Blocks 2.29 [.090] Pin Size (Lead Wire and Direct Connect)
.108
[2.74]
Housings
.530
Dia.
[13.46]
.108
[2.74]
.683
Dia.
[17.35]
.324
[8.23]
.108
[2.74]
.229
[5.82]
.108
[2.74]
.090 ± .001
[2.29 ± 0.03]
Pin Dia.
3 Plcs.
.459
[11.66]
.090 ± .001
[2.29 ± 0.03]
Pin Dia.
4 Plcs.
.324
[8.23]
Pin Location
E
Pin Location
B, C and D
Pin Location
A
.324
[8.23]
K
W
H
L
B
A
W
K
H
H
L
C
D
Type
A
2 Position with Standoff
B
3 Position
Center Forward
C
3 Position
Center Back
D
3 Position
Center Back Extra Wide
Header Pin
Circle Dia.
mm / inch
13.46
[.530]
13.46
[.530]
13.46
[.530]
13.46
[.530]
Economy Models
E
4 Position
58
L
K
W
17.35
[.683]
Dim L
E
Material /
Use¹
Accepts
Receptacle
Style
Part Number
A, B & C
1969357-1
A, B & C
360050-1
Dim W
Dim H
Dim K
mm / inch
22.45
[.884]
31.50
[1.240]
mm / inch
21.08
[.830]
18.05
[.710]
mm / inch
14.23
[.560]
8.15
[.320]
mm / inch
21.35
[.840]
PBT
Interior
PBT
Interior
31.00
[1.220]
17.65
[.695]
6.60
[.260]
20.85
[.820]
PBT
Interior
A, B & C
521078-1
30.48
[1.200]
17.65
[.695]
7.87
[.310]
20.40
[.803]
PBT
Exterior
A, B & C
1380145-1
2
30.48
[1.200]
17.65
[.695]
7.87
[.310]
20.40
[.803]
PBT
Exterior
A, B & C
1380145-2
3
30.48
[1.200]
30.48
[1.200]
30.48
[1.200]
17.65
[.695]
17.65
[.695]
17.65
[.695]
9.70
[.382]
9.70
[.382]
9.70
[.382]
20.40
[.803]
20.40
[.803]
20.40
[.803]
PBT
Exterior
PA6+GF
Exterior
A, B & C
2232327-1
3
A, B & C
2232327-2
4
PBT
Exterior
A, B & C
2232326-1
3
30.48
[1.200]
30.80
[1.21]
31.10
[1.225]
17.65
[.695]
17.80
[.701]
20.55
[.810]
9.70
[.382]
7.40
[.0291]
8.15
[.320]
20.40
[.803]
20.40
[.803]
21.35
[.840]
PA6+GF
Exterior
PBT
Exterior
PBT
Interior
A, B & C
2232326-2
4
A, B & C
235280-1
A, B & C
360033-1
30.50
[1.200]
30.50
[1.200]
30.50
[1.200]
17.65
[.695]
17.70
[.697]
17.70
[.697]
7.85
[.310]
7.90
[.311]
7.80
[.307]
20.40
[.805]
20.40
[.805]
20.40
[.805]
PBT
Interior
PBT
Exterior
PA6+GF
Exterior
A, B & C
281006-4
31.60
[1.244]
31.60
[1.244]
31.60
[1.244]
28.10
[1.110]
28.10
[1.110]
22.70
[.893]
22.70
[.893]
22.70
[.893]
22.70
[.893]
22.70
[.893]
9.30
[.366]
9.30
[.366]
9.30
[.366]
7.60
[.299]
7.60
[.299]
21.50
[.846]
21.50
[.846]
21.50
[.846]
18.10
[.712]
18.10
[.712]
PBT Filled
Interior
PBT Filled
Exterior
PA6+GF
Exterior
PBT Filled
Exterior
PBT Filled
Exterior
D&E
171370-3
D&E
171370-5
D&E
171370-6
4
F
2825082-1
5
F
2825082-2
4
37.85
[1.490]
22.85
[.900]
9.00
[.355]
21.45
[.845]
PBT
Interior
A, B & C
1217262-1
N/A
Notes
A, B & C
880631-5
2
A, B & C
1955415-1
4
3
Notes: 1.Interior use designates that the material can be subjected to refrigerants and lubricants often found in a compressor. 3.Flammability rating UL94 V-0
Consult TE Connectivity Product specification for additional information.
4.Flammability rating UL94 V-0. Glow Wire compliant to 750°C with No Flame per IEC 60335-1.
5.Flammability rating UL94 HB
2.Flammability rating UL94 V-2
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Cluster Blocks 2.29 [.090] Pin Size (Lead Wire and Direct Connect)
.670
[17.02]
.670
[17.02]
.313
[7.95]
Pin Receptacles
.313
[7.95]
.180
[4.57]
.180
[4.57]
.115
[2.92]
A
Lead Wire
Standard
Retention
.115
[2.92]
B
Lead Wire
High
Retention
C
Lead Wire
Standard
Retention
.590
[15.0]
.276
[7.0]
.180
[4.57]
D
Type
B
Lead Wire
High Retention
C
AMPLIVAR Direct Connect
High Retention Product
D
Lead Wire
Oval Contact
Magnet Wire
Size
mm² / CMA
F
Crimp Width
Insulation Dia
Crimp Width
mm / inch
mm / inch
mm / inch
0.30 - .75
[22 - 18]
2.03
0.080
1.30 - 2.40
.051 - .095
0.80 - 1.3
[18 - 16]
2.79
0.110
Lead Wire Size
Material
Part Number
3.05
0.120
Tin Plated Phos
Bronze¹
1599105-1
1.50 - 2.50
.060 - .100
3.56
0.140
Tin Plated Phos
Bronze¹
62131-3
2.79
0.110
2.30 - 4.30
.090 - .170
4.57
0.180
Tin Plated Phos
Bronze¹
63448-1
2.54
0.100
2.00 - 3.80
.080 - .150
3.30
0.130
Tin Plated Phos
Bronze¹
1217264-1
0.26-0.77
[400 - 1600]
2.270
0.090
1.50 - 2.55
0.06 - .100
3.560
0.140
Tin Plated Phos
Bronze¹
1742981-1
0.77 - 2.43
[1600 - 4800]
2.79
0.110
1.90 - 3.20
.075 - .125
3.94
0.155
Tin Plated Phos
Bronze¹
1742964-1
3
2,29
0.090
2.00 - 3.40
.080 - .134
3.81
0.150
Tin Plated Phos
Bronze¹
170063-2
2
0.11 - 0.73
[225 - 1445]
1.78
0.070
0.90 - 2.00
.035 - .079
3.3
0.130
Tin Plated Phos
Bronze¹
1123655-1
2, 4
0.77 - 2.13
[1600 - 4200]
2.79
0.110
2.00 - 2.90
.080 - .114
3.81
0.150
Tin Plated Phos
Bronze¹
353937-1
2, 4
2,29
0.090
2.00 - 3.40
.080 - .134
3.81
0.150
Tin Plated Phos
Bronze¹
2825083-1
5
0.30 - 2.08
[22 - 14]
0.50 - 1.25
[20 - 16]
E
AMPLIVAR Short Barrel
Oval Contact
F
Lead Wire
Oval Contact
Economy Model
Lead Wire
Standard Retention
Economy Model
E
mm² / AWG
A
Lead Wire
Standard Retention
.083
[2.12]
Lead Wire
Standard Retention
0.50 - 1.25
[20 - 16]
Cluster Blocks
Lead Wire
Standard Retention
Notes
Notes: 1.May contain an equivalent copper alloy.
2.Requires extra wide type D housing.
3.Connects up to 3 Copper or aluminum magnet wires without stripping insulation.
4.Connects up to 2 copper magnets without stripping insulation.
5.Requires extra wide type D, Economy Model housing.
59
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Cluster Blocks 3.18 [.125] Pin Size (Lead Wire and Direct Connect)
Housings
.229
[5.82]
.815
Dia.
[20.70]
.687
Dia.
[17.45]
.530
Dia.
[13.46]
.125 ± .001
[3.18 ± 0.03]
Pin Dia.
3 Plcs.
.125 ± .001
[3.18 ± 0.03]
Pin Dia.
3 Plcs.
.297
[7.55]
.459
[11.66]
Pin Location
A and B
.125 ±
.001
[3.18 ±
.353
[8.96]
.595
[15.12]
0.03]
Pin Dia.
3 Plcs.
.706
[17.92]
Pin Location
C and D
Pin Location
E
W
W
K
K
H
H
L
L
B
A
W
W
W
K
K
H
H
K
H
L
L
L
C
Type
Header Pin
Circle Dia.
mm / inch
A
3 Position
Center Forward
13.46
[.530]
mm / inch
Material /
Use’
Accepts
Receptacle Style
Part Number
31.17
[1.227]
PBT
Interior
A, B, C & D
360052-1
Dim L
Dim W
Dim H
Dim K
mm / inch
mm / inch
mm / inch
44.60
[1.755]
19.45
[0.765]
11.95
[0.470]
44.60
19.45
13.35
31.17
[1.755]
[0.765]
[.525]
[1.227]
PBT
Interior
A, B, C & D
1217181-1
44.60
[1.755]
19.45
[0.765]
11.95
[0.470]
31.10
[1.225]
PBT
Interior
A, B, C & D
360051-1
47.25
[1.860]
19.45
[.765]
13.35
[.525]
31.10
[1.225]
PBT
Interior
A, B, C & D
1217200-1
40.50
[1.595]
22.75
[.895]
9.65
[.380]
27.45
[1.080]
PBT
Interior
A, B, C & D
520995-1
43.95
[1.730]
22.75
[.895]
15.60
[.615]
27.45
[1.080]
PBT
Interior
A, B, C & D
1217186-1
17.45
[.687]
47.00
[1.850]
22.75
[.895]
15.60
[.615]
31.10
[1.225]
PBT
Interior
A, B, C & D
1217187-1
20.70
[.815]
50.15
[1.975]
25.80
[1.015]
15.00
[.590]
26.65
PBT
Interior
A, B, C & D
1217261-1
B
3 Position
Center Back
13.46
[.530]
C
3 Position
Center Forward
17.45
[.687]
D
3 Position
Center Back
E
3 Position
Center Forward
E
D
1.05
Notes: 1.Interior use designates that the material can be subjected to refrigerants and lubricants often found in a compressor.
Consult TE Connectivity product specification for additional information.
60
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Cluster Blocks 3.18 [.125] 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]
C
D
AMPLIVAR Direct Connect Contact
Type
Insulation Dia
Crimp Width
mm / inch
mm / inch
mm / inch
0.75 - 1.5
2.79
2.30 - 3.30
3.94
[18 - 16]
0.110
.090 - .130
0.155
mm² / AWG
A
Lead Wire
Standard Retention
B
Lead Wire
High Retention
C
AMPLIVAR Direct Connect
Standard Retention
D
AMPLIVAR Direct Connect
High Retention
Magnet Wire
Size
mm² / CMA
AMPLIVAR Direct Connect Contact
Crimp Width
Lead Wire Size
Cluster Blocks
.160
[4.06]
.160
[4.06]
Material
Part Number
Notes
Tin Plated
Phos Bronze¹
62244-3
2
Tin Plated
Phos Bronze¹
62243-3
2
2.0 - 6.0
3.56
3.30 - 4.30
4.57
14 - 10
0.140
.130 - .170
0.180
0.32-0.82 or 2x0.32
2.29
2.79 or 2x2.29 Max
3.56
[22-18 or 2x22]
0.090
.110 or 2x.090 Max
0.140
Tin Plated
Phos Bronze¹
1742657-1
2
0.75 - 1.5
[18 - 16]
2.79
0.110
2.30 - 3.30
.090 - .130
3.94
0.155
Tin Plated
Phos Bronze¹
1217176-1
2
2.0 - 6.0
[14 - 10]
3.56
0.140
3.30 - 4.30
.130 - .170
4.57
0.180
Tin Plated
Phos Bronze¹
1217175-1
2
0.20 - 0.81
400 - 1600
2.27
0.090
1.50 - 2.55
.060 - .100
3.56
0.140
Tin Plated
Phos Bronze¹
63453-1
2, 4
0.76 - 2.13
1500 - 4200
2.79
0.110
1.90 - 3.20
.075 - .125
3.94
0.155
Tin Plated
Phos Bronze¹
63454-1
2, 4
2.00 - 4.30
4000 - 8500
3.56
0.140
2.30 - 4.30
.090 - .170
4.32
0.170
Tin Plated
Phos Bronze¹
63455-1
2, 4
0.20 - 0.81
400 - 1600
2.27
0.090
1.50 - 2.55
.060 - .100
3.56
0.140
Tin Plated
Phos Bronze¹
1217172-1
2, 4
0.76 - 2.13
1500 - 4200
2.79
0.110
1.90 - 3.20
.075 - .125
3.94
0.155
Tin Plated
Phos Bronze¹
1217174-1
2, 4
2.00 - 4.30
3.56
2.30 - 4.30
4.32
4000 - 8500
0.140
.090 - .170
0.170
Tin Plated
Phos Bronze¹
1217173-1
2, 4
Notes: 1.Material shown is for reference only. May contain an equivalent copper alloy.
