0638834200

Continuous Molded Strip Applicator Mini-Mac Applicator Mechanical Feed Continuous Molded Strip Application Tooling Specification Sheet Order No. 63883-4200 FEATURES



Directly adapts to most crimp presses and automatic wire processors Applicator designed to industry-standard mounting and shut height of 135.80mm (5.346") Conductor and insulation rings allow quick adjustment for conductor and cut-off tooling height change Quick set-up time; plus the crimp height, track and feed adjustments can be set without removing the applicator from the crimp press SCOPE Products: InsulKrimp™ Quick Disconnect, (FIQD’s) Male and Female Terminals Continuous Molded Strip for 14-16 AWG. Testing Mechanical The tensile test, or pull test, is a means of evaluating the mechanical properties of the crimped connections. The following charts show the UL and government specifications (MIL-T-7928) for various wire sizes. The tensile strength is shown in pounds. It indicates the minimum acceptable force to break or separate the terminal from the conductor. Color Code Yellow Yellow Red Red Red Blue Blue Yellow Yellow Red Blue Wire Size (AWG) 26 24 22 20 18 16 14 12 10 8 6 *UL - 486 A 3 5 8 13 20 30 50 70 80 90 100 *UL – 486 C N/A N/A 8 10 10 15 25 35 40 45 50 *UL – 310 N/A N/A 8 13 20 30 50 70 80 N/A N/A *Military Class 2 7 10 15 19 38 50 70 110 150 225 300 *UL - 486 A - Terminals (Copper conductors only) *UL - 486 C - Butt Splices, Parallel Splices, Closed End Connectors, and Wire Nuts *UL - 310 - Quick Disconnects, Flag and Couplers *Military Class 2- Military Approved Terminals only as listed Doc No: ATS-638834200 Revision: D Release Date: 12-07-04 Revision Date: 05-16-12 UNCONTROLLED COPY Page 1 of 6 Continuous Molded Strip Applicator Product List The following is a partial list of the product order numbers and their specifications that this tool is designed to run. Updates to this list are available on www.molex.com. Terminal No. Terminal Eng. No. 19003-0041 19003-0045 19003-0051 19003-0057 19003-0085 19003-0086 19003-0134 19003-0137 19023-0055 19023-0064 19276-0004 BB-2206C BB-2206VBC BB-2207C BB-2208C BB-2215C BB-2216C BB-2207VC BB-2208VC 19023-0055 19023-0064 BB-2206C-LIF Wire Size AWG mm² 16-14 1.30-2.00 16-14 1.30-2.00 16-14 1.30-2.00 16-14 1.30-2.00 16-14 1.30-2.00 16-14 1.30-2.00 16-14 1.30-2.00 16-14 1.30-2.00 16-14 1.30-2.00 16-14 1.30-2.00 16-14 1.30-2.00 Insulation Diameter Maximum mm In. 4.06 .160 4.06 .160 4.06 .160 4.06 .160 4.06 .160 4.06 .160 4.06 .160 4.06 .160 4.06 .160 4.06 .160 4.06 .160 Strip Length mm In. 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 DEFINITION OF TERMS The following illustration is a generic terminal representation and not an exact image of any terminal listed in the scope. MWID OR MAX INSULATION DIAMETER Fully Insulated Male and Female Quick Disconnect STRIP LENGTH FEMALE QD MALE QD REF CONTINUOUS MOLDED STRIP TAB SIZE TAB SIZE Figure 1 Doc No: ATS-638834200 Revision: D Release Date: 12-07-04 Revision Date: 05-16-12 BRUSH WIRE STOP UNCONTROLLED COPY Page 2 of 6 Continuous Molded Strip Applicator CONDUCTOR CRIMP DIE Tool Calibration USE SOFT METAL SLUG METHOD To recalibrate this applicator, make sure the power is completely shut off on the press. E2 1. The Mini-Mac applicator must be properly installed in the press. “X” CRIMP 2. Crimping dies must be properly installed in the Mini-Mac HEIGHT applicator. E1 3. The recommended method of measuring the crimp height of CRIMP PROFILE the conductor dies is the soft metal slug method, (See Use soft metal slug (solder) method to Figure 2). measure the “X” dimension. Verify tooling 4. The slug must have a diameter 0.51mm (.020”) larger than crimp height calibration by referring to the the “X” No Go dimension before crimping. Go/No Go dimensions shown in the chart 5. Place the soft metal slug (solder) into the nest of the bottom below. die and crimp (by hand cycling the press) similar to a terminal. The crimp height can be measured with a blade Figure 2 type micrometer or dial caliper, (Dimension “X”). 