0638925100

Mini-Mac Applicator for Board-In Crimp Terminals Mini-Mac Applicator Specification Sheet Order No. 63892-5100 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 barrel crimp height and .063mm (.0025") for insulation height. See notes on Page 2. Independent adjustment rings allow users to quickly adjust the conductor or insulation crimp height without affecting each other. SCOPE Products: Board-In Crimp Terminal, 22-26 AWG. Terminal Series No. 4811 41817 5190 Insulation Diameter Strip Length Terminal

Terminal Order No. IPC/WHMA-A620
Maximum AWG mm² mm In. mm In. mm In. 16-02-0034 16-02-0047 22-26 0.12-0.35 1.30-1.52 .051-.060 1.52 .060 5.97-6.35 .235-.250 16-02-0118 22-26 0.12-0.35 1.30-1.52 .051-.060 1.52 .060 5.97-6.35 .235-.250 08-70-0060 39-00-0193 22-26 0.12-0.35 1.30-1.70 .051-.067 1.70 .067 5.97-6.35 .235-.250
To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.

Overall insulation OD specification for terminal. Wire Size Terminal Series No. 4811 41817 5190 Doc No: ATS-638925100 Revision: B PC Board Hole “A” Diameter AWG mm² mm In. 16-02-0034 16-02-0047 22-26 0.12-0.35 1.30±.06 .051±.002 16-02-0118 22-26 0.12-0.35 1.30±.06 .051±.002 08-70-0060 39-00-0193 22-26 0.12-0.35 1.24±.08 .048±.003 Terminal Order No. Release Date: 01-23-07 Revision Date: 08-20-09 Wire Size UNCONTROLLED COPY Page 1 of 5 Mini-Mac Applicator for Board-In Crimp Terminals DEFINITION OF TERMS PC Board Hole A Diameter INSULATION CRIMP E D E WIRE E-E CONDUCTOR CRIMP 1.57 ± 0.18 mm (.062 ±-.007”) Thick PC Board F Figure 1 Section E-E CRIMP SPECIFICATIONS After crimping, the conductor profiles should measure the following (See Figure 1). Terminal Series No. 4811-1 41817 5190 Ψ Wire Size AWG 22 24 26 22 24 26 22 24 26 mm2 0.35 0.20 0.12 0.35 0.20 0.12 0.35 0.20 0.12 D mm 0.88-0.97 0.88-0.97 0.88-0.97 0.88-0.97 0.88-0.97 0.88-0.97 0.88-0.97 0.88-0.97 0.88-0.97 Dimensions (Figure 1) E-E In mm In. .035-.038 1.19-1.24 047-.049 .035-.038 1.19-1.24 .047-.049 .035-.038 1.19-1.24 .047-.049 .035-.038 1.19-1.24 047-.049 .035-.038 1.19-1.24 .047-.049 .035-.038 1.19-1.24 .047-.049 .035-.038 1.12-1.17 .044-.046 .035-.038 1.12-1.17 .044-.046 .035-.038 1.12-1.17 .044-.046 F (Ref.) mm In. 0.97 .038 0.97 .038 0.97 .038 0.97 .038 0.97 .038 0.97 .038 0.97 .038 0.97 .038 0.97 .038 Pull Force Minimum N Lb. 13.30 3.0 13.30 3.0 13.30 3.0 13.30 3.0 13.30 3.0 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. The insulation and barrel crimps are adjustable, by the cams (rings) on top of the Mini-Mac ram. The conductor crimp height is not adjustable. Shimming may be required of the conductor punch to optimize this for different wire types. Doc No: ATS-638925100 Revision: B Release Date: 01-23-07 Revision Date: 08-20-09 UNCONTROLLED COPY Page 2 of 5 Mini-Mac Applicator for Board-In Crimp Terminals PARTS LIST Mini-Mac Applicator 63892-5100 Item Order No Engineering No. Description Quantity Perishable Tooling 63892-5170 63892-5170 Tool Kit (All “Y” Items) REF 1 11-18-4272 60702A103 Conductor Punch 1Y 2 11-18-4295 60702A202 Combination Anvil 1Y 3 11-18-4294 60702A201 Insulation Punch 1Y 4 11-18-4271 60702A102 Barrel Form Punch 1Y 5 11-18-4032 60705A106 Cut-Off Plunger 1Y 6 11-18-4033 60705A107 Cut-off Plunger Retainer 1Y 7 11-18-4276 60702A107 Rear Cut-Off Plunger and Wire Stop 1Y 8 11-18-4277 60702A108 Rear Cut-off Plunger Retainer 1Y Other Components 9 11-18-4034 60705A108 Front Plunger Striker 1 10 11-18-4083 60707-8 Feed Guide 1 11 11-18-4278 60702A109 Rear Plunger Striker 1 12 11-18-4279 60702A110 Tooling Washer 1 13 11-18-4282 60702A113 Rear Cover 1 14 11-24-1067 4996-4 Cut-off Plunger Spring 2 15 63803-5108 63803-5108 Conductor Bushing 1 Frame 16 63801-3201 63801-3201 Top 1 17 63801-3282 63801-3282 Base 1 18 63801-6550 63801-6550 Track 1 Hardware 19 N/A N/A M3 by 8 Long SHCS 2** 20 N/A N/A M4 by 8 Long SHCS 2** 21 N/A N/A M4 by 8 Long BHCS 2** 22 N/A N/A M8 by 20 Long BHCS 1** 23 N/A N/A #6-32 by 3/8” Long BHCS 1** 24 N/A N/A #6-32 by 3/8” Long SHCS 1** 25 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-638925100 Revision: B Release Date: 01-23-07 Revision Date: 08-20-09 UNCONTROLLED COPY Page 3 of 5 Mini-Mac Applicator for Board-In Crimp Terminals Assembly Drawing 20 4 (2) 24 15 3 11 1 9 16 12 22 (2) 21 13 18 (2) 16 19 17 10 7 5 8 (2) 14 23 6 25 2 Doc No: ATS-638925100 Revision: B Release Date: 01-23-07 Revision Date: 08-20-09 (4) Figure 1 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 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-638925100 Revision: B Release Date: 01-23-07 Revision Date: 08-20-09 UNCONTROLLED COPY Page 5 of 5