2.Receptacle must be contained in a housing listed on the previous page for proper performance.
3.Stand-alone receptacle can be used with or without a housing.
4.Connects up to 3 copper or aluminum magnet wires without removing the insulation.
61
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
This product line is not recommended for new designs,
MTM Crimpband Splices as the application machines are no longer manufactured.
Product Facts
Made from a continuous coil
of ribbon connector
material
Magnet wires MTM
Crimpband splices have
machine-piercing serrations
designed for displacing
magnet wire insulation.
Available in brass, tinplated brass, and coppernickel alloy material
Make parallel or pigtail
connections on same
machine
100% of Crimpband
material is used in scrap
free terminations
Crimpband material coupled
with appropriate toolsets
accommodate specific
CMA ranges
Produced in TE
equipment on your
production floor
Meets UL 486C crimp
tensile requirements
Applications
62
Motors windings and
connections
Coil connections
Transformer windings and
connections
Lighting ballasts
Power supplies
Cut
Formed
Crimped
TE features the MTM
Crimpband system that is
comprised of two key
features: the semiautomatic termination
machine and a reel of MTM
Crimpband material.
In a one-step crimping
operation, the machine
feeds, cuts, forms and
crimps the material to
provide a low-cost, high
reliability crimp connection.
The MTM Crimpband
splices are formed during
the crimping process from
machined longitudinal
grooved material that pierces
magnet wire varnish film
insulation during crimping.
TE provides a wide range of
toolset types and Crimpband
splices to meet various
production requirements.
Three magnet wires
maximum can be
terminated together with
stranded lead wire in one
splice.
When aluminum magnet wire
is used, MTM Crimpband
splices must be tin plated.
MTM Crimpband splices
are specifically designed to
terminate magnet wire to
itself or in combination with
standard solid or stranded
lead wire.
Depending on your
specific application, MTM
Crimpband splices are
available in 7, 9, 11 and 13
serration versions for
terminations in the 400 to
13,000 CMA range.
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
This product line is not recommended for new designs,
as the application machines are no longer manufactured.
MTM Crimpband Splices (Continued)
MTM Crimpband
Interconnection System
Catalog 82221
Notes: To insure that the proper Crimpband splice is chosen, TE recommends
the following:
1. Submit 10 samples of wire combinations and/or components to be
crimped with any special requirements to your TE sales
representative.
2. Pull-out force and/or millivolt drop tests will be performed to insure
that the proper Crimpband material, toolset and crimp heights are
recommended.
3. Tooling and testing will be documented on a Material & Tooling
Sheet (M & T sheet).
4. Crimpband material quotes, tooling quotes and samples will be
submitted to the customer.
How the System Operates
Feed (Magnet Wire
Connector Material)
Machine feeds strip until
the strip hits the wire stop.
Shear (Blank Length)
The strip is cut by the
cutter block former bar
insert tooling.
W
Bend (Crimp Formed)
The former bar drives the
cut strip over the anvil,
bending the cut strip into
an upside down “U”.
T
A
Wire (Placement)
In pigtail and parallel
(Thru) splices magnet
wires must be placed on
top of the lead wire.
Magnet Wires
on top
Legend
L
Leased
L
See Figure 1 and/or Legend below
W Dim.
T Dim.
Connector
Material
Finish
Width
Thickness
6R
20
T
092
6R
Machine Basis
P
G*
Purchase
General
* Customer has their own Tooling
20
T
Tooling
Size Code
032
032/036
036
045
051
061
061/076
076
076/092
092
092/125
125
125/160
125/165
165
Material
Code
Lead Wire
B
Crimpband
Splice No.
Example:
Blank
Length
W
Connector Specification Code
L
D
A
The anvil retracts as the
driver takes the formed
strip down into the
clincher.
B.L. Dim.
Tooling
Size
092
Serrations
Section A-A
Crimp (Crimp Formed)
Machine
Basis
Burrs
B
Blank Length
B/L (Nom.)
.167
.228
.224
.246
.267
.292
.324
.339
.361
.379
.413
.446
.485
.506
.546
Note: For B/L above, .546 consult
TE for tooling size code.
Connector Width Code
4R
5 Serrations
6R
7 Serrations
8R
9 Serrations
10R
11 Serrations
Material
Thickness
Code
12
14
16
20
25
Material
Code
B
A
TB
T±.002
Dim.
.012
.014
.016
.020
.025
W
.138
.154
.194
.234
D
Serration
Depth
.005
.005
.007
.007
.007
UL486C Pull Out
Wire Size Force Requirements
AWG
Underwriters
Laboratory (lbs.)
26
3
24
5
22
8
20
10
18
10
16
15
14
25
12
35
10
40
Material/Finish
CDA 260 Brass
CDA 725 Copper/
Nickel Alloy
Pre-Tin over
CDA 260 Brass
63
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
MTM Crimpband Splices (Continued)
Catalog 82221
This product line is not recommended for new designs,
as the application machines are no longer manufactured.
11 Serrations
T
W
AWG/
Wire Range
mm2
Solid Dia.
.059-.087
141∕ 2-111∕ 2
1.80-4.00
1.50-2.21
.059-.087
141∕ 2-111∕ 2
1.80-4.00
1.50-2.21
.071-.097
131∕ 2-101∕ 2
2.54-4.50
1.70-2.46
.071-.097
131∕ 2-101∕ 2
2.54-4.50
1.70-2.46
CMA
Range
3500-7500
3500-7500
4500-9500
4500-9500
Stock
Mat’l
Thk. (T) Width (W) Material
.025
.234
Brass
0.64
5.94
.025
.234
Tin Plated
0.64
5.94
Brass
.025
.234
Brass
0.64
5.94
.025
.234
Tin Plated
0.64
5.94
Brass
Toolset
Part
Number
Descriptive
X-ref
P125/
16510R25B
L125/
16510R25TB
P165/
20010R25B
P165/
20010R25TB
125/165
1601842-1
125/165
1601705-1
165/200
1601847-1
165/200
1601848-1
Toolset
Part
Number
032/036
1601794-1†
Descriptive
X-ref
P032/
0368R16TB
061
1601607-1†
L0618R16TB
061
1601608-1
L0618R20B
9 Serrations
T
W
AWG/
Wire Range
mm2
Solid Dia.
24-20
.020-.033
0.20-0.50
0.51-0.84
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
16-12
.051-.078
1.30-3.46
1.29-1.98
16-12
.051-.078
1.30-3.46
1.29-1.98
16-12
.051-.078
1.30-3.46
1.29-1.98
16-12
.051-.078
1.30-3.46
1.29-1.98
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
151∕ 2-12
.055-.082
1.54-3.46
1.40-2.10
.059-.087
141∕ 2-111∕ 2
1.80-4.00
1.50-2.21
.059-.087
141∕ 2-111∕ 2
1.80-4.00
1.50-2.21
14-11
.063-.092
2.00-4.20
1.60-2.34
.084-.114
111∕ 2-9
4.00-6.50
2.13-2.90
†
CMA
Range
400-1100
900-2600
900-2600
900-2600
1600-4000
1600-4000
1800-4600
1800-4600
2600-6100
2600-6100
2600-6100
2600-6100
3000-6750
3000-6750
3000-6750
3000-6750
3500-7500
3500-7500
4000-8500
7000-13000
Stock
Mat’l
Thk. (T) Width (W)
.016
.194
0.41
4.93
.018
.194
0.46
4.93
.018
.194
0.46
4.93
.018
.194
0.46
4.93
.016
.194
0.41
4.93
.020
.194
0.51
4.93
.020
.194
0.51
4.93
.020
.194
0.51
4.93
.020
.194
0.51
4.93
.020
.194
0.51
4.93
.025
.194
0.64
4.93
.025
.194
0.64
4.93
.016
.194
0.41
4.93
.016
.194
0.41
4.93
.020
.194
0.51
4.93
.025
.194
0.64
4.93
.025
.194
0.64
4.93
.025
.194
0.64
4.93
.025
.194
0.64
4.93
.025
.194
0.64
4.93
Material
Tin Plated
Brass
Tin Plated
Brass
Brass
Tin Plated
Brass
Tin Plated
Brass
Tin Plated
Brass
061
1601814-1†
P0618R20TB
076
1601824-1
P0768R16TB
076
1601857-1
PO768R20TB
Brass
076/092
1601823-1
Tin Plated
Brass
076/092
1601639-1
Brass
092/125
1601678-1†
Tin Plated
Brass
092/125
1601835-1†
P076/
0928R20B
L076/
0928R20TB
P092/
1258R20B
L092/
1258R20TB
L092/
1258R25B
P092/
1258R25TB
Brass
125
1601717-1†
L1258R16B
Tin Plated
Brass
125
1601718-1
L1258R16TB
Brass
125
1601846-1
P1258R20B
Brass
125
1601719-1
L1258R25B
Brass
125/165
1601706-1
125/165
1601707-1
L125/
1658R25B
L125/
1658R25TB
165
1601750-1†
L1658R25TB
200/202
1601761-1
L200/
2028R25TB
Brass
092/125
1601833-1
Tin Plated
Brass
092/125
1601677-1
Tin Plated
Brass
Tin Plated
Brass
Tin Plated
Brass
These part numbers are available upon special request; contact TE engineering for details.
64
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
MTM Crimpband Splices (Continued)
Catalog 82221
This product line is not recommended for new designs,
as the application machines are no longer manufactured.
7 Serrations
T
W
CMA
Range
170-800
400-1100
400-1100
400-1100
400-1100
600-1300
600-1300
900-2600
900-2600
1600-4000
1600-4000
1600-4000
1800-4600
2200-5200
2600-6100
2600-6100
3000-6750
3000-6750
3000-6750
Stock
Mat’l
Thk. (T) Width (W)
.012
.154
0.30
3.91
.012
.154
0.30
3.91
.012
.154
0.30
3.91
.016
.154
0.41
3.91
.016
.154
0.41
3.91
.016
.154
0.41
3.91
.020
.154
0.51
3.91
.016
.154
0.41
3.91
.016
.154
0.41
3.91
.016
.154
0.41
3.91
.016
.154
0.41
3.91
.020
.154
0.51
3.91
.016
.154
0.41
3.91
.016
.154
0.41
3.91
.016
.154
0.41
3.91
.020
.154
0.51
3.91
.012
.154
0.30
3.91
.016
.154
0.41
3.91
.016
.154
0.41
3.91
Part
Number
Material
Toolset
Brass
032
Brass
032/036
1601539-1
Cu Ni
032/036
1601538-1
Descriptive
X-ref
1601800-1 P0326R12BUF1
L032/
0366R12B
L032/
0366R12AUF1
L032/
0366R16B
P032/
0366R16TB
Brass
032/036
1601540-1
Tin Plated
Brass
032/036
1601793-1
Brass
045
1601559-1
L0456R16B
Brass
045
1601560-1†
L0456R20B
Brass
061
1601604-1
L0616R16B
Tin Plated
Brass
061
1601606-1
L0616R16TB
Brass
076
1601644-1
L0766R16B
Tin Plated
Brass
076
1601646-1†
L0766R16TB
Brass
076
1601647-1†
L0766R20B
Brass
076/092
1601637-1
L076/
0926R16BX
L0926R16TB
Tin Plated
Brass
Tin Plated
Brass
092
1601683-1
092/125
1601675-1
Brass
092/125
1601832-1
Brass
125
1601844-1
P1256R12B
Brass
125
1601845-1
P1256R16B
Tin Plated
Brass
125
1601716-1†
L1256R16TB
L092/
1256R16TB
P092/
1256R20B
Crimpband
AWG/
Wire Range
mm2
Solid Dia.
