0638837200

Continuous Molded Strip Applicator Mini-Mac Applicator Application Tooling Specification Mechanical Feed - Continuous Molded Strip Order No. 63883-7200 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) Female Terminals for 18-22 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 *UL – 486 C *UL – 310 3 5 8 13 20 30 50 70 80 90 100 N/A N/A 8 10 10 15 25 35 40 45 50 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-638837200 Revision: C Release Date: 12-07-04 Revision Date: 12-05-08 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. 19003-0009 19003-0015 19003-0022 19003-0028 19003-0034 AA-2201XC AA-2202XC AA-2203XC AA-2204XC AA-2205XC Wire Size AWG 22-18 22-18 22-18 22-18 22-18 mm² 0.35-0.80 0.35-.080 0.35-0.80 0.35-0.80 0.35-0.80 Insulation Diameter Maximum mm In. 5.84 .230 5.84 .230 5.84 .230 5.84 .230 5.84 .230 Strip Length mm 6.35 6.35 6.35 6.35 6.35 In. .250 .250 .250 .250 .250 DEFINITION OF TERMS The following illustration is a generic terminal representation and not an exact image of any terminal listed in the scope. Fully Insulated Female and Male Quick Disconnect MWID OR MAX INSULATION DIAMETER STRIP LENGTH FEMALE QD CONTINUOUS MOLDED STRIP MALE QD REF TAB SIZE TAB SIZE BRUSH WIRE STOP Figure 1 Doc No: ATS-638837200 Revision: C Release Date: 12-07-04 Revision Date: 12-05-08 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 CRIMP PROFILE of 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 type micrometer or dial caliper, (Dimension “X”). Figure 2 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 Mini-Mac Applicator Manual Section 2.1 for adjustments. CRIMP SPECIFICATIONS Wire Size AWG mm² 22 20 18 0.35 0.50 0.80 “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 .098 2.45 .095 2.41 .103 2.62 Pull Force Minimum Lbs N 8.0 13.0 20.0 35.6 57.8 90.0 Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. Doc No: ATS-638837200 Revision: C Release Date: 12-07-04 Revision Date: 12-05-08 UNCONTROLLED COPY Page 3 of 6 Continuous Molded Strip Applicator PARTS LIST Mini-Mac Applicator 63883-7200 Item Order No Engineering No. Description Quantity Perishable Tooling 63883-7270 63883-7270 Tool Kit (All “Y” Items) REF 1 63465-0002 63465-0002 Conductor Punch 1Y 2 63464-0002 63464-0002 Conductor Anvil 1Y 3 63469-0002 63469-0002 Cut-off Punch 1Y 4 63462-0043 63462-0043 Cut-off Anvil 1Y Other Components (Ref. 30050) 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). Note: Crimp profiles used in 63883-7200 are equivalent to 19030-0072/MMC-AX-205, 19030-0054/MMC-AA-595X, and 19030-0069/MMC-AX-201 (UL file number E79133). Doc No: ATS-638837200 Revision: C Release Date: 12-07-04 Revision Date: 12-05-08 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-638837200 Revision: C 5 Release Date: 12-07-04 Revision Date: 12-05-08 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 wire-processing 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. Americas Headquarters Lisle, Illinois 60532 U.S.A. 1-800-78MOLEX amerinfo@molex.com Far East North Headquarters Yamato, Kanagawa, Japan 81-462-65-2324 feninfo@molex.com Far East South Headquarters Jurong, Singapore 65-6-268-6868 fesinfo@molex.com European Headquarters Munich, Germany 49-89-413092-0 eurinfo@molex.com Corporate Headquarters 2222 Wellington Ct. Lisle, IL 60532 U.S.A. 630-969-4550 Fax: 630-969-1352 Visit our Web site at http://www.molex.com Doc No: ATS-638837200 Revision: C Release Date: 12-07-04 Revision Date: 12-05-08 UNCONTROLLED COPY Page 6 of 6