Application Specification AMPINNERGY* Wire- to- Wire (WTW) Connectors NOTE i 114-- 6051 11 DEC 09 Rev C All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2_. Figures and illustrations are for identification only and are not drawn to scale. 1. INTRODUCTION This specification covers the requirements for application of AMPINNERGY WTW Connectors. A mating connector consists of two hermaphroditic housings, each loaded with a terminated hermaphroditic contact. The connectors are stackable in four directions and may be used as free hanging applications, surface mounted, or panel mounted. Built--in interlocking features provide the connectors and accessory mounting adapter with resistance to shock and vibration. This application specification obsoletes Instruction Sheet 408--3198. When corresponding with Tyco Electronics Personnel, use the terminology provided on this specification to help facilitate your inquiry for information. Basic terms and features of components are provided in Figure 1. Contact without Insulation Barrel Hermaphroditic Housing Contact with Insulation Barrel Hermaphroditic Housing Alignment Slot Contact Insertion Opening NOTE: Not to scale. Alignment Tab Optional External Locking Latch Mounting Adapter Figure 1 2. REFERENCE MATERIAL 2.1. Revision Summary S Updated to current application specification requirements S New logo and format 2.2. Customer Assistance Reference Part Number 556137 and Product Code 3951 are representative of AMPINNERGY WTW Connectors. These numbers are used in a customer service network to access tooling and product application information. This service is provided by your local Tyco Electronics Representative or, after purchase, by calling the Tooling Assistance Center or the Product Information number at the bottom of this page . TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111 E2009 Tyco Electronics Corporation, Harrisburg, PA PRODUCT INFORMATION 1-- 800-- 522-- 6752 All International Rights Reserved TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 14 LOC B AMPINNERGY WTW Connectors 114- 6051 2.3. Drawings Customer Drawings for specific products are available from the responsible Tyco Electronics Engineering Department via the service network. The information contained in the Customer Drawing takes priority if there is a conflict with this specification or any other technical documentation supplied by Tyco Electronics. 2.4. Specifications Product Specification 108--1373 provides product performance requirements and test information for these connectors. 2.5. Instructional Material The following list includes available instruction sheets (408--series) that provide assembly procedures for product, operation, maintenance and repair of tooling, and customer manuals (409--series) that provide setup, operation, and maintenance of machines. Document Number Document Title 408--2095 408--3277 408--3295 408--4105 408--4190 408--7424 408--8040 408--8053 408--9685 408--9807 408--9816 408--9905 409--5128 409--5842 409--5852 409--5862 409--5878 Hand Crimping Tool 69710--1 AMPINNERGY Wire to Wire Stackable Connectors Preparing Reel of Contacts for Application Tooling Straight Action Crimper 217200--1 C--Head Pneumatic Adapter 318161--1 Checking Terminal Crimp Height or Gaging Die Closure Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type) Conversion Guide for Miniature Quick--Change Applicators Extraction Tool 844751--2 Crimping Die Assemblies 58490--1 and 58491--1 Handling of Reeled Products Crimping Die Assemblies 58492--1 and 58493--1 Basic AMP--O--LECTRIC* Model "K" Terminating Machines, and Accessories AMP--O--LECTRIC Model "G" Terminating Machine 354500--1 AMPOMATOR* CLS III--G Lead--Making Machine 626 Pneumatic Tool Assemblies 189721--[ ] and 189722--[ ] AMPOMATOR CLS IV+ Lead--Making Machine 3. REQUIREMENTS 3.1. Storage A. Ultraviolet Light Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housing material. B. Reel Storage When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically. C. Shelf Life The contacts and housings should remain in the shipping containers until ready for use to prevent deformation to