.013-.028
271∕ 2-21
0.09-0.40
0.33-0.71
24-20
.020-.033
0.20-0.50
0.51-0.84
24-20
.020-.033
0.20-0.50
0.51-0.84
24-20
.020-.033
0.20-0.50
0.51-0.84
24-20
.020-.033
0.20-0.50
0.51-0.84
22-19
.024-.036
0.38-0.60
0.70-0.91
22-19
.024-.036
0.38-0.60
0.70-0.91
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
.042-.068
171∕ 2-131∕ 2
0.95-2.54
1.07-1.80
.047-.072
161∕ 2-13
1.10-2.60
1.19-1.83
16-12
.051-.078
1.30-3.46
1.29-1.98
16-12
.051-.078
1.30-3.46
1.29-1.98
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
UF designates Ultra-Fine serrations which are recommended for applications using wire size 28 AWG [0.32 mm]
or smaller.
† These part numbers are available upon special request; contact TE engineering for details.
1
65
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
This product line is not recommended for new designs,
RTM Crimpband Splices as the application machines are no longer manufactured.
Product Facts
Made from a continuous coil
of “Ribbon Connector”
material
RTM Crimpband have
grooved serrations for
improved axial retention.
Available in brass, tin-plate d
brass and copper-nickel
alloy (CA725) materia l
Make parallel or pigtail
connections on same
machine
Used for electrical and nonelectrical connections.
100% of RTM Crimpband
material is used in scrap
free terminations
Crimpband material coupled
with appropriate toolsets
accommodate specific CMA
ranges
Produced in TE equipment
on your production floor
Meets UL 486C crimp
tensile requirements
Applications
Stranded and solid wire-towire connections
Light bulb LED assembly
Switch lead assembly
Resistor lead assembly
Printed circuit board lead
assembly
Flex-film lead assembly
Glass reed switch lead
assembly
Cut
Formed
Crimped
Mod I
TE features the RTM
Crimpband system that is
comprised of two key
features: the semiautomatic termination
machine and a reel of RTM
Crimpband material.
In a one-step crimping
operation, the machine
feeds, cuts, forms and
crimps the material to
provide a low-cost, high
reliability crimp connection.
The RTM Crimpband
splices are formed during
the crimping process from
Mod III
milled longitudinal groove
material that produce rolled,
rounded serrations.
They are designed to
terminate pre-stripped
stranded and solid wire
conductors together as well
as wire conductors to switch
tabs, resistors, printed
circuit board, flex circuit and
light bulb LED and glass
reed switch assemblies, etc.
The flexibility of the RTM
Crimpband system provides
opportunity for use in
custom applications for
either electrical and / or
mechanical connections.
TE provides a wide range of
toolset types and crimpband
splices to meet various
production requirements.
Depending on your specific
application, RTM Crimpband
splices are available in 3, 6,
7, 8, 9, 10 14 and 20 ridge
serration versions for
terminations in the 170 to
13,000 CMA range.
66
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
RTM Crimpband Splices (Continued)
RTM Crimpband
Interconnection System
Catalog 82221
This product line is not recommended for new designs,
as the application machines are no longer manufactured.
Notes: To insure that the proper Crimpband splice is chosen, TE recommends
the following:
1. Submit 10 samples of wire combinations and/or components to be
crimped with any special requirements to your TE sales
representative.
2. Pull-out force and/or millivolt drop tests will be performed to insure
that the proper Crimpband material, toolset and crimp heights are
recommended.
3. Tooling and testing will be documented on a Material & Tooling
Sheet (M & T sheet).
4. Crimpband material quotes, tooling quotes and samples will be
submitted to the customer.
How the System Operates
Feed (Ribbon
Connector Material)
Machine feeds strip until
the strip hits the wire stop.
Shear (Blank Length)
The strip is cut by the
cutter block former bar
insert tooling.
W
Bend (Crimp Formed)
The former bar drives the
cut strip over the anvil,
bending the cut strip into
an upside down “U”.
Ridges
T
Section A-A
A
Wire (Placement)
Pigtail and parallel (Thru)
splice terminations are
made on the same
machine.
A
Crimp (Crimp Formed)
The anvil retracts as the
driver takes the formed
strip down into the
clincher.
W
B.L. Dim.
Tooling
Size
092
L
L
See Figure 1 and/or Legend below
W Dim.
T Dim.
Connector
Material
Material
Width
Thickness
F
20
TCRS
092
F
20
Crimpband
Splice No.
Example:
Lead Wires
Connector Specification Code
Machine
Basis
Blank
Length
TCRS
Legend
Machine Basis
L
P
Leased
Purchase
Tooling
Size Code
032
032/036
036
045
051
061
061/076
076
076/092
092
092/125
125
125/160
125/165
165
Blank Length
B/L (Nom.)
.167
.228
.224
.246
.267
.292
.324
.339
.361
.379
.413
.446
.485
.506
.546
Note: For B/L above, .546 consult
factory for tooling size code
Connector
Width
Code
B
C
D
E
F
G
H
L
M
N
P
W
Dim.
.076
.138
.154
.185
.216
.234
.247
.086
.330
.500
.114
N
No. of
Ridges
3
6
7
8
9
10
10
3
14
20
5
Material
Thickness
Code
12
16
18
20
22
24
25
Material
Code
B
A
TB
TCRS
SS
ST
T±.002
Dim.
.012
.016
.018
.020
.022
.024
.025
Material/Finish
UL486C Pull Out
Wire Size Force Requirements
AWG
Underwriters
Laboratory (lbs.)
26
3
24
5
22
8
20
10
18
10
16
15
14
25
12
35
10
40
CDA 260 Brass
CDA 725 Copper/
Nickel Alloy
Pre-Tin over
CDA 260 Brass
1010 Cold Rolled
Steel, Tin Plated
301 or 302
Stainless Steel
Stainless Steel,
Tin Plated
67
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
RTM Crimpband Splices (Continued)
Catalog 82221
This product line is not recommended for new designs,
as the application machines are no longer manufactured.
20 Ridges
T
W
AWG/
Wire Range
CMA
Stock
Mat’l
mm2
Solid Dia.
Range
Thk. (T) Width (W) Material
.084-.114 7000-13000 .020
.500
Tin Plated
111∕ 2-9
4.00-6.50
2.13-2.90
0.51
12.70
Brass
Toolset
200/202
Part
Number
Descriptive
X-ref
1601771-1 L200/202N20TB
14 Ridges
T
W
AWG/
Wire Range
CMA
mm2
Solid Dia.
Range
22-19
.024-.036
600-1300
0.38-0.60
0.61-0.91
22-19
.024-.036
600-1300
0.38-0.60
0.61-0.91
†
Stock
Mat’l
Thk. (T) Width (W)
.012
.330
0.30
8.38
.012
.330
0.30
8.38
Material
Toolset
Part
Number
Descriptive
X-ref
Cu Ni
045
1601577-1†
L045M12A
Brass
045
1601578-1
L045M12B
These part numbers are available upon special request; contact TE engineering for details.
10 Ridges
T
W
AWG/
Wire Range
mm2
Solid Dia.
22-19
.024-.036
0.38-0.60
0.61-0.91
21-181∕ 2
.028-.039
0.40-0.75
0.71-0.99
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.084-.114
111∕ 2-9
4.00-6.50
2.13-2.90
.084-.114
111∕ 2-9
4.00-6.50
2.13-2.90
†
CMA
Range
Stock
Mat’l
Thk. (T) Width (W)
.012
.234
600-1300
0.30
5.94
.016
.234
800-1500
0.41
5.94
.012
.234
900-2600
0.30
5.94
.020
.234
900-2600
0.51
5.94
.020
.234
7000-13000 0
.51
5.94
.025
.234
7000-13000
0.64
5.94
Material
Toolset
Part
Number
Descriptive
X-ref
Brass
045
1601575-1
L045G12B
Cu Ni
051
1601593-1†
L051G16A
Brass
061
1601632-1†
L061G12B
Brass
061
1601633-1
L061G20B
Brass
200/202
1601853-1
Brass
200/202
1601769-1
P200/
202G20B
L200/
202G25BX
These part numbers are available upon special request; contact TE engineering for details.
68
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
RTM Crimpband Splices (Continued)
Catalog 82221
This product line is not recommended for new designs,
as the application machines are no longer manufactured.
9 Ridges
T
W
AWG/
Wire Range
CMA
mm2
Solid Dia.
Range
22-19
.024-.036
600-1300
0.38-0.60
0.61-0.91
.030-.051
201∕ 2-16
900-2600
0.45-1.30
0.76-1.29
Stock
Mat’l
Thk. (T) Width (W)
.012
.216
0.30
5.49
.012
.216
0.30
5.49
Material
Stainless
Steel
Stainless
Steel
Toolset
Part
Number
Descriptive
X-ref
045
1601807-1
P045F12SS
061
1601520-1
G061F12SS
Toolset
Part
Number
032/036
1601553-1
Descriptive
X-ref
L032/
036E12A
8 Ridges
T
W
AWG/
Wire Range
CMA
Stock
Mat’l
mm2
Solid Dia.
Range
Thk. (T) Width (W) Material
24-20
.020-.033
.012
.185
400-1100
Cu Ni
0.20-0.50
0.51-0.84
0.30
4.70
18-14
.040-.063 1600-4000
.018
.185
Tin Plated
0.80-2.00
1.02-1.60
0.46
4.70
CRS
111∕ 2-9
.084-.114 7000-13000 .024
.185
Brass
4.00-6.50
2.13-2.90
0.61
4.70
076
1601669-1 L076E18TCRS
L200/
202E24B
1601768-1
Toolset
Part
Number
032/036
1601550-1
032/036
1601551-1
032/036
1601797-1
032/036
1601798-1
Descriptive
X-ref
L032/
036D12B
L032/
036D16A
P032/
036D16B
P032/
036D16TB
045
1601572-1
L045D12B
045
1601573-1
L045D16A
Crimpband
200/202
7 Ridges
T
W
AWG/
Wire Range
mm2
Solid Dia.
24-20
.020-.033
0.20-0.50
0.51-0.84
24-20
.020-.033
0.20-0.50
0.51-0.84
24-20
.020-.033
0.20-0.50
0.51-0.84
24-20
.020-.033
0.20-0.50
0.51-0.84
22-19
.024-.036
0.38-0.60
0.61-0.91
22-19
.024-.036
0.38-0.60
0.61-0.91
CMA
Range
400-1100
400-1100
400-1100
400-1100
600-1300
600-1300
Stock
Mat’l
Material
Thk. (T) Width (W)
.012
.154
Brass
0.30
3.91
.016
.154
Cu Ni
0.41
3.91
.016
.154
Brass
0.41
3.91
.016
.154
Tin Plated
0.41
3.91
Brass
.012
.154
Brass
0.30
3.91
.016
.154
Cu Ni
0.41
3.91
69
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
RTM Crimpband Splices (Continued)
7 Ridges
Catalog 82221
This product line is not recommended for new designs,
as the application machines are no longer manufactured.
(Continued)
T
W
AWG/
Wire Range
mm2
Solid Dia.
