0638852300

Air Feed Mylar Tape Applicator Mini-Mac Applicator Application Tooling Specification Air Feed-Mylar Tape Order No. 63885-2300 FEATURES Œ Œ Œ Œ 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: Insulkrimp™ Piggyback FIQD Terminals 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 chart shows the UL and government specifications (MIL-T-7928) for various wire sizes. The tensile strength is shown in pounds and indicates the minimum acceptable force to break or separate the terminal from the conductor. Color Code Red Red Red Wire Size (AWG) 22 20 18 *UL - 486 A 8 13 20 *UL – 486 C 8 10 10 *UL – 310 8 13 20 *Military Class 2 15 19 38 *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 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. Note: To process the following terminals, use both conductor and insulation tooling. Terminal No. Terminal Eng. No. 19013-0002 19013-0026 AA-2317T 19013-0026 Doc No. ATS-638852300 Revision: C Wire Size AWG mm² 18-22 0.80-0.35 18-22 0.80-0.35 Release Date: 12-08-04 Revision Date: 05-24-07 Insulation Diameter Maximum mm In. 3.56 .140 3.56 .140 UNCONTROLLED COPY Strip Length mm In. 7.92 .312 7.92 .312 Page 1 of 6 Air Feed Mylar Tape Applicator *Note: To process the following terminals, use conductor tooling only. Insulation tooling is NOT intended for “expanded flare” terminals. Remove the insulation punch (Item #3), anvil (Item #4), and collar (Item #53) for crimping expanded flare products. (See parts list and assembly drawing) Terminal No. ✴ ✴ Terminal Eng. No. 19013-0004 19013-0028 AA-2317XT 19013-0028 Wire Size AWG mm² 18-22 0.80-0.35 18-22 0.80-0.35 Insulation Diameter Maximum mm In. 5.84 .230 5.84 .230 Strip Length mm In. 7.92 .312 7.92 .312 DEFINITION OF TERMS The following illustrations are a generic terminal representation and not an exact image of any terminal listed in the scope. Insulated Terminal MWID OR MAX INSULATION DIAMETER Un-Insulated Terminal MWID OR MAX INSULATION DIAMETER BARREL BRUSH STRIP LENGTH STUD SIZE (REF) STUD SIZE (REF) BARREL STRIP LENGTH INSULATION FERRULE Figure 2 BRUSH Figure 1 Fully Insulated Male and Female Quick Disconnect STRIP LENGTH FEMALE QD MWID OR MAX INSULATION DIAMETER BRUSH MALE QD REF TAB SIZE WIRE STOP TAB SIZE Figure 3 Doc No. ATS-638852300 Revision: C Release Date: 12-08-04 Revision Date: 05-24-07 UNCONTROLLED COPY Page 2 of 6 Air Feed Mylar Tape Applicator CONDUCTOR CRIMP DIE Tool Calibration USE SOFT METAL I ns ul ated Termi nal M W ID O RM AX I NSU LATI ON DI AM ETE R M WI D OR M AX IN SULA TI ON DI AM ETER U n-In sul ated Te rmin al BA RRE L BRU SH STR IP LENG TH STUD SI ZE ( REF) STU D SIZE ( RE F) BA RRE L STR IP LENG TH IN SULA TIO N FER RU LE B RUS H Fi gur e1 Fi gur e2 ST RIP LE NGT H 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 HEIGHT Mini-Mac applicator. E1 3. The recommended method of measuring the crimp CRIMP PROFILE height of the conductor dies is the soft metal slug Use soft metal slug (solder) method to measure method. See Figure 4. the “X” dimension. Verify tooling crimp height 4. The slug must have a diameter 0.51mm (.020”) calibration by referring to the Go/No Go larger than the “X” No Go dimension before dimensions shown in the chart below. crimping. 5. Place the soft metal slug (solder) into the nest of Figure 4 the bottom 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”). 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 .35 .50 .80 “X” Dimension Conductor Crimp Mean Go No Go In mm In mm In mm .080 2.03 .077 1.96 .087 2.21 .080 2.03 .077 1.96 .087 2.21 .080 2.03 .077 1.96 .087 2.21 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-638852300 Revision: C Release Date: 12-08-04 Revision Date: 05-24-07 UNCONTROLLED COPY Page 3 of 6 Air Feed Mylar Tape Applicator PARTS LIST Mini-Mac Applicator 63885-2300 Item Order No Engineering No. Description Quantity Perishable Tooling 63885-2370 63885-2370 Tool Kit (All “Y” Items) REF 1 63465-0009 63465-0009 Conductor Punch 1Y 2 63464-0009 63464-0009 Conductor Anvil 1Y 3 63463-0005 63463-0005 Insulation Punch 1Y 4 63462-0006 63462-0006 Insulation Anvil 1Y Other Components (REF 850050) 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 Long SHCS 1** 17 N/A N/A M4 by 10 Long SHCS 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: Insulation tooling is NOT intended for “expanded flare” terminals. Remove the insulation punch (Item #3), anvil (Item #4), and collar (Item #11) for crimping expanded flare products. (See product list) Note: Crimp profiles used in 63885-2300 are equivalent to 19032-0258 and 19032-0263 (UL file number E79133). Doc No. ATS-638852300 Revision: C Release Date: 12-08-04 Revision Date: 05-24-07 UNCONTROLLED COPY Page 4 of 6 Air Feed Mylar Tape Applicator Assembly Drawing 12 10 11 1 12 3 9 20 8 17 (2) 7 14 6 15 2 16 4 18 13 21 19 5 Figure 5 *Note: Insulation tooling is NOT intended for “expanded flare” terminals. Remove the insulation punch (Item #3), anvil (Item #4), and collar (Item #11) for crimping expanded flare products. (See product list) Doc No. ATS-638852300 Revision: C Release Date: 12-08-04 Revision Date: 05-24-07 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 wire-processing 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. 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-638852300 Revision: C Release Date: 12-08-04 Revision Date: 05-24-07 UNCONTROLLED COPY Page 6 of 6