0638854600

Air Feed Mylar Tape Applicator Mini-Mac Applicator Air Feed Mylar Tape Application Tooling Specification Sheet Order No. 63885-4600 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: Vibrakrimp™ Ring Tongue, Rectangular Tongue, Spade Tongue, Hook Tongue, Snap Spade and Flanged Spade 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 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-638854600 Revision: B Release Date: 05-14-08 Revision Date: 11-05-13 UNCONTROLLED COPY Page 1 of 8 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. 19033-0009 19033-0010 19072-0045 19072-0047 19072-0049 19072-0052 19072-0054 19072-0056 19072-0058 19072-0060 19072-0062 19072-0064 19072-0066 19072-0068 19072-0070 19072-0072 19072-0074 19072-0077 19072-0079 19072-0081 19072-0083 19097-0045 19097-0047 19097-0049 19097-0052 19097-0054 19097-0056 19097-0061 19097-0063 19097-0065 19097-0069 19097-0071 19097-0073 19097-0075 19149-0042 19149-0044 19149-0046 19149-0048 19149-0050 19149-0052 19149-0054 19149-0056 19149-0058 19149-0060 19149-0062 Doc. No: ATS-638854600 Revision: B Wire Size: 16 – 14 AWG 1.00 – 2.50mm² Wire Strip Length Insulation Diameter Maximum Terminal Eng No. (Reference) In mm In mm B-479T .250 6.35 .170 4.32 B-489T .250 6.35 .170 4.32 BB-418-10T .250 6.35 .170 4.32 BB-418-14T .250 6.35 .170 4.32 BB-418-38T .250 6.35 .170 4.32 BB-418-56T .250 6.35 .170 4.32 BB-423-02T .250 6.35 .170 4.32 BB-423-04T .250 6.35 .170 4.32 BB-423-06T .250 6.35 .170 4.32 BB-423-08T .250 6.35 .170 4.32 BB-425-10T .250 6.35 .170 4.32 BB-425-14T .250 6.35 .170 4.32 BB-425-56T .250 6.35 .170 4.32 BB-437-04T .250 6.35 .170 4.32 BB-437-06T .250 6.35 .170 4.32 BB-437-08T .250 6.35 .170 4.32 BB-437-10T .250 6.35 .170 4.32 BB-439-04T .250 6.35 .170 4.32 BB-439-06T .250 6.35 .170 4.32 BB-439-08T .250 6.35 .170 4.32 BB-439-10T .250 6.35 .170 4.32 BB-413-04T .250 6.35 .170 4.32 BB-413-06T .250 6.35 .170 4.32 BB-413-08T .250 6.35 .170 4.32 BB-482-06T .250 6.35 .170 4.32 BB-482-08T .250 6.35 .170 4.32 BB-482-10T .250 6.35 .170 4.32 BB-485-06T .250 6.35 .170 4.32 BB-485-08T .250 6.35 .170 4.32 BB-485-10T .250 6.35 .170 4.32 BB-488-04T .250 6.35 .170 4.32 BB-488-06T .250 6.35 .170 4.32 BB-488-08T .250 6.35 .170 4.32 BB-488-10T .250 6.35 .170 4.32 BB-407-04T .250 6.35 .170 4.32 BB-407-06T .250 6.35 .170 4.32 BB-424-04T .250 6.35 .170 4.32 BB-424-06T .250 6.35 .170 4.32 BB-424-08T .250 6.35 .170 4.32 BB-427-06T .250 6.35 .170 4.32 BB-427-08T .250 6.35 .170 4.32 BB-427-10T .250 6.35 .170 4.32 BB-481-06T .250 6.35 .170 4.32 BB-481-08T .250 6.35 .170 4.32 BB-481-10T .250 6.35 .170 4.32 Release Date: 05-14-08 Revision Date: 11-05-13 UNCONTROLLED COPY Page 2 of 8 Air Feed Mylar Tape Applicator Terminal No. 19149-0064 19149-0066 19149-0068 19149-0070 19149-0072 19149-0074 19181-0008 19181-0010 19181-0012 19186-0034 19186-0036 19186-0038 19186-0039 19186-0044 19186-0046 19186-0048 19186-0050 19186-0052 19186-0054 19186-0056 19186-0058 19186-0060 19203-0065 19203-0066 19203-0067 19203-0068 19203-0071 19203-0073 19203-0075 19203-0087 19203-0088 19203-0089 19203-0090 19203-0231 19210-0020 19210-0022 19210-0024 19210-0026 19210-0028 19210-0034 19210-0036 Doc. No: ATS-638854600 Revision: B Wire Size: 16 – 14 AWG 1.00 – 2.50mm² Wire Strip Length Insulation Diameter Maximum Terminal Eng No. (Reference) In mm In mm BB-484-06T .250 6.35 .170 4.32 BB-484-08T .250 6.35 .170 4.32 BB-484-10T .250 6.35 .170 4.32 BB-487-04T .250 6.35 .170 4.32 BB-487-06T .250 6.35 .170 4.32 BB-487-08T .250 6.35 .170 4.32 BB-419-06T .250 6.35 .170 4.32 BB-419-08T .250 6.35 .170 4.32 BB-419-10T .250 6.35 .170 4.32 BB-416-04T .250 6.35 .170 4.32 BB-416-06T .250 6.35 .170 4.32 BB-416-08T .250 6.35 .170 4.32 BB-416-10T .250 6.35 .170 4.32 BB-480-06T .250 6.35 .170 4.32 BB-480-08T .250 6.35 .170 4.32 BB-480-10T .250 6.35 .170 4.32 BB-483-06T .250 6.35 .170 4.32 BB-483-08T .250 6.35 .170 4.32 BB-483-10T .250 6.35 .170 4.32 BB-486-04T .250 6.35 .170 4.32 BB-486-06T .250 6.35 .170 4.32 BB-486-08T .250 6.35 .170 4.32 