22-19
.024-.036
0.38-0.60
0.61-0.91
.028-.039
21-181∕ 2
0.40-0.75
0.71-0.99
.028-.039
21-181∕ 2
0.40-0.75
0.71-0.99
.028-.039
21-181∕ 2
0.40-0.75
0.71-0.99
.028-.039
21-181∕ 2
0.40-0.75
0.71-0.99
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
20-15
.033-.057
0.60-1.60
0.84-1.45
.035-.061
191∕ 2-141∕ 2
0.60-1.80
0.89-1.54
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
†
CMA
Range
600-1300
800-1500
800-1500
800-1500
800-1500
900-2600
900-2600
900-2600
900-2600
900-2600
900-2600
900-2600
900-2600
900-2600
900-2600
900-2600
1100-3200
1200-3700
1600-4000
1600-4000
1600-4000
1600-4000
1600-4000
1600-4000
1600-4000
1600-4000
1600-4000
1600-4000
1600-4000
Stock
Mat’l
Part
Toolset
Thk. (T) Width (W) Material
Number
.016
.154
Brass
045
1601507-1†
0.41
3.91
.012
.154
Brass
051
1601587-1
0.30
3.91
.016
.154
Brass
051
1601588-1
0.41
3.91
.020
.154
Nickel Plated
051
1601591-1
0.51
3.91
Steel
.020
.154
Tin Plated
051
1601811-1†
0.51
3.91
CRS
.012
.154
Cu Ni
061
1601818-1†
0.30
3.91
.012
.154
Brass
061
1601620-1†
0.30
3.91
.012
.154
Tin Plated
061
1601514-1†
0.30
3.91
Brass
.016
.154
Cu Ni
061
1601819-1
0.41
3.91
.016
.154
Brass
061
1601820-1
0.41
3.91
.016
.154
Tin Plated
061
1601623-1
0.41
3.91
Brass
.018
.154
Brass
061
1601625-1
0.46
3.91
.018
.154
Tin Plated
061
1601628-1
0.46
3.91
Brass
.020
.154
Cu Ni
061
1601629-1
0.51
3.91
.020
.154
Brass
061
1601630-1
0.51
3.91
.020
.154
Tin Plated
061
1601631-1
0.51
3.91
Brass
.016
.154
Brass
061/076 1601601-1
0.41
3.91
.016
.154
Brass
061/092 1601603-1
0.41
3.91
.012
.154
Cu Ni
076
1601828-1
0.30
3.91
.012
.154
Brass
076
1601655-1†
0.30
3.91
.016
.154
Cu Ni
076
1601656-1
0.41
3.91
.016
.154
Brass
076
1601829-1
0.41
3.91
.016
.154
Tin Plated
076
1601658-1
0.41
3.91
Brass
.018
.154
Cu Ni
076
1601660-1
0.46
3.91
.018
.154
Brass
076
1601661-1
0.46
3.91
.018
.154
Tin Plated
076
1601664-1
0.46
3.91
Brass
.020
.154
Brass
076
1601665-1
0.51
3.91
.020
.154
076
1601667-1
0.51
3.91
.024
.154
Brass
076
1601668-1
0.61
3.91
Descriptive
X-ref
G045D16B
L051D12B
L051D16B
L051D20NPS
P051D20TCRS
P061D12A
L061D12B
G061D12TB
P061D16A
P061D16B
L061D16TB
L061D18B
L061D18TB
L061D20A
L061D20B
L061D20TBX
L061/076D16B
L061/092D16B
P076D12A
L076D12B
L076D16A
P076D16B
L076D16TB
L076D18AX
L076D18B
L076D18TB
L076D20B
L076D20TCRS
L076D24B
These part numbers are available upon special request; contact TE engineering for details.
70
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
RTM Crimpband Splices (Continued)
7 Ridges
Catalog 82221
This product line is not recommended for new designs,
as the application machines are no longer manufactured.
(Continued)
T
W
†
CMA
Range
1800-4600
2200-5200
2200-5200
2200-5200
2200-5200
2200-5200
2200-5200
2200-5200
2600-6100
2600-6100
2600-6100
3000-6750
3000-6750
3000-6750
3000-6750
3000-6750
3000-6750
3000-6750
3500-7500
3500-7500
3500-7500
3500-7500
4000-8500
4000-8500
4500-9500
7000-13000
7000-13000
7000-13000
7000-13000
Stock
Mat’l
Thk. (T) Width (W)
.016
.154
0.41
3.91
.016
.154
0.41
3.91
.016
.154
0.41
3.91
.016
.154
0.41
3.91
.018
.154
0.46
3.91
.018
.154
0.46
3.91
.018
.154
0.46
3.91
.020
.154
0.51
3.91
.020
.154
0.51
3.91
.020
.154
0.51
3.91
.020
.154
0.51
3.91
.016
.154
0.41
3.91
.018
.154
0.46
3.91
.018
.154
0.46
3.91
.018
.154
0.46
3.91
.020
.154
0.51
3.91
.020
.154
0.51
3.91
.020
.154
0.51
3.91
.018
.154
0.46
3.91
.020
.154
0.51
3.91
.020
.154
0.51
3.91
.020
.154
0.51
3.91
.020
.154
0.51
3.91
.020
.154
0.51
3.91
.020
.154
0.51
3.91
.016
.154
0.41
3.91
.020
.154
0.51
3.91
.020
.154
0.51
3.91
.020
.154
0.51
3.91
Material
Toolset
Part
Number
Brass
076/092
1601642-1
Descriptive
X-ref
L076/
092D16BX
Cu Ni
092
1601689-1
L092D16ASP
Brass
092
1601691-1
L092D16B
Tin Plated
Brass
092
1601693-1
L092D16TB
Cu Ni
092
1601694-1
L092D18A
Brass
092
1601695-1
L092D18B
Tin Plated
Brass
092
1601841-1
P092D18TB
Brass
092
1601528-1†
G092D20B
Cu Ni
092/125
1601680-1
Brass
092/125
1601681-1
Tin Plated
CRS
092/125
1601682-1
L092/
125D20A
L092/
125D20B
092/
125D20TCRS
Brass
125
1601529-1
G125D16B
Cu Ni
125
1601531-1
G125D18A
Brass
125
1601726-1
L125D18B
Tin Plated
Brass
125
1601729-1
L125D18TBX
Brass
125
1601730-1
L125D20B
Tin Plated
Brass
125
1601731-1
L125D20TB
125
1601733-1 L125D20TCRS
Tin Plated
Brass
125/165
1601709-1
Brass
125/165
1601711-1
Tin Plated
Brass
125/165
1601712-1
L125/
165D18TB
L125/
165D20A
L125/
165D20B
L125/
165D20TB
Cu Ni
125/165
1601710-1
Cu Ni
165
1601754-1†
L165D20A
Brass
165
1601755-1
L165D20B
Brass
165/200
1601532-1
Brass
200/202
1601764-1
Cu Ni
200/202
1601765-1
Brass
200/202
1601852-1
Tin Plated
Brass
200/202
1601766-1
Crimpband
AWG/
Wire Range
mm2
Solid Dia.
171∕ 2-13
.042-.068
0.95-2.54
1.07-1.80
.047-.072
161∕ 2-13
1.10-2.60
1.19-1.83
.047-.072
161∕ 2-13
1.10-2.60
1.19-1.83
.047-.072
161∕ 2-13
1.10-2.60
1.19-1.83
161∕ 2-13
.047-.072
1.10-2.60
1.19-1.83
.047-.072
161∕ 2-13
1.10-2.60
1.19-1.83
.047-.072
161∕ 2-13
1.10-2.60
1.19-1.83
.047-.072
161∕ 2-13
1.10-2.60
1.19-1.83
16-12
.051-.078
1.30-3.46
1.29-1.98
16-12
.051-.078
1.30-3.46
1.29-1.98
16-12
.051-.078
1.30-3.46
1.29-1.98
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
.059-.087
141∕ 2-111∕ 2
1.80-4.00
1.50-2.21
.059-.087
141∕ 2-111∕ 2
1.80-4.00
1.50-2.21
.059-.087
141∕ 2-111∕ 2
1.80-4.00
1.50-2.21
.059-.087
141∕ 2-111∕ 2
1.80-4.00
1.50-2.21
14-11
.063-.092
2.00-4.20
1.60-2.34
14-11
.063-.092
2.00-4.20
1.60-2.34
131∕ 2-101∕ 2
.071-.097
2.54-4.50
1.70-2.46
.084-.114
111∕ 2-9
4.00-6.50
2.13-2.90
.084-.114
111∕ 2-9
4.00-6.50
2.13-2.90
.084-.114
111∕ 2-9
4.00-6.50
2.13-2.90
.084-.114
111∕ 2-9
4.00-6.50
2.13-2.90
G165/
200D20B
L200/
202D16B
L200/
202D20A
P200/
202D20B
L200/
202D20TB
These part numbers are available upon special request; contact TE engineering for details.
71
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
RTM Crimpband Splices (Continued)
Catalog 82221
This product line is not recommended for new designs,
as the application machines are no longer manufactured.
6 Ridges
T
W
AWG/
Wire Range
mm2
Solid Dia.
24-20
.020-.033
0.20-0.50
0.51-0.84
24-20
.020-.033
0.20-0.50
0.51-0.84
22-19
.024-.036
0.38-0.60
0.61-0.91
22-19
.024-.036
0.38-0.60
0.61-0.91
22-19
.024-.036
0.38-0.60
0.61-0.91
.028-.039
21-181∕ 2
0.40-0.75
0.71-0.99
.028-.039
21-181∕ 2
0.40-0.75
0.71-0.99
.028-.039
21-181∕ 2
0.40-0.75
0.71-0.99
.028-.039
21-181∕ 2
0.40-0.75
0.71-0.99
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
20-15
.033-.057
0.60-1.60
0.84-1.45
20-15
.033-.057
0.60-1.60
0.84-1.45
20-15
.033-.057
0.60-1.60
0.84-1.45
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
.042-.068
171∕ 2-13
0.95-2.54
1.07-1.80
.047-.072
161∕ 2-13
1.10-2.60
1.19-1.83
161∕ 2-13
.047-.072
1.10-2.60
1.19-1.83
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
.055-.082
151∕ 2-12
1.54-3.46
1.40-2.10
†
CMA
Range
400-1100
400-1100
600-1300
600-1300
600-1300
800-1500
800-1500
800-1500
800-1500
900-2600
900-2600
900-2600
900-2600
900-2600
900-2600
1100-3200
1100-3200
1100-3200
1600-4000
1600-4000
1600-4000
1600-4000
1600-4000
1800-4600
2200-5200
2200-5200
3000-6750
3000-6750
3000-6750
Stock
Mat’l
Thk. (T) Width (W)
.012
.138
0.30
3.51
.016
.138
0.41
3.51
.012
.138
0.30
3.51
.016
.138
0.41
3.51
.016
.138
0.41
3.51
.012
.138
0.30
3.51
.016
.138
0.41
3.51
.016
.138
0.41
3.51
.018
.138
0.46
3.51
.016
.138
0.41
3.51
.016
.138
0.41
3.51
.016
.138
0.41
3.51
.018
.138
0.46
3.51
.018
.138
0.46
3.51
.020
.138
0.51
3.51
.016
.138
0.41
3.51
.016
.138
0.41
3.51
.018
.138
0.46
3.51
.016
.138
0.41
3.51
.016
.138
0.41
3.51
.018
.138
0.46
3.51
.018
.138
0.46
3.51
.018
.138
0.46
3.51
.016
.138
0.41
3.51
.016
.138
0.41
3.51
.016
.138
0.41
3.51
.016
.138
0.41
3.51
.018
.138
0.46
3.51
.018
.138
0.46
3.51
Material
Toolset
Part
Number
Tin Plated
Brass
032/036
1601548-1
Brass
032/036
1601549-1
Descriptive
X-ref
L032/
036C12TB
L032/
036C16B
Brass
045
1601566-1
L045C12B
Cu Ni
045
1601569-1
L045C16A
Brass
045
1601571-1
L045C16B
Brass
051
1601808-1†
P051C12B
Cu Ni
051
1601809-1
P051C16A
Brass
051
1601810-1
P051C16B
Brass
051
1601586-1†
L051C18B
Cu Ni
061
1601614-1
L061C16A
Brass
061
1601511-1
G061C16B
Tin Plated
Brass
061
1601617-1
L061C16TB
Cu Ni
061
1601618-1
L061C18AX
Brass
061
1601619-1
L061C18B
Brass
061
1601513-1†
G061C20B
Brass
061/076
1601597-1
Tin Plated
Brass
061/076
1601599-1
Brass
061/076
1601600-1†
L061/
076C16B
L061/
076C16TB
L061/
076C18B
Cu Ni
076
1601650-1
L076C16A
Brass
076
1601651-1
L076C16B
Cu Ni
076
1601652-1†
L076C18A
Brass
076
1601827-1
P076C18B
076
1601654-1† L076C18TCRS
Brass
076/092
1601640-1
L076/
092C16B
Cu Ni
092
1601837-1
P092C16AX
Brass
092
1601687-1
L092C16B
Tin Plated
Brass
125
1601721-1
L125C16TB
Cu Ni
125
1601722-1
L125C18A
Brass
125
1601723-1
L125C18B
These part numbers are available upon special request; contact TE engineering for details.