6. Adjustment of the crimp height can be accomplished by indexing the conductor cam. The letter “A” gives the loosest position and “K” gives the tightest position. A total adjustment of 0.50mm (.020”) can be achieved by adjusting the conductor cam. Note: If the crimp height is too tight on the setting “A”, check the shut height of the press. See the Industrial MiniMac Applicator Manual Section 2.1 for adjustments. CRIMP SPECIFICATIONS Wire Size AWG mm² 16 14 1.30 2.00 “X” Dimension Conductor Crimp Mean Go No Go In mm In mm In mm .098 2.45 .095 2.41 .103 2.62 .098 2.45 .095 2.41 .103 2.62 Pull Force Minimum Lbs N 30.0 50.0 133.5 222.4 The above specifications are guidelines to an optimum crimp. Tool Qualification Notes: 1. Pull Force should be measured with no influence from the insulation crimp. 2. The above specifications are guidelines to an optimum crimp. Doc No: ATS-638834200 Revision: D Release Date: 12-07-04 Revision Date: 05-16-12 UNCONTROLLED COPY Page 3 of 6 Continuous Molded Strip Applicator PARTS LIST Mini-Mac Applicator 63883-4200 Engineering No. Description Quantity Perishable Tooling 63883-4270 63883-4270 Tool Kit (All “Y” Items) REF 1 63465-0004 63465-0004 Conductor Punch 1Y 2 63464-0004 63464-0004 Conductor Anvil 1Y 3 63469-0001 63469-0001 Cut-off Punch 1Y 4 63462-0041 63462-0041 Cut-off Anvil 1Y Other Components 5 63443-0021 63443-0021 Lower Tooling Key 1 6 63466-0912 63466-0912 Anvil Mount 1 7 63466-0913 63466-0913 Terminal Support 1 8 63466-0921 63466-0921 Terminal Stripping Blade 1 9 63466-0931 63466-0931 Terminal Nose Support 1 10 63600-1290 63600-1290 Washer 1 11 63890-0866 63890-0866 Collar-6.4 Long 1 12 63890-0868 63890-0868 Collar-9.5 Long 1 Frame 13 63801-3201 63801-3201 Top 1 14 63801-3281 63801-3281 Base 1 15 63801-4450 63801-4450 Track 1 Hardware 16 N/A N/A M3 by 12 Long SHCS 1** 17 N/A N/A M4 by 10 Long SHCS 2** 18 N/A N/A M4 by 20 Long SHCS 1** 19 N/A N/A M4 by 45 Long SHCS 1** 20 N/A N/A M5 by 12 Long SHCS 1** 21 N/A N/A M8 by 30 Long BHCS 1** 22 N/A N/A 3mm by 6 Long Roll Pin 1** ** Available from an industrial supply company such as MSC (1-800-645-7270). Item Order No Note: Crimp profiles used in 63883-4200 are equivalent to 19030-0074/MMC-BB-206 (UL file number E79133). Doc No: ATS-638834200 Revision: D Release Date: 12-07-04 Revision Date: 05-16-12 UNCONTROLLED COPY Page 4 of 6 Continuous Molded Strip Applicator Assembly Drawing 13 11 1 12 3 10 21 13 9 20 15 7 6 8 2 4 17 (2) 16 18 14 22 19 Doc No: ATS-638834200 Revision: D 5 Release Date: 12-07-04 Revision Date: 05-16-12 Figure 3 UNCONTROLLED COPY Page 5 of 6 Continuous Molded Strip Applicator NOTES 1. Molex recommends an extra perishable tooling kit be maintained at your facility. 2. Verify tooling alignment by manually cycling the press with applicator before crimping under power. Check that all screws are tight. 3. Slugs, terminals, dirt, and oil should be kept clear of work area. 4. Wear safety glasses at all times. 5. For recommended maintenance refer to the Mini-Mac Applicator Manual (Document no. 63880-0000). CAUTION: This applicator should only be used in a press with a shut height of 135.80 mm (5.346”). Tooling damage could result at a lower setting. CAUTION: To prevent injury, never operate this applicator without the guards supplied with the press or wireprocessing machine in place. Reference the press or wire process manufacturer’s instruction manual. CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling. Contact Information For more information on Molex application tooling please contact Molex at 1-800-786-6539. Visit our Web site at http://www.molex.com Doc No: ATS-638834200 Revision: D Release Date: 12-07-04 Revision Date: 05-16-12 UNCONTROLLED COPY Page 6 of 6