those components. The components should be used on a first in, first out basis to avoid storage contamination that could adversely affect signal transmissions. D. Chemical Exposure Do not store contacts near any chemicals listed below as they may cause stress corrosion cracking in the contacts. Alkalies Amines NOTE i 2 of 14 Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfides Nitrites Sulfur Compounds Tartrates Where the above environmental conditions exist, phosphor--bronze contacts are recommended instead of brass if available. Tyco Electronics Corporation Rev C AMPINNERGY WTW Connectors 114- 6051 3.2. Special Characteristics AMPINNERGY WTW Connectors are single--position, hermaphroditic housings available in different colors for circuit coding and identification. The housings are stackable in four different directions through the use of molded interlocking keys and keyways. The housings are designed for free hanging, panel mounting, or surface mounting applications with accessory mounting adapters. The contacts are supplied in strip or loose piece form. Strip form contacts are designed to be crimped by a miniature quick--change applicator used in a Terminating Machine. Loose piece form contacts are designed to be crimped by a die assembly used in a Pneumatic Adapter or Hand Crimping Tool. 3.3. Wire Selection AMPINNERGY WTW Contacts will accept wire sizes and insulation diameters listed in Figure 2, along with the strip lengths, crimp heights, and crimp widths. CAUTION DO NOT nick, cut, or scrape the wire conductor during the stripping operation. ! The applied crimp dimension (within the functional range of the product) is dependent on the termination tooling being used. Refer to the documentation (applicator logs and instruction sheets) supplied with the termination tooling for the applied crimp height. See Section 5, TOOLING. NOTE i INSULATION DIAMETER RANGE WIRE SIZE ------ 18 2.11--2.3 [.083--.118] ------ 16 2.11--2.3 [.083--.118] ------ 14 12 10 WIRE BARREL CRIMP WIDTH HEIGHT (REF) STRIP LENGTH 5 54 6 35 [.218--.250]s 5.54--6.35 [ 218 250]s 2.11--2.3 [.083--.118] -----3.71--4.29 [.146--.169] -----3.71--4.29 [.146--.169] sApplicators only 6.35 7.14 [.250 6.35--7.14 [.250--.281]s .281]s 7.87--8.66 [.310--.341]u [ ] 2 26 2 16 [.089--.085] 2.26--2.16 [ 089 085] 3.56 [.140] 2 36 2 16 [.093--.085] 2.36--2.16 [ 093 085] INSULATION BARREL CRIMP HEIGHT ------ BELLMOUTH CRIMP HEIGHT 2.97--2.47 2.97 2.47 [.117--.097] 3.56 [.140] 3.15--2.95 [.124--.116] -----3.45--3.25 [.136--.128] 3.07--2.57 3.07 2.57 [.121--.101] 2 54 2 39 [.100--.094] 2.54--2.39 [ 100 094] 3.56 [.140] -----3.95--3.75 [.156--.148] 3.25--2.75 3.25 2.75 [.128--.108] 2 97 2 79 [.117--.110] 2.97--2.79 [ 117 110] 4.57 [.180] 3.68--3.18 3.68 3.18 [.145--.125] 3 33 3 15 [.131--.124] 3.33--3.15 [ 131 124] 4.57 [.180] -----4.55--4.35 [.179--.171] -----5.15--4.95 [.203--.195] 4.03--3.53 4.03 3.53 [.159--.139] UDie Assembly only Figure 2 3.4. Crimped Contact Requirements Locate the contact to be crimped in the appropriate tooling according to the instructions packaged with that tooling. Detailed instructions covering the placement of contacts in the tooling and the use of such tooling is packaged with each tool. Terminate the contact according to the directions shipped with the appropriate tooling. See Section 5, TOOLING. CAUTION ! NOTE Wire insulation shall NOT be cut or broken during the crimping operation, nor shall the insulation be crimped into the contact wire barrel. Reasonable care should be taken by tooling operators to provide undamaged wire terminations. Periodic inspections must be made to ensure crimped contact formation is consistent as shown. i Rev C Tyco Electronics Corporation 3 of 14 AMPINNERGY WTW Connectors 114- 6051 A. Wire Barrel Crimp Height The crimp applied to the wire portion of the contact is the most compressed area and is most critical in ensuring optimum electrical and mechanical performance of the crimped contact. The crimp height must be within the dimensions provided in Figure 3. B. Wire Barrel Crimp Length For optimum crimp effectiveness, the crimp must be within the area shown