72
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
RTM Crimpband Splices (Continued)
Catalog 82221
This product line is not recommended for new designs,
as the application machines are no longer manufactured.
3 Ridges
T
W
†
CMA
Range
Stock
Mat’l
Thk. (T) Width (W)
.012
.076
170-800
0.30
1.93
.012
.076
400-1100
0.30
1.93
.012
.076
400-1100
0.30
1.93
.016
.076
400-1100
0.41
1.93
.016
.076
400-1100
0.41
1.93
.018
.076
400-1100
0.46
1.93
.016
.076
600-1300
0.41
1.93
.016
.076
600-1300
0.41
1.93
.016
.076
600-1300
0.41
1.93
.016
.076
600-1300
0.41
1.93
.016
.076
800-1500
0.41
1.93
.016
.076
800-1500
0.41
1.93
.016
.076
800-1500
0.41
1.93
.020
.076
800-1500
0.51
1.93
.016
.076
900-2600
0.41
1.93
.016
.076
900-2600
0.41
1.93
.016
.076
900-2600
0.41
1.93
.016
.076
900-2600
0.41
1.93
.016
.076
1100-3200
0.41
1.93
.016
.076
1600-4000
0.41
1.93
.020
.076
1600-4000
0.51
1.93
Material
Toolset
Part
Number
Descriptive
X-ref
Brass
032
1601555-1
L032B12B
Cu Ni
032/036
1601542-1
Brass
032/036
1601795-1
Brass
032/036
1601545-1
Tin Plated
Brass
032/036
1601546-1
Brass
032/036
1601547-1†
L032/
036B12A
P032/
036B12B
L032/
036B16B
L032/
036B16TB
L032/
036B18B
Cu Ni
045
1601503-1
G045B16A
Brass
045
1601562-1
L045B16B
045
1601504-1†
G045B16TB
045
1601564-1 L045B16TBSP
Cu Ni
051
1601580-1†
L051B16A
Brass
051
1601582-1†
L051B16B
Tin Plated
Brass
045
1601583-1†
L051B16TB
Tin Plated
Brass
Tin Plated
Brass
Brass
051
1601584-1
L051B20B
Tin Plated
Brass
061
1601612-1†
L061B16TB
Cu Ni
061
1601610-1
L061B16A
Brass
061
1601611-1
L061B16B
Brass
061
1601635-1
L061L16B
Tin Plated
Brass
061/076
1601596-1
L061/
076B16TBX
Brass
076
1601825-1
P076B16B
Brass
076
1601649-1
L076B20B
Crimpband
AWG/
Wire Range
mm2
Solid Dia.
.013-.028
271∕ 2-21
0.09-0.40
0.33-0.71
24-20
.020-.033
0.20-0.50
0.51-0.84
24-20
.020-.033
0.20-0.50
0.51-0.84
24-20
.020-.033
0.20-0.50
0.51-0.84
24-20
.020-.033
0.20-0.50
0.51-0.84
24-20
.020-.033
0.20-0.50
0.51-0.84
22-19
.024-.036
0.38-0.60
0.61-0.91
22-19
.024-.036
0.38-0.60
0.61-0.91
22-19
.024-.036
0.38-0.60
0.61-0.91
22-19
.024-.036
0.38-0.60
0.61-0.91
.028-.039
21-181∕ 2
0.40-0.75
0.71-0.99
.028-.039
21-181∕ 2
0.40-0.75
0.71-0.99
.028-.039
21-181∕ 2
0.40-0.75
0.71-0.99
.028-.039
21-181∕ 2
0.40-0.75
0.71-0.99
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
201∕ 2-16
.030-.051
0.45-1.30
0.76-1.29
.030-.051
201∕ 2-16
0.45-1.30
0.76-1.29
20-15
.033-.057
0.60-1.60
0.84-1.45
18-14
.040-.063
0.80-2.00
1.02-1.60
18-14
.040-.063
0.80-2.00
1.02-1.60
These part numbers are available upon special request; contact TE engineering for details.
73
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Power Splice
Product Facts
Compression crimp
eliminates cold solder
points, weld burns and wire
enbrittlement usually
connected with thermal-type
terminations
Precisely controlled crimp
termination helps eliminate
human error, for maximum
reliability
Excellent tensile strength,
up to 90 lbs axial retention,
vibration resistant
Provides a superior
electrical connection that is
free of many contaminates
such as stripper residue and
solder flux
8000 - 38,000 CMA nominal
capacity
Accepts up to six magnet
wires and two standard
solid or stranded lead wires
Superior test results: low
resistance, high stability
High termination rates, low
wire consumption and the
elimination of rejects
caused by solder flux or
heat damage results in the
lowest applied costs
Applications
Hermetic/Compressor
motors
Squirrel cage DC motors
Capacitor start motors
Gear & Traction motors
Power supplies
Liner, Torroid & RF
transformers
Circuit breakers & welders
TE features the Power Splice
terminal that is
specifically designed to
terminate a wide range of
lead and magnet wire
combinations.
The splice contains two
cavities that separate and
cradle magnet wire and
stripped lead wires prior to
crimping.
The outer saddle accepts
up to six-magnet wire
allowing for a CMA range of
15,000 to 30,000.
The inner saddle accepts
pre-stripped lead wires that
total up to 10,900 CMA.
In a one step automatic
operation, the magnet wire
film insulation is multiple
ring-stripped as it is forced
into the serrations while the
lead wire is simultaneously
terminated during the
precisely controlled crimp.
The outer saddle has
machined, sharp edges
made by a special
production process that
pierces the insulating layer
of the magnet wire in a
manner that provides a
large contact area.
The resulting termination
produces a high tensile
strength, air sealed
connection that is as
resistant to corrosion as the
insulated conductor with up
to 90 lbs axial retention.
As many as six magnet
wires can be terminated
simultaneously in one splice
in combination with up to
two pre-stripped standard
solid or stranded lead wire.
A semi-automatic machine
provides high output per
hour terminations.
74
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Power Splice (Continued)
.425
[10.80]
.375
[9.53]
.408
[10.36]
Type
A
1
Magnet Wire Range
CMA
15,000-30,000
Lead Wire Range
CMA
4200-10,900
Part Number
Reeled
1601953-11
Total combined CMA not to exceed 38000.
Magnet wire
insulation
piercing
serrations
Inner saddle for lead wire
(CMA 4,200-10,900)
Magnet wires smaller
than #18 AWG (1.0 mm)
are placed here
Outer saddle accepts up to 6 magnet wires
(CMA 15,000-30,000) #20 AWG minimum
.118
[3.00]
.430 ± .010
[10.92 ± 0.25]
Power Splice
R .060
[1.52]
.430 Max.
[10.92] Cut-off
.408
[10.36]
Direction of Feed
.385
[9.78]
.296
[7.52]
R .024
[0.61]
Part Number 111-000-001
75
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Application Tooling
Worldwide Leadership in Wire and PCB Manufacturing Products
Leadership demands commitment and TE is committed to meeting manufacturing
needs worldwide with technology, products and systems, and service.
Application Tooling of TE Connectivity
TE has long been recognized as a leader in providing the tools for wire harness and printed circuit manufacturing. There’s a good reason. Our products
are designed to meet and anticipate our customers’ ever-changing requirements and built to the highest quality standards, for longest, most productive
performance lifetimes.
Whatever your production volume and job mix, we can
the tools to get it
done. With a full range of tooling from hand tools to high volume, fully automated systems, TE is able to meet most manufacturing demands worldwide.
It’s an ability that comes from our experience with manufacturers large and
small, giving us a unique view of the trends and challenges in wire harness and
PCB manufacturing. It all derives from our commitment to your manufacturing
challenges, giving you the advantage in your marketplace.
This catalog is just a sampling of the types of solutions that will make your job
easier, faster, more productive and more profitable. Make tooling, assembly
equipment, and service from TE part of your thinking, now and as you grow
into the future.
TE Connectivity Service and Support
Few suppliers can match TE customer service and support. From helping you
select the tooling for your requirements to maintenance and repair and analyzing your operation for maximum productivity, our worldwide capabilities
in your production and bottom line.
and experience will make a real
For more information regarding the
products and services shown in this
brochure, visit our website at
www.tooling.te.com
ProductionChek Service — In a consultative role, our field engineer will meet
with you to determine your objectives and known production issues, then
observe and record in detail each step in your operation. Based on this information, the engineer will be able to make recommendations for improvement,
typically in people, process or equipment.
Tool Repair and Certification — Our field engineers will set up, certify, and
repair application tooling on site or recommend our factory-level service.
Flexible plans, including options for premium access to parts and service, will
keep your PCB assembly automation equipment running at peak performance.
For additional maintenance services, the TE Technical Support Center is dedicated to providing the answers you need, toll-free at 1-800-522-6752. Support
contracts are available for preventive maintenance, training, emergency situations and other specific requirements.
76
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Application Tooling
Magnet Wire Crimp Application Equipment
MAG-MATE and AMPLIVAR splices and terminals are available in a wide range of configurations to meet most
magnet-wire termination needs. All provide high reliability with minimal wire preparation. TE Connectivity
a wide variety of magnet-wire termination solutions for thru splicing, pigtail splicing and coil termination.
AMPLIVAR Product Terminator (APT) Machines
The new APT 5A magnet wire pigtail splice machine
a
fast,
system, with no need to strip mag-wire insulation.
Simply place the wires in the target area and depress the foot
switch. The machine automatically shears the splice or Direct
Connect contact from the strip, crimps it, shears
excess wire,
and advances the next splice or contact into position.
APT bench machines are available in two versions: the 5A with
automatic precision adjustment controlled by the crimp quality
monitor (CQM) and the 5E with manual precision adjustment.
Using CQM, the APT 5A provides 100% inspection and automatic
adjustment of crimp height. If a questionable crimp is detected, visual and
audible alarms alert the operator.
The lower cost, manual adjust APT 5E is a simpler version with the advantage of faster set-up times but without CQM capability.
Power Splice Machine
Not CE approved, contact engineering for quotation.
The Power Splice Machine and applicator from TE provides reliable pigtail
splice termination of magnet wire and solid or stranded lead wire. This
machine can terminate pigtail splices consisting of up to two solid or stranded
copper lead wires in wire size from 10-14 AWG and having a Circular Mil Area
(CMA) of 4,100 - 11,000. The splice will simultaneously accept combinations of
multiple copper magnet wires in a range of 11-20 AWG. The total CMA range
for lead wire and magnet wire is 4,000 to 40,000.
Application Tooling
77
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Application Tooling
Magnet Wire Crimp Application Equipment
AMPLIVAR Terminator for Parallel and End Connections
Primarily sold in Europe.
The machine was developed for processing magnet wire connections.
versions for end-feed and side-feed contacts are available. The design takes into
account that the motor windings and coils can be supplied directly to the
connectors. The exposed crimp position permits precise handling. In case of end
connections the projecting magnet wires are cut
AMPLIVAR splices and terminals are specifically designed to terminate magnet
wires or in combination with standard solid or stranded wire. 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 crimping operation.
