0638858200

Air Feed Mylar Tape Applicator for InsulKrimp™ Ring Tongue Terminal Mini-Mac Applicator Application Tooling Specification Air Feed-Mylar Tape Order No. 63885-8200 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™ Ring Tongue Terminals for 10-12 AWG, and 14-16 AWG Heavy Duty. 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 specifications 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 Yellow Yellow Wire Size (AWG) 16 14 12 10 *UL - 486 A 30 50 70 80 *UL - 486 A - Terminals (Copper conductors only) 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 Order No. Terminal Eng. No. 19070-0110 19070-0116 C-201-12XT C-201-76XT Terminal Order No. Terminal Eng. No. 19054-0064 19054-0068 19054-0071 Doc No. ATS-638858200 Revision: A B-201-12HDXT B-201-38HDXT B-201-76HDXT Release Date: 06-14-07 Revision Date: 06-14-07 Insulation Diameter Maximum AWG mm² mm In. 10-12 5.25-3.30 6.35 .250 10-12 5.25-3.30 6.35 .250 Wire Size Insulation Diameter Maximum AWG mm² mm In. 14-16 2.00-1.30 6.35 .250 14-16 2.00-1.30 6.35 .250 14-16 2.00-1.30 6.35 .250 Wire Size Strip Length mm 9.53 9.53 In. .375 .375 Strip Length UNCONTROLLED COPY mm 7.92 7.92 7.92 In. .312 .312 .312 Page 1 of 6 Air Feed Mylar Tape Applicator for InsulKrimp™ Ring Tongue Terminal 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-638858200 Revision: A Release Date: 06-14-07 Revision Date: 06-14-07 UNCONTROLLED COPY Page 2 of 6 Air Feed Mylar Tape Applicator for InsulKrimp™ Ring Tongue Terminal Tool Calibration CONDUCTOR CRIMP DIE 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“X” CRIMP Mac applicator. HEIGHT 3. The recommended method of measuring the crimp E1 height of the conductor dies is the soft metal slug CRIMP PROFILE method. See Figure 4. 4. The slug must have a diameter 0.51mm (.020”) larger Use soft metal slug (solder) method to measure than the “X” No Go dimension before crimping. the “X” dimension. Verify tooling crimp height 5. Place the soft metal slug (solder) into the nest of the calibration by referring to the Go/No Go bottom die and crimp (by hand cycling the press) dimensions shown in the chart below. similar to a terminal. The crimp height can be measured with a blade type micrometer or dial caliper, Figure 4 (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 16 14 12 10 1.30 2.00 3.30 5.25 “X” Dimension Conductor Crimp Mean Go No Go In mm In mm In mm .160 4.06 .157 3.99 .168 4.27 .160 4.06 .157 3.99 .168 4.27 .160 4.06 .157 3.99 .168 4.27 .160 4.06 .157 3.99 .168 4.27 Pull Force Minimum Lbs N 30.0 50.0 70.0 80.0 133.5 222.5 311.4 355.9 Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. Doc No. ATS-638858200 Revision: A Release Date: 06-14-07 Revision Date: 06-14-07 UNCONTROLLED COPY Page 3 of 6 Air Feed Mylar Tape Applicator for InsulKrimp™ Ring Tongue Terminal PARTS LIST Mini-Mac Applicator 63885-8200 Item Order No Engineering No. Description Quantity Perishable Tooling 63885-8270 63885-8270 Tool Kit (All “Y” Items) REF 1 63465-8201 63465-8201 Conductor Punch 1Y 2 63464-0015 63464-0015 Conductor Anvil 1Y 3 63463-8202 63463-8202 Insulation Punch 1Y 4 63462-0016 63462-0016 Insulation Anvil 1Y Other Components (REF 858250) 5 63443-0021 63443-0021 Lower Tooling Key 1 6 63443-2305 63443-2305 3.25mm Spacer 1 7 63466-0912 63466-0912 Anvil Mount 1 8 63466-0913 63466-0913 Terminal Support 1 9 63466-0921 63466-0921 Terminal Stripping Blade 1 10 63600-1290 63600-1290 Washer 1 11 63801-5815 63801-5815 Guide Bar 1 12 63890-0866 63890-0866 Collar-6.4mm Long 1 13 63890-0867 63890-0867 Collar-7.7mm Long 1 Frame 14 63801-3301 63801-3301 Air Feed Applicator Frame Head 1 15 63801-3281 63801-3281 Base 1 16 63801-5850 63801-5850 Track Assembly 1 17 63801-3390 63801-3390 Air Kit 1 Hardware 18 N/A N/A M3 by 12 Long SHCS 1** 19 N/A N/A M4 by 6 Long BHCS 2** 20 N/A N/A M4 by 10 Long SHCS 2** 21 N/A N/A M4 by 25 Long SHCS 1** 22 N/A N/A M4 by 50 Long SHCS 1** 23 N/A N/A M8 by 30 Long BHCS 1** 24 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 63885-8200 are equivalent to 19032-0190/MMT-C-530, 19032-0127, and 19288-0179/ATP-C-530, (UL file number E32244). Doc No. ATS-638858200 Revision: A Release Date: 06-14-07 Revision Date: 06-14-07 UNCONTROLLED COPY Page 4 of 6 Air Feed Mylar Tape Applicator for InsulKrimp™ Ring Tongue Terminal Assembly Drawing 14 12 13 1 14 3 10 19 23 (2) 9 11 20 (2) 8 7 17 2 16 6 18 4 15 21 24 5 Figure 5 22 Doc No. ATS-638858200 Revision: A Release Date: 06-14-07 Revision Date: 06-14-07 UNCONTROLLED COPY Page 5 of 6 Air Feed Mylar Tape Applicator for InsulKrimp™ Ring Tongue Terminal 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-638858200 Revision: A Release Date: 06-14-07 Revision Date: 06-14-07 UNCONTROLLED COPY Page 6 of 6