and must meet the crimp dimensions provided in Figure 2. Effective crimp length shall be defined as that portion of the wire barrel, excluding bellmouth(s), fully formed by the crimping tool. Instructions for adjusting, repairing, and inspecting tools are packaged with the tools. See Figure 16. C. Bellmouth Crimp Height Rear bellmouth crimp height shall be evident and conform to the dimensions given in Figure 3. D. Cutoff Tab The cutoff tab shall be cut to the dimensions shown in Figure 3. NOTE: Contact without Insulation Barrel Shown End of Wire to be Flush to 1.52 [.060] Max from End of Wire Barrel No Wire Strands Showing In This Area Crimp Length No Front Bellmouth Insulation Does Not Enter Wire Barrel Bellmouth Crimp Height X X See View A Wire Barrel Crimp Width 0.13 [.005] Max. Wire Barrel Flash View A 0.00 - 0.38 [.000 - .015] Cutoff Tab Wire Barrel Crimp Height 0.13 [.005] Max. Burr Section X- X Figure 3 (cont'd) 4 of 14 Tyco Electronics Corporation Rev C AMPINNERGY WTW Connectors 114- 6051 End of Wire to be Flush to 1.52 [.060] Max from End of Wire Barrel NOTE: Contact with Insulation Barrel Shown No Wire Strands Showing In This Area Crimp Length No Front Bellmouth Wire and Insulation Must Both Be Visible In This Area Bellmouth Crimp Height X X See View A 0.13 [.005] Max. Burr View A Wire Barrel Crimp Width Wire Barrel Crimp Height 0.13 [.005] Max. Wire Barrel Flash 0.00 - 0.38 [.000 - .015] Cutoff Tab Section X- X Figure 3 (end) E. Burrs The cutoff burr shall not exceed the dimensions shown in Figure 3 in view A. F. Wire Barrel Flash The wire barrel flash shall not exceed the dimensions shown in Figure 3 in Section X--X. G. Wire Location After crimping, the wire conductor and insulation must be visible in the transition area between the wire and insulation barrels. H. Conductor Location The conductor may extend beyond the wire barrel to the maximum shown in Figure 3. I. Wire Barrel Seam The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam. J. Twist and Roll There shall be no twist, roll, deformation, or other damage to the mating portion of the crimped contact that will prevent proper mating. See Figure 4. Rev C Tyco Electronics Corporation 5 of 14 AMPINNERGY WTW Connectors 114- 6051 15_ (Max) Wire Barrel Front of Receptacle Contact Figure 4 K. Straightness The force applied during crimping may cause some bending between the crimped wire barrel and the mating portion of the contact. Such deformation is acceptable within the following limits. 1. Up and Down The crimped contact, including cutoff tab and burr, shall not be bent above or below the datum line more than the amount shown in Figure 5. 2. Side to Side The side--to--side bending of the contact may not exceed the limits provided in Figure 5. Datum Line 3_ (Max) 3_ (Max) Datum Line 3_ (Max) NOTE: Angles are drawn for clarification only and are not to scale. 3_ (Max) Figure 5 3.5. Tensile Strength Crimped contacts should hold the wire firmly and have a crimp pull--out test value meeting that specified in the table in Figure 6. 6 of 14 Tyco Electronics Corporation Rev C AMPINNERGY WTW Connectors NOTE i 114- 6051 Adjust tensile testing machine for head travel of 25.4 mm [1 in.] per minute. Directly and gradually apply force for 1 minute. WIRE BARREL CRIMP PULL-- OUT TEST Minimum Force Newtons Pounds 89 20 Wire Size, AWG 18 16 133 30 14 222 50 12 311 70 10 356 80 Figure 6 3.6. Assembly and Contact Installation A. Housing Assembly Align key on one housing with keyway on other housing as shown in Figure 7. Slide housing forward until special locking feature is engaged (an audible click). Repeat this procedure until desired multiple assembly is engaged. Key Multiple Assembly Keyway Figure 7 B. Contact Installation Orient crimped contact so that the stabilizing ears align with the housing slots as shown in Figure 8. Insert contact into housing until it bottoms, and audible click is heard or felt. Pull back lightly on wire to assure retention of crimped contact in housing. Repeat this procedure for multiple assembly. Stabilizing Ears Crimped Contact Housing Contact Slot Figure 8 C. Mounting Adapter The mounting