As many as three magnet wires can be terminated,
simultaneously in one splice. Nearly the entire AMPLIVAR splice
program can be applied with this machine in combination with
suitable applicators. The comprehensive range of manufacturing possibilities
demands a specific machine and applicator combination.
AMP-O-LECTRIC Model G Terminator with Thru-Splice Applicator
Not CE Approved.
Applying thru-splices is fast and
when you have access to both
sides of the applicator for placing and holding the wires. The
AMP-O-LECTRIC model G splice terminator with a standard G splice
applicator provides front and rear access to maximize production
cy. It provides full guarding for operator safety and is available with or
without a Crimp Quality Monitor. Request catalog 889021 for more
information.
78
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Application Tooling
Magnet Wire Crimp Application Equipment
Crimpband application machines have been discontinued and are no longer offered by TE.
Crimpband Application Tooling
Not CE approved, contact engineering for quotation.
solderless crimping systems to handle a wide range of wire
TE
connections including solid and stranded lead wire, insulated magnet wire,
and component leads. Each system is comprised of continuous, serrated
Crimpband material and a crimping machine. The TE solution allows the
flexibility to create a shape and size, which optimizes the crimp’s electrical
and mechanical performance.
The TE crimping system produces a very economical and reliable interconnection. Utilizing a continuous crimpband material the machine will feed,
cut form, and crimp your application resulting in a very strong and uniform
interconnect crimp.
Whether your application required a wire-to-wire, wire to components
leads, wire to terminals, or magnet wire splice termination, the very
flexible and dependable crimping machine will provide high-speed scrap
free interconnects.
Substantial increase in production interconnection rates can be realized
versus traditional soldering. Not to mention it completely eliminates the
noxious fumes.
The mod I crimping system is used when running standard RTM and MTM
crimpband product. In addition, left and right horn termination machines
are available when your application requires additional working envelope.
Application Tooling
www.te.com/appliances
79
Magnet Wire Terminals and Termination Systems
Catalog 82221
Application Tooling
Magnet Wire MAG-MATE Terminal Application Equipment
MPT-5 MAG-MATE Product Terminator
Not CE approved, refer to Mark I, Mark II pages 83, 84.
The MPT-5 is an air-operated machine with microprocessor control that inserts
MAG-MATE terminals into customer-designed cavities in the coil bobbin or
similar magnet-wire housing, terminating the wire for connectivity. Please
note: The customer designed cavities must follow TE specification guidelines. Termination of single, dual, triple and up to quadruple termination possible depending on the application details. The machine is
available in either vertical or horizontal configuration to
match the customer’s application.
The dual reel capability of the MPT-5 machine allows inserMAG-MATE terminals, with the capability to
tion of two
alternate between inserting one and two terminals at a time. The MPT-5 is
also capable of trimming excess magnet wire.
The MPT-5 Terminator also has the capability to alternate between inserting
2 bridged (or commoned) terminals and 2 separated terminals.
Request catalog 1308387 for more information.
MAG-MATE Terminal Cavity and Fixture Design
MAG-MATE terminals insert into a molded-in cavity in the coil bobbin. The bobbin is
generally secured in a fixture during the insertion/termination process. TE engineers
work with our customers to support cavity and fixture design, at any level. We can
provide complete design of cavities and fixtures for customer’s applications, work
with our customer’s engineers, or simply provide CAD models and other engineering
data as needed. Consultation early in the design process allows customers maximum benefit from our decades of magnet-wire experience.
Product Line Integration
The MPT-5 and APT IIIA Machines have the production capacity and the electronics
for easy integration into automated production lines. TE Engineers work with your
system integrators to assure the
of TE equipment into the line’s
design and assembly.
80
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Application Tooling
Magnet Wire MAG-MATE Terminal Application Equipment
MPT-5 S/L Machine (for SIAMEZE and Lead Lok Terminals)
Not CE approved, refer to Mark I, Mark II pages 83, 84.
For quick, easy and reliable termination of magnet wire, TE
the
MPT-5 S/L MAG-MATE product terminator — an air-operated insertion machine with
microprocessor control.
The MPT-5 S/L machine inserts a SIAMEZE terminal into a customer-designed cavity in
the coil bobbin or similar mag-wire housing, terminating the wire for connectivity.
Please note: The customer designed cavities must follow TE specification guidelines. It
can insert both the SIAMEZE terminal and the Lead Lok terminal to assure your lead
wire connection. The MPT-5 S/L
dual reel capability and is also capable of trimming excess magnet wire. The dual reel capability of the MPT-5 S/L allows insertion of
SIAMEZE terminals, with the capability to alternate between inserting one
two
and two terminals at a time.
The MPT-5 S/L machine is available as a horizontal or vertical bench machine or as a
discrete module for integration into automated lines.
MPT-5 S/L
EMT — Entry Level Magnet Wire Terminator
(for loose piece SIAMEZE, Lead Lok, or MAG-MATE Terminals)
Not CE approved, contact engineering for quotation.
The Entry Level Magnet Wire Terminator tube design is based on the proven MPT-5
system and incorporates a fine adjust mechanism for easy set-up. The floating tube
bottoms on the top of the terminal cavity to create the datum for the insertion depth
of the terminal. The insertion depth can be adjusted in .002” [.05 mm] increments
quickly and easily.
An unobstructed view of the tube bottom permits the operator to easily load loose
piece terminals. A two-handed actuation system protects the operators during the
insertion process and the open architecture design allows operators to easily load
and unload the stators on and o the fixture.
Entry Level
Terminator
Application Tooling
81
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Application Tooling
Magnet Wire MAG-MATE Terminal Application Equipment
Manual Hand Tool
(for loose piece SIAMEZE, Lead Lok, or MAG-MATE Terminals)
• Inserts loose piece terminals into molded cavities
• Insertion depth is repeatable due to the hand tools design which requires the
operator to fully compress the handle before it is allowed to retract
• Since tooling captures the cavities during insertion, no fixturing is needed
• Hand tools are available quickly for prototyping, repair, and/or low volume
applications
** The manual hand tool is not compatible with every application. Please contact
TE Connectivity for more information.
Manual Hand Tool
Manual Arbor Press
(for loose piece SIAMEZE, Lead Lok, or MAG-MATE Terminals)
• Inserts loose piece terminals into molded cavities
• One tip is capable of inserting the SIAMEZE wire-to-wire terminal, the
lead wire and the Lead Lok terminal
• Insertion tip bottoms on the top of the cavity to provide repeatable
insertion depth capability
• Customers often supply their own fixtures for prototyping or low volume
requirements
• Tips, arbor presses, and CERTI-LOK hand tools are available quickly for
prototyping applications requirements
Manual Arbor Press
Hand Insertion Tools
• Inserts loose piece terminals into molded cavities
• Available quickly for prototyping application requirements
• Available for each type of MAG-MATE terminal
Full Line of Crimp Tooling
Insertion Tools
• TE
a full line of hand tools, bench equipment, and automatic machines to
perform the wire crimps for the mating end of these MAG-MATE connections.
CERTI-LOK Tools
82
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Application Tooling
Magnet Wire MAG-MATE Terminal Application Equipment
MAG-MATE Inserter MK I with Pneumatic Control,
Primarily sold in Europe.
• Single, dual, triple and quadruple insertion
• Module easily integrated into production lines using simple handshake
signals
• Holding fixture for bobbin can be designed and built by TE
• Can apply standard MAG-MATE and SIAMEZE terminals
• Load-while-running feature increases productivity
• Cycle time: 0.9 - 1.3 s depending on terminal type
• Mechanical insertion force limiter optional
MK I Inserter
MAG-MATE Inserter MK I with Electro Pneumatic
Control (PLC),
Primarily sold in Europe.
•
•
•
•
Single contact
Double contacts with or without bridge
2 single contacts alternately with 2 bridged contacts
Module is easily integrated into customer’s production line using simple handshake signals
• Terminations up to 4 terminals at a time as single or linked type
• Mechanical insertion force limiter optional
MAG-MATE and SIAMEZE Inserter Mark II with PLC,
Primarily sold in Europe.
TE magnet wire terminations are a perfect connecting alternative to all
soldering techniques used in a lead-free environment. Special
knowledge is required to design a mass manufacturing line for
insulation displacement crimps on thin lacquerd insulated wires with
high yield. Design aspects of the terminal, the cavity and the
machine all need to be harmonized. With the Inserter Mark II, TE
an economic solution especially for the application of
can
MAG-MATE and SIAMEZE terminals.
Mark II
Inserter
with PLC
Application Tooling
83
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Application Tooling
Magnet Wire MAG-MATE Terminal Application Equipment
MAG-MATE and SIAMEZE Inserter Mark II with PLC and
Insertion Force Control,
Primarily sold in Europe.
This advanced insertion machine provides the features of the
MAG-MATE inserter Mark II with an additional force distance
control system. The machine is designed to apply multiple
contacts and will be customized according to
the customer or product specific requirement. The
contacts can be used as single contacts or in strip form
(bridge function adjusted "on-the-fly").
A gauge is available to check the adjusted insertion
force and to recalibrate the insertion force control sensor.
Request catalog 7-1773440-4 for more
information.
Mark II Inserter
with PLC and
Insertion Force
Control
Pneumatic Insertion Tool for MAG-MATE Terminals,
Primarily sold in Europe.
The pneumatic tool for MAG-MATE terminals features a rotary
insertion angles.
insertion finger to faciliate
This tool is designed for use in TE standard insertion machines
such as P200 and P300 but can also be integrated into
customized production lines or assembly cells.
Pneumatic
Insertion Tool
84
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Application Tooling
Magnet Wire MAG-MATE Terminal Application Equipment
Customer Specific Machines
This unique machine was developed to process all IDC terminals regardless
of shape and configuration. The insertion head module is capable of
inserting individual or multiple terminals and can be configured for dual
feed, left and right hand supply reels.
The servo-driven NC-Axis facilitates precisely controlled insertion with
programmable ramp profile. If required, a servo driven torque motor will
locate the stator/bobbin to programmable positions.
during the insertion cycle
Excess magnet wire and wrap post are
and removed via a ventury. The cutting punches are cam actuated via our
patented linear slide module.
The machine is designed and built for easy maintenance. Spare parts
(punches, insertion blades, trim blades, die plate inset) are easy to access
and replace.
Custom Built IDC Terminal Insertion Head
The insertion head module is designed to be integrated into a rotary index
or linear transfer line. The IDC terminal insertion can be in vertical or
horizontal plane. The terminal strip feeds from the right and/or from the
left, if necessary with 2
terminal configurations.
Wrap posts and excess magnet wire can be removed via a trim blade.
Insertion force monitoring is available as an option.
Cam driven linear
slide module for
punch actuation.
The insertion head module is custom built according to your requirements.
Request catalog 7-1773440-4 for more information.
Application Tooling
Horizontal Design
Vertical Design
85
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Technical Information
Tensile Strength
of Magnet Wire1
Wire
Size
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
1
Nominal Nominal
Dia.
Dia.
Copper Aluminum
(lbs.)
(lbs.)
438
142
340
113
269
89
213
71
189
56
134
44
106
35
84
28
66
22
53
17
42
14
33
11
6
8
21
7
16
5
13
4
10
3
8
2.7
6
2.1
5
1.7
4
1.3
3
1.1
2
.86
2
.68
1
.55
1
.43
1
.34
.81
.27
.65
.21
.65
.21
.42
.13
.32
.10
.25
.083
.20
.067
.16
.054
.12
.041
.10
.034
.08
.027
.06
.022
.05
.017
.04
.013
.03
.010
.02
.009
.02
.007
.01
.005
C.
–80
–70
–60
–50
–45
–40
–35
–30
–25
–20
–19
–18
–17
–16
–15
–14
–13
–12
–11
–10
–09
–08
–07
–06
–05
–04
–03
–02
–01
0
1
2
4
5
6
7
8
F.
–112.0
–94.0
–76.0
–58.0
–49.1
–40.0
–31.0
–22.0
–13.0
–04.0
–02.2
–00.4
1.4
3.2
5.0
6.8
8.6
10.4
12.2
14.0
15.8
17.6
19.4
21.2
23.0
24.8
26.6
8.4
30.2
32.0
33.8
35.6
39.2
41.0
42.8
44.6
46.4
C.
