0638854200

Air Feed Mylar Tape Applicator Mini-Mac Applicator Application Tooling Specification Air Feed-Mylar Tape Order No. 63885-4200 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 Male and Female Standard and Expanded Flare FIQD Terminals 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 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 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 *Military Class 2 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 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. 63885-4200 Revision: B Release Date: 12-08-04 Revision Date: 10-04-05 UNCONTROLLED COPY Page 1 of 7 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. Note: To process the following terminals, use both conductor and insulation tooling. Terminal No. Terminal Eng. No. 19003-0042 19003-0052 19003-0058 19003-0077 19003-0078 19003-0080 19003-0133 19003-0136 19023-0054 19023-0063 BB-2206T BB-2207T BB-2208T BB-2215T BB-2216T BB-2206VBT BB-2207VT BB-2208VT 19023-0054 19023-0063 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 Insulation Diameter Max. 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 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 *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. ✴ ✴ ✴ Doc No. 63885-4200 Revision: B 19003-0049 19003-0055 19003-0061 Terminal Eng. No. BB-2206XT BB-2207XT BB-2208XT Release Date: 12-08-04 Revision Date: 10-04-05 Wire Size AWG mm² 16-14 1.30-2.00 16-14 1.30-2.00 16-14 1.30-2.00 Insulation Diameter Max. mm In. 6.60 .260 6.60 .260 6.60 .260 UNCONTROLLED COPY Strip Length mm In. 6.35 .250 6.35 .250 6.35 .250 Page 2 of 7 Air Feed Mylar Tape Applicator 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 BARREL BRUSH MWID OR MAX INSULATION DIAMETER STRIP LENGTH STUD SIZE (REF) STUD SIZE (REF) BARREL STRIP LENGTH INSULATION FERRULE BRUSH Figure 1 Figure 2 STRIP LENGTH Fully Insulated Male and Female Quick Disconnect FEMALE QD MWID OR MAX INSULATION DIAMETER BRUSH MALE QD REF TAB SIZE Doc No. 63885-4200 Revision: B Release Date: 12-08-04 Revision Date: 10-04-05 WIRE STOP TAB SIZE Figure 3 UNCONTROLLED COPY Page 3 of 7 Air Feed Mylar Tape Applicator Tool Calibration To recalibrate this applicator, make sure the power is completely shut off on the press. 1. The Mini-Mac applicator must be properly installed in the press. 2. Crimping dies must be properly installed in the Mini-Mac applicator. 3. The recommended method of measuring the crimp height of the conductor dies is the soft metal slug method, (See Figure 4). 4. The slug must have a diameter 0.51mm (.020”) larger than the “X” No Go dimension before crimping. 5. Place the soft metal slug (solder) into the nest of 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. CONDUCTOR CRIMP DIE USE SOFT METAL SLUG METHOD E2 “X” CRIMP HEIGHT E1 CRIMP PROFILE Use soft metal slug (solder) method to measure the “X” dimension. Verify tooling crimp height calibration by referring to the Go/No Go dimensions shown in the chart below. Figure 2 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 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 Min. Lbs N 30 50 133.5 222.4 Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. Doc No. 63885-4200 Revision: B Release Date: 12-08-04 Revision Date: 10-04-05 UNCONTROLLED COPY Page 4 of 7 Air Feed Mylar Tape Applicator PARTS LIST Mini-Mac Applicator 63885-4200 Item Order No Engineering No. Description Quantity Perishable Tooling 63885-4270 63885-4270 Tool Kit (All “Y” Items) REF 1 63465-0004 63465-0004 Conductor Punch 1Y 2 63464-0004 63464-0004 Conductor Anvil 1Y 3 63463-0007 63463-0007 Insulation Punch 1Y 4 63462-0009 63462-0009 Insulation Anvil 1Y Other Components (Ref. 50050) 31 63466-0912 63466-0912 Anvil Mount 1 32 63466-0913 63466-0913 Terminal Support 1 33 63443-0021 63443-0021 Lower Tooling Key 1 42 63466-0921 63466-0921 Terminal Stripping Blade 1 51 63600-1290 63600-1290 Washer 1 52 63890-0866 63890-0866 Collar-6.4mm Lg. 1 53 63890-0867 63890-0867 Collar-7.7mm Lg. 1 Frame 81 63801-3301 63801-3301 Air Feed Applicator Frame Head REF 82 63801-3281 63801-3281 Base REF 83 63801-5850 63801-5850 Track Assembly REF 84 63801-3390 63801-3390 Air Kit REF Hardware 91 N/A N/A M3 by 12 Lg SHCS 1** 92 N/A N/A M4 by 10 Lg SHCS 2** 93 N/A N/A M4 by 16 Lg. SHCS 1** 94 N/A N/A M4 by 45 Lg. SHCS 1** 95 N/A N/A M8 by 30 Lg. BHCS 1** 96 N/A N/A 3mm by 6 Lg. 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 #53) for crimping expanded flare products. (See product list) Note: Crimp profiles used in 63885-4200 are equivalent to 19032-0220/MMT-BB-275 and 19288-0104/ATP-BB-275 (UL file number E79133). Doc No. 63885-4200 Revision: B Release Date: 12-08-04 Revision Date: 10-04-05 UNCONTROLLED COPY Page 5 of 7 Air Feed Mylar Tape Applicator Assembly Drawing 81 * 1 * 52 53 81 3 51 95 42 92 (2) 32 83 31 84 2 * 4 91 93 82 96 94 33 Figure 5 *Note: 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 product list) Doc No. 63885-4200 Revision: B Release Date: 12-08-04 Revision Date: 10-04-05 UNCONTROLLED COPY Page 6 of 7 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. Molex Application Tooling Group 1150 E. Diehl Road Naperville, IL 60563 Tel: (630) 969-4550 Fax: (630) 505-0049 Visit our Web site at http://www.molex.com Doc No. 63885-4200 Revision: B Release Date: 12-08-04 Revision Date: 10-04-05 UNCONTROLLED COPY Page 7 of 7