adapter is available in black only. It is designed to slide into the molded keyways of the housing and allow the connector to be surface mounted or panel mounted. See Figure 9. Rev C Tyco Electronics Corporation 7 of 14 AMPINNERGY WTW Connectors 114- 6051 Mounting Adapter In Place Housing Mounting Adapter Figure 9 3.7. Strain Relief When bending or forming wires, hold wires at least 6.35 mm [.250 in.] beyond rear of connector before bending them in desired direction. CAUTION Do not bend unsupported wires. This may put strain on the contacts inside the connectors. ! Provide strain relief for wires approximately 25.4 mm [1 in.] from rear of housing if the installation is to be subjected to bending forces. 3.8. Panel Mounting Slide accessory mounting adapters onto appropriate housings until locking feature is engaged (an audible click). See Figure 9. Cut panel opening as required for single or multiple position connectors, see Figure 10. Insert connector through panel cutout and secure connector with 8--32 screws and nuts or equivalent (customer supplied). Mounting Hole Dia (Typ) 4.19 [.165] Panel X Width 8-- 32 Nut Height 4.83 [.190] WIDTH = Multiples of 9.68 + 1.02 [.381 + .040] HEIGHT = Multiples of 9.68 + 1.02 [.381 + .040] X = Multiples of 9.68 + 10.16 [.381 + .400] 8-- 32 Screw Figure 10 8 of 14 Tyco Electronics Corporation Rev C AMPINNERGY WTW Connectors 114- 6051 3.9. Surface Mounting Slide accessory mounting adapters onto appropriate housings until locking feature is engaged (an audible click). See Figure 9. Drill holes as indicated in Figure 11 and secure connector with 8--32 screws and nuts or equivalent (customer supplied). 7.47 [.294] X 8-- 32 Screw Back Edge of Mounting Adapter 4.19 [.165] Dia (Typ) X = Multiples of 9.68 + 10.16 [.381 + .400] PC Board 8-- 32 Nut Figure 11 3.10. Mating Connectors Orient housing alignment slot with housing alignment tab. Snap mating connectors together; see Figure 12. Alignment Slot Surface Mount Panel Mount Alignment Tab Figure 12 3.11. Disassembly Procedures A. Contact Removal DANGER Rev C To avoid personal injury, disconnect the electrical supply prior to removing contacts. Tyco Electronics Corporation 9 of 14 AMPINNERGY WTW Connectors 114- 6051 The contact is retained in the housing by an internal latch. It is necessary to deflect the latch upward to remove the contact. Align blade of Extraction Tool 844751--2 (408--9685) with FRONT of connector. Insert blade between the contact and the internal latch. While pulling lightly on contact wire, lift up internal latch and pull contact from housing. See Figure 13. Contact Extraction Tool Internal Latch Figure 13 B. Separate Housings and Mounting Adapters Insert a flat tip screwdriver between a housing and a mounting adapter, or between two housings as shown in Figure 14. Twist screwdriver to pry apart connectors. Screwdriver Figure 14 3.12. External Locking Latch An external locking latch is available for AMPINNERGY WTW Connectors for extra mated retention force. This latch provides approximately 100 lbs of retention force. See Figure 15. External Locking Latch Mated Housings Figure 15 10 of 14 Tyco Electronics Corporation Rev C AMPINNERGY WTW Connectors 114- 6051 4. QUALIFICATIONS AMPINNERGY WTW Connectors are Listed by Underwriters Laboratories Inc. (UL) in File E28476, and Certified by CSA International, in File LR7189. 5. TOOLING This section provides a selection of tools for various application requirements. They include hand tools for manual application of loose piece form contacts, and semi--automatic and automatic machines for power assist application of strip form contacts. Modified designs and additional tooling concepts may be available to meet other application requirements. For additional information, contact one of the service groups at the bottom of page 1. A listing of tooling recommendations covering the full wire size range is provided in Figure 16. NOTE i WIRE SIZED DTerminals will accept one each wire sizes 18, 16, and 14 or combinations of 18 and 16 AWG wire. Terminals will also accept one each wire sizes 12 or 10, or combinations of 12, 18, 16, and 14 AWG wire. [Use