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
42
43
44
45
46
F.
48.2
50.0
51.8
53.6
55.4
57.2
59.0
60.8
62.6
64.4
66.2
68.0
69.8
71.6
73.4
75.2
77.0
78.8
80.6
82.4
84.2
86.0
87.8
89.6
91.4
93.2
95.0
96.8
98.6
100.4
102.2
104.0
107.6
109.4
111.2
113.0
114.8
C.
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
80
81
82
83
84
F.
116.6
118.4
120.2
122.0
123.8
125.6
127.4
129.2
131.0
132.8
134.6
136.4
138.2
140.0
141.8
143.6
145.4
147.2
149.0
150.8
152.6
154.4
156.2
158.0
159.8
161.6
163.4
165.2
167.0
168.8
170.6
172.4
176.0
177.8
179.6
181.4
183.2
C.
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
110
120
130
140
150
160
170
180
190
200
220
240
260
280
300
400
600
700
800
900
1000
F.
185.0
186.8
188.6
190.4
192.2
194.0
195.8
197.6
199.4
201.2
203.0
204.8
206.6
208.4
210.2
212.0
230.0
248.0
266.0
284.0
302.0
320.0
338.0
356.0
374.0
392.0
428.0
464.0
500.0
536.0
572.0
752.0
1112.0
1292.0
1472.0
1652.0
1832.0
C = 5/9 (F – 32)
F = 9/5 C + 32
Magnet wire tensile will change as
the psi of magnet wire changes.
Note: Copper magnet wire is
calculated at 33,000 psi. Aluminum
magnet wire is calculated at 11,000
psi (EC grade). Magnet wire should
be tensiled on each coil. After
termination of the AMPLIVAR splice,
the tensile strength will be 70%
(min.) of the original magnet wire
tensile values.
86
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Technical Information (Continued)
Circular Mil Area
(CMA) and diameter
for magnet wires
(AWG wire size
range 52–25 1/2)
AWG
Bare
Wire
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
35
34
33
32
31
301/2
30
291/2
29
281/2
28
271/2
27
261/2
26
251/2
Bare Wire
Dia.
in.
mm
.0008
.020
.0009
.023
.0010
.025
.0011
.028
.0012
.031
.0014
.035
.0016
.040
.0018
.045
.0020
.050
.0022
.056
.0025
0.06
.0028
0.07
.0031
0.08
.0035
0.09
.0040
0.10
.0045
0.11
.0050
0.13
.0056
0.14
.0056
0.14
.0063
0.16
.0071
0.18
.0080
0.20
.0089
0.23
.0095
0.24
.0100
0.25
.0107
0.27
.0113
0.29
.0120
0.30
.0126
0.32
.0134
0.34
.0142
0.36
.0151
0.38
.0159
0.40
.0169
0.43
CMA
Bare
0.6
0.8
1.0
1.2
1.5
2.0
2.5
3.1
4.0
4.8
6.3
7.8
9.6
12.0
16.0
20.0
25.0
31.0
31.0
40.0
50.0
64.0
79.0
90.0
100.0
115.0
128.0
144.0
159.0
180.0
202.0
225.0
258.0
289.0
Single Film
Coated Dia.
in.
mm
.0010
.025
.0011
.028
.0012
.031
.0013
.033
.0014
.035
.0016
.040
.0017
.043
.0019
.048
.0022
.056
.0025
.063
.0028
0.07
.0031
0.08
.0035
0.09
.0039
0.10
.0045
0.11
.0050
0.13
.0056
0.14
.0062
0.16
.0062
0.16
.0069
0.18
.0077
0.20
.0084
0.21
.0092
0.23
.0099
0.25
.0106
0.27
.0114
0.29
.0120
0.30
.0126
0.32
.0136
0.35
.0144
0.37
.0152
0.39
.0160
0.41
.0170
0.43
.0180
0.46
CMA
Single Film
Coated
1.0
1.2
1.5
1.7
2.0
2.5
2.9
3.6
4.8
6.2
8.0
10.0
12.0
15.0
20.0
25.0
31.0
38.0
38.0
48.0
59.0
71.0
85.0
98.0
112.0
130.0
144.0
159.0
185.0
207.0
231.0
256.0
289.0
324.0
Heavy Film
Coated Dia.
in.
mm
.0011
.028
.0012
.031
.0013
.033
.0014
.035
.0015
.038
.0018
.045
.0019
.048
.0021
.053
.0025
.063
.0027
.069
.0030
0.08
.0034
0.09
.0038
0.10
.0043
0.11
.0049
0.12
.0055
0.14
.0060
0.15
.0067
0.17
.0067
0.17
.0075
0.19
.0085
0.22
.0095
0.24
.0105
0.27
.0111
0.28
.0116
0.29
.0123
0.31
.0130
0.33
.0137
0.35
.0144
0.37
.0153
0.39
.0161
0.41
.0170
0.43
.0179
0.45
.0190
0.48
CMA
Heavy Film
Coated
1.2
1.5
1.7
2.0
2.2
3.1
3.6
4.4
6.2
7.3
9.0
12.0
14.0
18.0
24.0
30.0
36.0
45.0
45.0
56.0
72.0
90.0
110.0
123.0
135.0
151.0
169.0
187.0
207.0
234.0
259.0
289.0
320.0
361.0
Technical Information
87
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Technical Information (Continued)
Circular Mil Area
(CMA) and diameter
for magnet wires
(AWG wire size
range 25–8)
AWG
Bare
Wire
25
241/2
24
231/2
23
221/2
22
211/2
21
201/2
20
191/2
19
181/2
18
171/2
17
161/2
16
151/2
15
141/2
14
131/2
13
121/2
12
111/2
11
101/2
10
9
8
Bare Wire
Dia.
in.
mm
.0179
0.45
.0190
0.48
.0201
0.51
.0214
0.54
.0226
0.57
.0240
0.61
.0253
0.64
.0269
0.68
.0285
0.72
.0303
0.77
.0320
0.81
.0340
0.86
.0359
0.91
.0381
0.97
.0403
1.02
.0428
1.09
.0453
1.15
.0481
1.22
.0508
1.29
.0540
1.37
.0571
1.45
.0606
1.54
.0641
1.63
.0681
1.73
.0720
1.83
.0764
1.94
.0808
2.05
.0858
2.18
.0907
2.30
.0963
2.35
.1019
2.59
.1144
2.91
.1285
3.26
CMA
Bare
320
361
404
458
511
576
640
724
812
918
1,024
1,156
1,289
1,452
1,624
1,832
2,052
2,314
2,581
2,916
3,260
3,672
4,109
4,638
5,184
5,837
6,529
7,362
8,226
9,274
10,384
13,087
16,512
Single Film
Coated Dia.
in.
mm
.0190
0.48
.0200
0.51
.0213
0.54
.0226
0.57
.0238
0.60
.0252
0.64
.0266
0.68
.0282
0.72
.0298
0.76
.0315
0.80
.0334
0.85
.0353
0.90
.0373
0.95
.0395
1.00
.0418
1.06
.0443
1.13
.0468
1.19
.0496
1.26
.0524
1.33
.0560
1.42
.0587
1.49
.0622
1.58
.0658
1.67
.0698
1.77
.0738
1.87
.0783
1.99
.0827
2.10
.0877
2.23
.0927
2.35
.0983
2.50
.1040
2.64
.1166
2.96
.1307
3.32
CMA
Single Film
Coated
361
400
455
511
566
635
708
795
888
992
1,116
1,246
1,391
1,560
1,747
1,962
2,190
2,460
2,746
3,136
3,446
3,869
4,330
4,872
5,446
6,131
6,839
7,691
8,593
9,663
10,820
13,600
17,080
Heavy Film
Coated Dia.
in.
mm
.0200
0.51
.0212
0.54
.0223
0.57
.0236
0.60
.0249
0.63
.0263
0.67
.0277
0.70
.0293
0.74
.0310
0.79
.0328
0.83
.0346
0.88
.0365
0.93
.0386
0.98
.0409
1.04
.0431
1.09
.0456
1.16
.0482
1.22
.0510
1.30
.0583
1.37
.0570
1.45
.0602
1.53
.0639
1.62
.0675
1.71
.0711
1.81
.0749
1.90
.0793
2.01
.0838
2.13
.0888
2.26
.0938
2.38
.0994
2.52
.1050
2.67
.1177
2.99
.1318
3.35
CMA
Heavy Film
Coated
400
449
497
557
620
692
767
858
961
1,076
1,197
1,340
1,490
1,673
1,858
2,079
2,323
2,601
2,894
3,249
3,624
4,082
4,556
5,055
5,670
6,188
7,090
7,885
8,892
9,880
11,151
13,971
17,530
88
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Technical Information (Continued)
Circular Mil Area
(CMA) and diameter
for lead wires
(AWG wire size
range 30–8)
Wire
Size
Dia. (Mils)
7
1
7
19
1
7
1
6
10
16
8
1
26
7
3
12
10
8
1
10
8
16
4
1
26
13
7
56
19
10
8
1
21
6
8
16
10
1
7
19
10
1
26
7
19
19
16
1
7
65
7
4.0
10.0
5.0
3.1
12.6
5.6
14.2
6.3
5.0
4.0
5.6
15.9
3.1
6.3
10.0
5.0
5.6
6.3
17.9
6.3
7.1
5.0
10.0
20.1
4.0
5.6
8.0
2.8
5.0
7.1
8.0
22.6
5.0
10.0
8.9
6.3
8.0
25.3
10.0
6.3
10.0
10.0
6.3
12.6
7.9
9.2
10.0
40.3
15.2
5.0
15.3
Wire Area
in
Circ. Mils
112
100
175
181
159
219
202
238
250
256
251
253
250
278
300
300
314
318
320
397
403
400
400
404
416
408
448
439
475
504
512
511
525
600
634
635
640
640
700
754
1,000
1,024
1,032
1,111
1,186
1,608
1,600
1,624
1,617
1,625
1,639
Wire
Size
—
—
18 AN
18 AN
16
16
16
16
16
—
16
14 AN
14
14
14
14
—
14
14
14
—
12
12 AN
12
12
12
12
12
12
12
10
—
10
10
10
10
10
—
10
9
9
9
8
8
8
8
8
8
8
8 AN
Strands
No.
41
7
19
19
7
1
65
19
105
26
7
19
37
7
19
1
41
105
168
84
7
19
19
259
19
7
37
1
165
84
7
37
414
37
1
7
19
41
105
7
1
525
7
133
37
1
7
19
49
133
Dia. (Mils)
6.3
16.0
10.0
11.3
19.2
50.8
6.3
11.7
5.0
10.0
20.0
14.2
10.5
24.2
14.7
64.4
10.0
6.3
5.0
71
25.3
17.9
17.9
5.0
18.5
30.5
13.3
80.8
6.3
8.9
36.0
16.0
5.0
16.7
101.9
38.5
23.4
15.9
10.0
43.0
114.4
5.0
45.0
11.1
21.1
128.5
48.6
29.5
18.4
11.3
Wire Area
in
Circ. Mils
1,627
1,792
1,900
2,426
2,580
2,581
2,580
2,601
2,625
2,600
2,800
3,831
4,079
4,099
4,106
4,109
4,100
4,167
4,200
4,234
4,481
6,088
6,088
6,475
6,503
6,512
6,545
6,529
6,549
6,654
9,072
9,472
10,350
10,319
10,384
10,376
10,404
10,365
10,500
12,943
13,087
13,125
14,175
16,386
16,472
16,512
16,533
16,534
16,589
16,982
Technical Information
30
30
28
28
28
27
27
26
26
26
26
26
26
26
26
26 AN
25
25
25
24
24
24
24
24
24
24
24
24
24 AN
23
23
23
—
22
22
22
22
22
22
22 AN
20
20
20
20
20 AN
18
—
18
18
18
18
Strands
No.
