0638857000

Air Feed Mylar Tape Applicator Mini-Mac Applicator Air Feed- Mylar Tape Application Tooling Specification Sheet Order No. 63885-7000 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: InsulKrimp™ Style, Male and Female, Fully Insulated Quick Disconnect, 18-22 AWG, Mylar Tap 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 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 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. Doc No. ATS-638857000 Revision: D Release Date: 12-08-04 Revision Date: 05-24-12 UNCONTROLLED COPY Page 1 of 6 Air Feed Mylar Tape Applicator Note: To process the following terminals, use both conductor and insulation tooling. Terminal No. Terminal Eng. No. 19003-0003 19003-0007 19003-0013 19003-0020 19003-0026 19003-0032 19003-0074 19003-0075 19003-0127 19003-0130 19023-0051 19023-0060 19276-0003 AA-2201T AA-2201VNT AA-2202T AA-2203T AA-2204T AA-2205T AA-2213T AA-2214T AA-2202VT AA-2203VT 19023-0051 19023-0060 AA-2201T-LIF Wire Size AWG mm² 22-18 0.35-0.80 22-18 0.35-0.80 22-18 0.35-0.80 22-18 0.35-0.80 22-18 0.35-0.80 22-18 0.35-0.80 22-18 0.35-0.80 22-18 0.35-0.80 22-18 0.35-0.80 22-18 0.35-0.80 22-18 0.35-0.80 22-18 0.35-0.80 22-18 0.35-0.80 Insulation Diameter Maximum mm In. 3.43 .135 3.43 .135 3.43 .135 3.43 .135 3.43 .135 3.43 .135 3.43 .135 3.43 .135 3.43 .135 3.43 .135 3.43 .135 3.43 .135 3.43 .135 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 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 #10) for crimping expanded flare products. (See parts list and assembly drawing). 19003-0010 AA-2201XT Wire Size AWG mm² 22-18 0.35-0.80 19003-0016 AA-2202XT 22-18 0.35-0.80 5.84 .230 6.35 .250 19003-0023 AA-2203XT 22-18 0.35-0.80 5.84 .230 6.35 .250 19003-0029 AA-2204XT 22-18 0.35-0.80 5.84 .230 6.35 .250 19003-0035 AA-2205XT 22-18 0.35-0.80 5.84 .230 6.35 .250 Terminal No. • • • • • Terminal Eng. No. DEFINITION OF TERMS Insulation Diameter Maximum. mm In. 5.84 .230 Strip Length mm In. 6.35 .250 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-638857000 Revision: D Figure 1 WIRE STOP TAB SIZE Release Date: 12-08-04 Revision Date: 05-24-12 UNCONTROLLED COPY Page 2 of 6 Air Feed Mylar Tape Applicator The following illustrations are a generic terminal representation and not an exact image of any terminal listed in the scope. 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 .090 2.29 .088 2.24 .092 2.34 .094 2.38 .092 2.34 .096 2.44 .098 2.45 .095 2.41 .103 2.62 Pull Force Minimum Lbs N 8 13 20 35.6 57.8 90.0 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. 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 2). 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 MiniMac Applicator Manual Section 2.1 for adjustments. Doc No. ATS-638857000 Revision: D Release Date: 12-08-04 Revision Date: 05-24-12 UNCONTROLLED COPY Page 3 of 6 Air Feed Mylar Tape Applicator PARTS LIST Mini-Mac Applicator 63885-7000 Item Order No Engineering No. Description Quantity Perishable Tooling 63885-7070 63885-7070 Tool Kit (All “Y” Items) REF 1 63465-0002 63465-0002 Conductor Punch 1Y 2 63464-0002 63464-0002 Conductor Anvil 1Y 3 63463-0005 63463-0005 1Y • Insulation Punch 4 63462-0006 63462-0006 1Y • Insulation Anvil 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 1 10 63890-0866 63890-0866 • Collar-6.4mm Long 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 #10) for crimping expanded flare products. (See product list) Note: Crimp profiles used in 63885-7000 are equivalent to 19288-0049 / ATP-AA-575-CC and 19288-0233 / ATP-M-675-CC (UL file number E79133). Doc No. ATS-638857000 Revision: D Release Date: 12-08-04 Revision Date: 05-24-12 UNCONTROLLED COPY Page 4 of 6 Air Feed Mylar Tape Applicator Assembly Drawing 12 1 • • 11 10 12 3 9 20 8 17 (2) 7 14 6 15 2 • 16 4 18 13 21 19 • 5 Figure 3 Note: Insulation tooling is NOT intended for “expanded flare” terminals. Remove the insulation punch (Item #3), anvil (Item #4), and collar (Item #10) for crimping expanded flare products. (See product list) Doc No. ATS-638857000 Revision: D Release Date: 12-08-04 Revision Date: 05-24-12 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-638857000 Revision: D Release Date: 12-08-04 Revision Date: 05-24-12 UNCONTROLLED COPY Page 6 of 6