0638918100

Mini-Mac Applicator for Board-In Crimp Terminals Mini-Mac Applicator Application Tooling Specification Sheet Order No. 63891-8100 FEATURES Directly adapts to most automatic wire processing machines Applicator designed to industry standard mounting and shut height 135.80mm (5.346") Quick set-up time; plus the crimp height, track and feed adjustments can be set without removing the applicator from the press Fine adjustment allows users to achieve target with little effort by adjusting in increments of .015mm (.0006") for conductor crimp height and .063mm (.0025") for insulation height Independent adjustment rings allow users to quickly adjust the conductor or insulation crimp height without affecting each other. SCOPE Products: Board-In-Crimp Terminal, 18-24 AWG. Terminal Series No. Terminal Order No. Wire Size Insulation Diameter IPC/WHMA-A620 (1) Terminal (2) mm In. mm In. Strip Length AWG mm² mm In. 08-70-0106 39-00-0276 98-00-0193 5298 39-00-0132 39-00-0277 98-00-0194 18-24 0.80-0.20 2.50-2.95 .098-.116 1.70-3.05 .067-.120 5.00-6.00 .200-.240 39-00-0230 (1) To achieve optimum IPC-A620 Class 2 insulation crimp, use this insulation diameter (2) Overall insulation diameter specification for terminal. Applicator 63891-8300 should be used for insulation OD 1.70-2.20mm. DEFINITION OF TERMS INSULATION CRIMP 1.80 +0.10/0.00mm (.071 +.004/.000”) Diameter PC Board Hole E D WIRE E CONDUCTOR CRIMP 1.57 ± 0.18 mm (.062 ±-.007”) Thick PC Board F Figure 1 Doc No: ATS-638918100 Revision: A E-E Release Date: 04-11-14 Revision Date: 04-11-14 Section E-E UNCONTROLLED COPY Page 1 of 5 Mini-Mac Applicator for Board-In Crimp Terminals CRIMP SPECIFICATIONS After crimping, the conductor profiles should measure the following (See Figure 1). Terminal Series No. 5298 Wire Size AWG 18 20 22 24 mm2 0.80 0.50 0.35 0.20 D mm 1.14 1.14 1.14 1.14 In .045 .045 .045 .045 Dimensions (Figure 1) E-E mm In. 1.70-1.78 .067-.070 1.70-1.78 .067-.070 1.70-1.78 .067-.070 1.70-1.78 .067-.070 F (Ref.) mm In. 1.40 .055 1.40 .055 1.40 .055 1.40 .055 ►Pull Force Minimum N Lb. 13.30 3.0 13.30 3.0 13.30 3.0 13.30 3.0 ►The crimp on this terminal is not an electrical crimp; the final soldering operation is the electrical connection. This minimum force is what should be expected when pulling the terminal with both insulation and conductor crimped. Notes: 1. The Conductor crimp (D dimension on Figure 1) should be set at the maximum height to contain all wire strands, meet minimum pull, and fit into the PCB Hole. Shimming may be required of the conductor punch to optimize this for different wire types. Doc No: ATS-638918100 Revision: A Release Date: 04-11-14 Revision Date: 04-11-14 UNCONTROLLED COPY Page 2 of 5 Mini-Mac Applicator for Board-In Crimp Terminals PARTS LIST Mini-Mac Applicator 63891-8100 Item Order No Engineering No. Description Quantity Perishable Tooling 63891-8170 63891-8170 Tool Kit (All “Y” Items) REF 1 11-18-4393 60730A104 Conductor Punch 1Y 2 11-18-4391 60730A102 Combination Anvil 1Y 3 11-18-5343 60730B138 Insulation Punch 1Y 4 11-18-5342 60730B136 Barrel Form Punch 1Y 5 11-18-4032 60705A106 Cut-Off Plunger 1Y 6 11-18-4033 60705A107 Cut-off Plunger Retainer 1Y 7 11-18-5406 60730B105 Knock-Out Blade 1Y Other Components 8 11-18-4083 60707-8 Feed Guide 1 9 11-18-4277 60702A108 Rear Plunger Retainer 1 10 11-18-4278 60702A109 Rear Plunger Striker 1 11-18-4394 60758A109 Wire Stop 1 11 12 11-18-4848 60800A123 Spring Retainer 1 13 11-18-4849 60800A124 Wire Hold down Spring 1 14 11-18-5116 60804A141 Compression Spring (Knock-Out) 1 15 11-18-5380 60712G124 Tooling Washer 1 16 11-24-1067 4996-4 Cut-off Plunger Spring 2 17 63443-6130 63443-6130 Rear Cover 1 18 63466-0502 63466-0502 Front Plunger Striker 1 19 63803-5121 63803-5121 Conductor Bushing 1 Frame 20 63801-3201 63801-3201 Top 1 21 63801-3282 63801-3282 Base 1 22 63801-6550 63801-6550 Track 1 Hardware 23 N/A N/A M3 by 6 Long SHCS 2** 24 N/A N/A M4 by 8 Long SHCS 2** 25 N/A N/A M4 by 12 Long BHCS 2** 26 N/A N/A M8 by 30 Long BHCS 1** 27 N/A N/A #6-32 by 3/8 Long BHCS 1** 28 N/A N/A #6-32 by 3/8 Long SHCS 1** 29 N/A N/A #8-32 by 3/8 Long BHCS 4** ** Available from an industrial supply company such as MSC (1-800-645-7270). Doc No: ATS-638918100 Revision: A Release Date: 04-11-14 Revision Date: 04-11-14 UNCONTROLLED COPY Page 3 of 5 Mini-Mac Applicator for Board-In Crimp Terminals Assembly Drawing 4 24 (2) 28 3 15 10 1 12 18 13 20 19 26 14 7 17 25 (2) 22 20 (2) 23 21 8 11 5 9 16 (2) 27 6 29 2 Doc No: ATS-638918100 Revision: A Release Date: 04-11-14 Revision Date: 04-11-14 (4) Figure 2 UNCONTROLLED COPY Page 4 of 5 Mini-Mac Applicator for Board-In Crimp Terminals NOTES 1. Molex recommends an extra perishable tooling kit be maintained at your facility. 2. Verify tooling alignment by manually cycling the press and 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 Manual. 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-638918100 Revision: A Release Date: 04-11-14 Revision Date: 04-11-14 UNCONTROLLED COPY Page 5 of 5