0638852000

Air Feed Mylar Tape Applicator Mini-Mac Applicator Air Feed- Mylar Tape Application Tooling Specification Sheet Order No. 63885-2000 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 insulation crimp 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: Avikrimp™ Fully Insulated Quick Disconnect, Female, for 18-22 AWG Wire, Mylar Tape. Testing Mechanical The tensile test, or pull test, is a means of evaluating the mechanical properties of the crimped connections. The following chart shows 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-638852000 Revision: D Release Date: 12-08-04 Revision Date: 05-23-12 UNCONTROLLED COPY Page 1 of 6 Air Feed Mylar Tape 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. 19002-0002 19002-0006 19002-0007 19002-0010 19002-0014 19002-0017 19002-0020 19002-0022 19277-0003 AA-5261T AA-5261BT AA-5267T AA-5271T AA-5275T AA-5279T AA-5293T AA-5285T AA-5261T-LIF Wire Size AWG mm² 18-22 0.80-0.35 18-22 0.80-0.35 18-22 0.80-0.35 18-22 0.80-0.35 18-22 0.80-0.35 18-22 0.80-0.35 18-22 0.80-0.35 18-22 0.80-0.35 18-22 0.80-0.35 Insulation Diameter Maximum mm In. 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 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 DEFINITION OF TERMS The following illustrations are a generic terminal representation and not an exact image of any terminal listed in the scope. MWID OR MAX INSULATION DIAMETER Fully Insulated Female Quick Disconnect STRIP LENGTH BRUSH TERMINAL STRIP MALE QD TAPE OR MOLDED REF FEMALE QD WIRE STOP TAB SIZE CUT-OFF TAB TAB SIZE Figure 1 CRIMP SPECIFICATIONS Wire Size Doc No: ATS-638852000 Revision: D 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 .100 2.54 .097 2.46 .104 2.64 .100 2.54 .097 2.46 .104 2.64 .100 2.54 .097 2.46 .104 2.64 Release Date: 12-08-04 Revision Date: 05-23-12 Pull Force Minimum Lbs N 8.0 13.0 20.0 35.6 57.8 90.0 UNCONTROLLED COPY Page 2 of 6 Air Feed Mylar Tape Applicator 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. CONDUCTOR CRIMP DIE Tool Calibration To recalibrate this applicator, make sure the power is completely shut off on the press. USE SOFT METAL SLUG METHOD E2 1. The Mini-Mac applicator must be properly installed in the press. 2. Crimping dies must be properly installed in the Mini-Mac “X” CRIMP applicator. HEIGHT E1 3. The recommended method of measuring the crimp height of the conductor dies is the soft metal slug method, (See Figure 2). CRIMP PROFILE 4. The slug must have a diameter 0.51mm (.020”) larger than the Use soft metal slug (solder) method to “X” No Go dimension before crimping. measure the “X” dimension. Verify 5. Place the soft metal slug (solder) into the nest of the bottom die tooling crimp height calibration by and crimp (by hand cycling the press) similar to a terminal. The referring to the Go/No Go dimensions crimp height can be measured with a blade type micrometer or shown in the chart below. dial caliper, (Dimension “X”). 6. Adjustment of the crimp height can be accomplished by indexing Figure 2 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. Doc No: ATS-638852000 Revision: D Release Date: 12-08-04 Revision Date: 05-23-12 UNCONTROLLED COPY Page 3 of 6 Air Feed Mylar Tape Applicator PARTS LIST Mini-Mac Applicator 63885-2000 Item Order No Engineering No. Description Quantity Perishable Tooling 63885-2070 63885-2070 Tool Kit (All “Y” Items) REF 1 63465-0005 63465-0005 Conductor Punch 1Y 2 63464-0005 63464-0005 Conductor Anvil 1Y 3 63463-0002 63463-0002 Insulation Punch 1Y 4 63462-0003 63462-0003 Insulation 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 63600-1290 63600-1290 Washer 1 10 63890-0866 63890-0866 Collar-6.4mm Long 1 11 63890-0867 63890-0867 Collar-7.7mm Long 1 Frame 12 63801-3301 63801-3301 Air Feed Applicator Frame Head 1 13 63801-3281 63801-3281 Base 1 14 63801-5850 63801-5850 Track Assembly 1 15 63801-3390 63801-3390 Air Kit 1 Hardware 16 N/A N/A M3 by 12 LongSHCS 1** 17 N/A N/A M4 by 10 LongSHCS 2** 18 N/A N/A M4 by 16 Long SHCS 1** 19 N/A N/A M4 by 45 Long SHCS 1** 20 N/A N/A M8 by 30 Long BHCS 1** 21 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 63885-2000 are equivalent to 19032-0045 / MMT-AA-512 and 19288-0028 / ATP-AA-512 (UL file number E79133). Doc No: ATS-638852000 Revision: D Release Date: 12-08-04 Revision Date: 05-23-12 UNCONTROLLED COPY Page 4 of 6 Air Feed Mylar Tape Applicator Assembly Drawing 12 11 10 1 12 3 9 20 8 17 (2) 7 14 6 15 2 16 4 18 13 21 19 Doc No: ATS-638852000 Revision: D Release Date: 12-08-04 Revision Date: 05-23-12 5 Figure 3 UNCONTROLLED COPY Page 5 of 6 Air Feed Mylar Tape 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 processing 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-638852000 Revision: D Release Date: 12-08-04 Revision Date: 05-23-12 UNCONTROLLED COPY Page 6 of 6