with 626 Pneumatic Tooling Assemblies 189721--2 or 189722--2. INSUL RANGE STRIP LENGTH APPL (408- 8040) POWER UNIT (DOC) HAND TOOL (DOC) DIE ASSY (DOC) CRIMPING HEAD[ (DOC) PNEU HOLDER[ (DOC) EXT TOOL (408- 9685) 69710-- 1 69710 (408-- 2095) 58493-- 1 58493 (408-- 9905) --- --- 844751 - 2 844751- --- --- --- --- 844751 - 2 844751- 69710-- 1 (408-- 2095) 189721 189721-- 2 (409-- 5862) 189722-- 2 (409 - 5862) (409- 58492 - 1 58492(408-- 9905) 217200-- 1 (408 - 4105) (408318161-- 1 (408- 4190)) ( 189928-- 1 189928 (408-- 4190) 844751 - 2 844751- 122500-- 2, - 3 (409-- 5852) 567403-- 1 18 - 16 18- --- 356500-- 1, - 2 (409-- 5878) 1213400-- 1, - 2 (409-- 5878) --567403 - 2 567403- 567403-- 3 354500-- 1 (409-- 5842) 565435-- 5 (409-- 5128) 354500-- 1 (409-- 5842) 122500-- 2, - 3 (409-- 5852) 680447-- 1 18 - 16 1816-- 14 2.11 - 2.3 2.11[.083-- .118] 1213400-- 1, - 2 (409-- 5878) 5.54 - 6.35 5.54[.218-- .250] 680447 - 2 680447- 680447-- 3 567403-- 1 14 --- 356500-- 1, - 2 (409-- 5878) --567403 - 2 567403- 567403-- 3 354500-- 1 (409-- 5842) 565435-- 5 (409-- 5128) 354500-- 1, - 2, - 9 (409-- 5842) 122500-- 2, - 3 (409-- 5852) 356500-- 1, - 2 (409-- 5878) 1213400-- 1, - 2 (409-- 5878) 354500-- 1 (409-- 5842) 565435-- 5 (409-- 5128) 354500-- 1 (409-- 5842) Figure 16 (cont'd) Rev C Tyco Electronics Corporation 11 of 14 AMPINNERGY WTW Connectors WIRE SIZED INSUL RANGE STRIP LENGTH 114- 6051 APPL (408- 8040) 567256-- 3 12 --- --- 567256 - 4 567256- 680449-- 1 12 - 10 12- 3.71-- 4.29 3.71 [.146-- .169] 6.76-- 7.54 6.76 [.266-- .297] 680449 - 2 680449- 680449 - 3 680449- 567256-- 3 10 --- --- 567256 - 4 567256- POWER UNIT (DOC) 122500-- 2, - 3 (409-- 5852) 356500-- 1, - 2 (409-- 5878) 1213400-- 1, - 2 (409-- 5878) 354500-- 1 (409-- 5842) 565435-- 5 (409-- 5128) 122500-- 2, - 3 (409-- 5852) 356500-- 1, - 2 (409-- 5878) 1213400-- 1, - 2 (409-- 5878) 354500-- 1 (409-- 5842) 565435-- 5 (409-- 5128) 354500-- 1, - 2, - 9 354500 (409-- 5842) 122500-- 2, - 3 (409-- 5852) 356500-- 1, - 2 (409-- 5878) 1213400-- 1, - 2 (409-- 5878) 354500-- 1 (409-- 5842) 565435-- 5 (409-- 5128) HAND TOOL (DOC) DIE ASSY (DOC) CRIMPING HEAD[ (DOC) PNEU HOLDER[ (DOC) EXT TOOL (408- 9685) 69710-- 1 (408-- 2095) 189721-- 2 (409- 5862)) ( 189722-- 2 (409-- 5862) 58490-- 1 (408-- 9807) (408 217200-- 1 (408-- 4105) 318161-- 1 318161 (408-- 4190) 189928-- 1 (408(408 - 4190) 844751-- 2 --- --- --- --- 844751 - 2 844751- 58491-- 1 9807)) ((40808 - 980 217200-- 1 (408-- 4105) 318161-- 1 318161 (408-- 4190) 189928-- 1 (408( 08 - 4190) 90) 844751-- 2 69710-- 1 (408-- 2095) 189721-- 2 (409 - 5862) (409189722-- 2 (409-- 5862) Hand Tool 69710--1 Pneumatic Tool Holder 189928--1 with C--Head Adapter 318161--1 Extraction Tool 844751--2 Crimping Die Assembly (Typ) Pneumatic Tool Holder 189928--1 with Straight Action Adapter 217200--1 Figure 16 (cont'd) 12 of 14 Tyco Electronics Corporation Rev C AMPINNERGY WTW Connectors 114- 6051 Typical Heavy Duty Mini--Applicator 626 Pneumatic Hand Tool Assemblies 189721--[ ] and 189722--[ ] AMP--O--LECTRIC Model "G" Terminating Machine 354500--[ ] AMPOMATOR CLS IV+ Lead--Making Machine 356500--[ ] or 1213400--[ ] AMP--O--LECTRIC Model "K" Terminating Machine 565435--5 AMPOMATOR CLS III--G Lead--Making Machine 122500--[ ] Figure 16 (end) Rev C Tyco Electronics Corporation 13 of 14 AMPINNERGY WTW Connectors 114- 6051 6. VISUAL AID Figure 17 shows a typical application of AMPINNERGY WTW Connectors. This illustration should be used by production personnel to ensure a correctly applied product. Applications which DO NOT appear correct should be inspected using the information in the preceding pages of this specification and in the instructional material shipped with the product or tooling. NO CONDUCTOR WIRES SHOWING IN WIRE BARREL SEAM NO DAMAGE OR DISTORTION TO CONTACT CONNECT0R MUST NOT BE CRACKED OR DAMAGED HARDWARE MUST BE SECURELY TIGHTENED HARDWARE MUST BE SECURELY TIGHTENED RECEPTACLE CONNECTOR MUST BE SEATED ON PC BOARD CONTACTS MUST BE LOCKED IN CONNECTOR CAVITY PLUG CONNECTOR AND RECEPTACLE CONNECTOR MUST BE LATCHED TOGETHER FIGURE 17. 14 of 14 VISUAL AID Tyco Electronics Corporation Rev C