BB-T-418-38T .250 6.35 .170 4.32 BB-T-423-06T .250 6.35 .170 4.32 BB-T-425-14T .250 6.35 .170 4.32 BB-T-425-56T .250 6.35 .170 4.32 BB-T-437-06T .250 6.35 .170 4.32 BB-T-437-08T .250 6.35 .170 4.32 BB-T-437-10T .250 6.35 .170 4.32 BB-U-423-06T .250 6.35 .170 4.32 BB-U-425-14T .250 6.35 .170 4.32 BB-U-437-06T .250 6.35 .170 4.32 BB-U-437-10T .250 6.35 .170 4.32 BB-U-437-08T .250 6.35 .170 4.32 BB-4193-06T .250 6.35 .170 4.32 BB-4194-08T .250 6.35 .170 4.32 BB-4195-10T .250 6.35 .170 4.32 BB-4707-05T .250 6.35 .170 4.32 BB-4707-06T .250 6.35 .170 4.32 BB-4716-08T .250 6.35 .170 4.32 BB-4717-10T .250 6.35 .170 4.32 Release Date: 05-14-08 Revision Date: 11-05-13 UNCONTROLLED COPY Page 3 of 8 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. MWID OR MAX INSULATION DIAMETER Insulated Terminal MWID OR MAX INSULATION DIAMETER Un-Insulated Terminal BARREL BRUSH STRIP LENGTH STUD SIZE (REF) STUD SIZE (REF) BARREL STRIP LENGTH INSULATION FERRULE Figure 2 BRUSH Figure 1 STRIP LENGTH Fully Insulated Male and Female Quick Disconnect FEMALE QD MWID OR MAX INSULATION DIAMETER BRUSH MALE QD REF TAB SIZE Doc. No: ATS-638854600 Revision: B TAB SIZE Release Date: 05-14-08 Revision Date: 11-05-13 WIRE STOP Figure 3 UNCONTROLLED COPY Page 4 of 8 Air Feed Mylar Tape Applicator 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. “X” CRIMP 2. Crimping dies must be properly installed in the MiniHEIGHT Mac applicator. E1 3. The recommended method of measuring the crimp CRIMP PROFILE height of the conductor dies is the soft metal slug method, (See Figure 4). Use soft metal slug (solder) method to Measure the 4. The slug must have a diameter 0.51mm (.020”) larger “X” dimension. Verify tooling crimp height calibration than the “X” No Go dimension before crimping. by referring to the Go/No Go dimensions shown in the chart below. 5. Place the soft metal slug (solder) into the nest of the bottom die and crimp (by hand cycling the press) Figure 4 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 “X” Dimension Conductor Crimp Pull Force Minimum Mean Go No Go AWG mm² Lbs. N In. mm In. mm In. mm 14 2.00 .094 2.39 .091 2.31 .098 2.49 50.0 222.2 16 1.30 .094 2.39 .091 2.31 .098 2.49 30.0 133.3 Crimp Inspection Marking o o Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. Doc. No: ATS-638854600 Revision: B Release Date: 05-14-08 Revision Date: 11-05-13 UNCONTROLLED COPY Page 5 of 8 Air Feed Mylar Tape Applicator PARTS LIST Mini-Mac Applicator 63885-4600 Item Order No Engineering No. Description Quantity Perishable Tooling 63885-4670 63885-4670 Tool Kit (All “Y” Items) REF 1 63465-0056 63465-0056 Conductor Punch 1Y 2 63464-0054 63464-0054 Conductor Anvil 1Y 3 63463-0037 63463-0037 Insulation Punch 1Y 4 63462-0040 63462-0040 Insulation Anvil 1Y Other Components 5 63466-0912 63466-0912 Anvil Mount 1 6 63466-0913 63466-0913 Terminal Support 1 7 63443-0021 63443-0021 Lower Tooling Key 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 Lg. 1 11 63890-0867 63890-0867 Collar-7.7mm Lg. 1 Frame 12 63801-3301 63801-3301 Air Feed Applicator Frame Head REF 13 63801-3281 63801-3281 Base REF 14 63801-5850 63801-5850 Track Assembly REF 15 63801-3390 63801-3390 Air Kit REF Hardware 16 N/A N/A M3 by 12 Lg SHCS 1** 17 N/A N/A M4 by 10 Lg SHCS 2** 18 N/A N/A M4 by 20 Lg. SHCS 1** 19 N/A N/A M4 by 50 Lg. SHCS 1** 20 N/A N/A M8 by 30 Lg. BHCS 1** 21 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: Crimp profiles used in 63885-4600 are equivalent to 19027-0074 / ATP-BB-420 (UL file number E32244). Doc. No: ATS-638854600 Revision: B Release Date: 05-14-08 Revision Date: 11-05-13 UNCONTROLLED COPY Page 6 of 8 Air Feed Mylar Tape Applicator Assembly Drawing 12 10 11 1 12 3 9 20 8 17 (2) 6 14 5 15 2 4 16 18 13 21 19 7 Figure 5 Doc. No: ATS-638854600 Revision: B Release Date: 05-14-08 Revision Date: 11-05-13 UNCONTROLLED COPY Page 7 of 8 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-638854600 Revision: B Release Date: 05-14-08 Revision Date: 11-05-13 UNCONTROLLED COPY Page 8 of 8