89
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Terminal Stud Hole Size
The chart shows sizes and
dimensions of various studs
and the corresponding
terminal stud hole sizes
used with devices.
Use to Select Proper Size
Terminal
Stud Size
U.S. Cust.
Metric
Stud Dia.
Minimum Terminal
Hole Diameter
#0
.060
.064
#1
.073
.077
.086
.090
#3
.099
.103
#4
.112
.116
#2
M2
#5
M3
.125
.129
#6
M3.5
.138
.142
#8
M4
.164
.168
#10
.190
.194
#12
.216
.220
#14
.242
.247
1/4"
M6
.250
.260
5/16"
M8
.312
.323
3/8"
.375
.385
7/16"
.437
.448
1/2"
M12
.500
For example, with stud #5
(.125 [3.18] Diameter), use
device listed for #5 stud
(.129 [3.28] Hole Diameter).
Stud Size
U.S. Cust.
Metric
Terminal stud hole sizes
may easily be checked by
fitting sample terminal to
black circle.
Stud Dia.
Minimum Terminal
Hole Diameter
.625
.651
.750
.776
.875
.901
1"
1.000
1.026
1-1/8"
1.125
1.151
1-1/4"
1.250
1.276
5/8"
M16
3/4"
7/8"
M22
.510
90
www.te.com/appliances
Catalog 82221
Magnet Wire Terminals and Termination Systems
Part Number Index
Note: This index lists all cataloged parts
by base no. only. Complete part nos.
(with prefixes and/or suffixes) are shown on
the page(s) indicated.
Part No.
Page
48
48
48
48
48
48
48
48
48
48
48
48
48
55
51
51
51
51
51
51
51
54
54
52
48
52
49
53
53
52
47
47
47
47
49
54
54
59
47
49
47
47
61
61
47
47
47
47
47
47
47
47
47
47
49
56
4
4
13
4
13
13
Part No.
62445
62447
62458
62459
62511
62512
62513
62514
62600
62606
62609
62610
62651
62652
62670
62678
62702
62743
62755
62780
62781
62833
62835
62888
62891
62896
62897
62898
62904
62922
62923
62928
62935
62938
62958
62992
63018
63026
63027
63036
63039
63062
63063
63064
63107
63108
63109
63128
63132
63136
63140
63145
63147
63155
63160
63165
63199
63216
63218
63235
63236
63237
Page
53
53
10
10
18
18
18
18
21
30
10
10
21
21
49
18
13
19
51
30
30
4
51
19
7
7
7
7
18
53
22
11
4
13
11
10
18
21
21
10
10
17
17
22
19
19
19
21
21
54
54
17
51
22
13
54
31
14
7
10
10
10
Part No.
63240
63253
63273
63277
63278
63309
63340
63353
63364
63397
63399
63403
63410
63425
63427
63429
63431
63443
63444
63446
63448
63453
63454
63455
63458
63459
63460
63461
63463
63464
63465
63480
63484
63486
63489
63495
63499
63504
63506
63561
63562
63564
63565
63569
63570
63571
63584
63585
63591
63601
63607
63612
63613
63614
63621
63622
63623
63632
63641
63649
63658
63659
Page
10
11
18
16
16
21
19
20
7
7
51
21
7
22
20
19
49
16
16
51
59
61
61
61
8
22
22
18
14
22
22
56
53
17
14
22
21
10
55
48
48
48
13
16
16
21
18
18
4
21
21
51
30
21
49
54
54
6
10
51
4
11
Part Number Index
41765
41766
41770
41899
41900
41904
42076
42119
42192
42776
42778
42779
42780
60177
60318
60319
60320
60321
60322
60323
60325
60384
60385
60752
61074
61151
61166
61440
61442
61710
62000
62001
62002
62040
62044
62069
62080
62131
62157
62194
62200
62201
62243
62244
62295
62303
62304
62305
62306
62307
62308
62309
62310
62311
62341
62381
62420
62429
62430
62431
62438
62439
91
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Part Number Index
Part No.
63660
63661
63662
63663
63664
63665
63666
63667
63670
63675
63690
63710
63711
63712
63713
63714
63716
63717
63718
63719
63720
63734
63735
63736
63737
63738
63740
63741
63742
63743
63744
63746
63762
63772
63775
63776
63777
63778
63782
63786
63788
63789
63795
63806
63807
63808
63810
63816
63818
63819
63827
63844
63856
63864
63870
63871
63888
63889
63899
63903
63940
63941
Page
11
11
4
18
18
18
20
20
18
31
10
26
26
26
26
26
26
26
26
26
26
26
26
26
26
26
26
26
26
26
26
17
20
16
7
18
17
31
19
4
16
4
30
14
14
14
14
22
13
13
17
30
10
52
53
53
27
53
14
27
55
55
Part No.
63942
63964
63965
63972
63973
63974
63975
63983
63995
63996
160809
160810
160897
170063
171370
235080
281006
281622
281633
284937
293029
293214
316300
350571
353937
356462
360033
360050
360051
360052
466010
466510
466816
485044
485079
505036
505044
505071
505072
505075
505079
520995
521078
565435
566410
566411
567343
567451
640212
680353
880631
926850
926851
926852
928770
928771
928854
964101
964106
964108
964110
964111
Page
Part No.
Page
Part No.
Page
55
56
14
14
14
14
6
20
20
20
13
13
13
59
58
58
58
7
7
41
40
38
18
52
59
55
58
58
60
60
54
53
54
51
51
52
52
51
51
51
52
60
58
53
55
55
54
54
52
55
58
5
5
5
5
5
5
7
5
5
5
5
964114
964156
964252
964290
964337
964338
964339
964340
964341
969082
969125
1123655
1217004
1217011
1217013
1217029
1217041
1217042
1217065
1217067
1217068
1217069
1217072
1217073
1217075
1217090
1217128
1217146
1217152
1217172
1217173
1217174
1217175
1217176
1217181
1217186
1217187
1217196
1217200
1217209
1217221
1217234
1217261
1217262
1217264
1217302
1217324
1217339
1217355
1217356
1217357
1217358
1217368
1217384
1217405
1217406
1217417
1217457
1217458
1217493
1217497
1217516
5
47
5
7
5
5
5
5
5
5
8
59
19
4
13
53
8
20
18
6
6
6
53
53
20
20
18
10
21
61
61
61
61
61
60
60
60
13
60
9
6
4
60
58
59
11
8
20
6
6
6
6
4
48
13
8
55
9
9
19
26
26
1217529
1217533
1217538
1217579
1217592
1217593
1217595
1217596
1217613
1217624
1217666
1217688
1217689
1217690
1217691
1217745
1217746
1217783
1217835
1217853
1217858
1217860
1217870
1217902
1217924
1217973
1247000
1247001
1247002
1247003
1247004
1380145
1394403
1394429
1394430
1394431
1394432
1394433
1394475
1394476
1394638
1394639
1418686
1534110
1534234
1534684
1534685
1534686
1534687
1599105
1601000
1601002
1601005
1601006
1601009
1601011
1601013
1601018
1601020
1601021
1601028
1601033
31
6
9
6
19
14
14
14
9
55
26
6
6
6
6
14
14
17
54
9
9
21
21
20
21
9
11
11
11
11
11
58
15
12
12
12
12
12
15
15
15
15
8
8
5
26
26
26
26
59
36
41
39
40
38
40
40
40
40
40
41
40
92
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Part Number Index
Page
Part No.
Page
Part No.
Page
Part No.
Page
1601035
1601037
1601039
1601041
1601045
1601046
1601049
1601052
1601056
1601058
1601059
1601061
1601063
1601064
1601066
1601068
1601072
1601073
1601074
1601075
1601077
1601095
1601097
1601099
1601104
1601110
1601112
1601115
1601117
1601118
1601119
1601120
1601128
1601133
1601136
1601137
1601138
1601139
1601140
1601142
1601155
1601159
1601161
1601174
1601194
1601196
1601204
1601214
1601226
1601232
1601237
1601243
1601421
1601424
1601425
1601426
1601427
1601431
1601432
1601433
1601434
1601435
40
38
39
38
39
36
40
41
36
40
39
41
38
39
38
40
40
39
36
37
37
38
39
38
38
38
39
41
36
41
38
38
38
39
36
37
38
41
36
40
38
41
41
40
39
37
39
38
40
37
36
38
42
42
42
42
42
42
42
42
42
42
1601436
1601437
1601438
1601440
1601447
1601475
1601503
1601504
1601507
1601511
1601513
1601514
1601520
1601528
1601529
1601531
1601532
1601538
1601539
1601540
1601542
1601545
1601546
1601547
1601548
1601549
1601550
1601551
1601553
1601555
1601559
1601560
1601562
1601564
1601566
1601569
1601571
1601572
1601573
1601575
1601577
1601578
1601580
1601582
1601583
1601584
1601586
1601587
1601588
1601591
1601593
1601596
1601597
1601599
1601600
1601601
1601603
1601604
1601606
1601607
1601608
1601610
42
42
42
42
42
42
73
73
70
72
72
70
69
71
71
71
71
65
65
65
73
73
73
73
72
72
69
69
69
73
65
65
73
73
72
72
72
69
69
68
68
68
73
73
73
73
72
70
70
70
68
73
72
72
72
70
70
65
65
64
64
73
1601611
1601612
1601614
1601617
1601618
1601619
1601620
1601623
1601625
1601628
1601629
1601630
1601631
1601632
1601633
1601635
1601637
1601639
1601640
1601642
1601644
1601646
1601647
1601649
1601650
1601651
1601652
1601654
1601655
1601656
1601658
1601660
1601661
1601664
1601665
1601667
1601668
1601669
1601675
1601677
1601678
1601680
1601681
1601682
1601683
1601687
1601689
1601691
1601693
1601694
1601695
1601705
1601706
1601707
1601709
1601710
1601711
1601712
1601716
1601717
1601718
1601719
73
73
72
72
72
72
70
70
70
70
70
70
70
68
68
73
65
64
72
71
65
65
65
73
72
72
72
72
70
70
70
70
70
70
70
70
70
69
65
64
64
71
71
71
65
72
71
71
71
71
71
64
64
64
71
71
71
71
65
64
64
64
1601721
1601722
1601723
1601726
1601729
1601730
1601731
1601733
1601750
1601754
1601755
1601761
1601764
1601765
1601766
1601768
1601769
1601771
1601793
1601794
1601795
1601797
1601798
1601800
1601807
1601808
1601809
1601810
1601811
1601814
1601818
1601819
1601820
1601823
1601824
1601825
1601827
1601828
1601829
1601832
1601833
1601835
1601837
1601841
1601842
1601844
1601845
1601846
1601847
1601848
1601852
1601853
1601857
1601953
1718165
1740417
1740418
1740419
1740574
1740603
1740698
1740829
72
72
72
71
71
71
71
71
64
71
71
64
71
71
71
69
68
68
65
64
73
69
69
65
69
72
72
72
70
64
70
70
70
64
64
73
72
70
70
65
64
64
72
71
64
65
65
64
64
64
71
68
64
75
30
15
15
15
5
8
8
26
Part Number Index
Part No.
93
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Part Number Index
Part No.
Page
Part No.
Page
Part No.
Page
Part No.
Page
1742125
1742159
1742160
1742167
1742203
1742211
1742347
1742398
1742410
1742605
1742614
1742657
7
9
18
14
6
8
6
21
8
13
10
61
1742708
1742781
1742819
1742820
1742828
1742881
1742882
1742898
1742964
1742977
1742979
1742981
11
9
20
20
7
55
55
47
59
55
55
59
1855633
1855634
1855680
1855681
1955415
1969357
1987143
1987199
1987222
1987223
1987224
1987225
55
55
55
55
58
58
12
8
28
28
28
28
1987226
2120743
2120744
2120745
2120746
2120747
2232326
2232327
2825082
2825083
28
27
27
27
27
27
58
58
58
59
94
www.te.com/appliances
Magnet Wire Terminals and Termination Systems
Catalog 82221
Engineering Notes
95
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Engineering Notes
96
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Magnet Wire Terminals and Termination Systems
Catalog 82221
Engineering Notes
97
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