Application Specification
114--10011
LOC B
1of 11
E2009 Tyco Electronics Corporation, Harrisburg, PA
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.
TOOLING ASSISTANCE CENTER 1--800--722--1111
PRODUCT INFORMATION 1--800--522--6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
Audio/Microphone Connectors 09 DEC 09 Rev B
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 the application of Audio/Microphone Connectors. The connectors
are designed to accept a wire size range of 18 through 28 AWG and are available in 4, 5, or 6 position. The
receptacle connector is panel mounted. Application may be done by machine for reel--mounted contacts and
by hand for replacement loose piece contacts.
‘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.
Figure 1
Socket Contact
Pin Contact 6--Position Receptacle
Housing (Typ)
Mounting Fins
Locking Tab
Entry Slot
Antirotation
Key
Locking Collar
Polarizing
Groove
Front (Ref)
Engagement
Groove
Plug Insert
Alignment
Groove
Locking Latch
Numbered
Contact
Cavities
Strain Relief
Collets
Polarizing Rib
(On Mating Face)
Latch Slot
Detent Plug Body
Flexible Cable Guard
Locking Tab
NOTE
i
Audio/Microphone Connectors 114- 10011
Rev B2 of 11 Tyco Electronics Corporation
2. REFERENCE MATERIAL
2.1. Revision Summary
This paragraph is reserved for a revision summary of the most recent additions and changes made to this
specification which include the following:
SUpdate specification to current corporate requirements
SNew logo and format
2.2. Customer Assistance
Reference Part Number 207313 and Product Code 4989 are representative numbers of Audio/Microphone
Connectors. Use of these numbers will identify the product line and expedite your inquiries through a service
network established to help you obtain product and tooling information. Such information can be obtained
through a local Tyco Electronics Representative or, after purchase, by calling the Tooling Assistance Center or
Product Information numbers at the bottom of page 1.
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. The information
contained in Customer Drawings takes priority if there is a conflict with this specification or with any other
technical documentation supplied by Tyco Electronics.
2.4. Specifications
Product Specification 108--10032 is available to provide test and performance results.
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, as well as setup and operation procedures of
applicators; and customer manuals (409--series) that provides setup, operation, and maintenance of machines.
Document Number Document Title
408--3295 Preparing Reel of Contacts for Application Tooling
408--4392 Hand Crimping Tool 90715--1
408--7347 Insertion Tools 91002--1 and --2
408--7424 Checking Terminal Crimp Height or Gaging Die Closure
408--7819 Audio Instrument Connectors
408--7859 Extraction Tool 91136--1
408--7901 Hand Crimping Tool 90363--1
408--8040 Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type)
408--9816 Handling of Reeled Products
409--5128 Basic AMP--O--LECTRIC* Model “K” Terminating Machines, and Accessories
409--5842 AMP--O--LECTRIC Model “G” Terminating Machine 354500--[ ]
409--5855 AMP--O--MATIC* Side Feed Stripper--Crimper Model II Machine No. 854040--3 and --4
409--5866 AMPOMATOR* CLS IV Lead--Making Machine 217500--[ ]
3. REQUIREMENTS
3.1. Storage
A. Reeled Contacts
When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically.
B. Shelf Life
The contacts and housings should remain in the shipping containers until ready for use to prevent
deformation to the contacts and/or damage to the housings. The products should be used on a first in, first
out basis to avoid storage contamination that could adversely affect signal transmissions.
C. Chemical Exposure
Do not store contacts or housings near any chemicals listed below, as they may cause stress corrosion
cracking in the components.
Audio/Microphone Connectors 114- 10011
Rev B 3 of 11Tyco Electronics Corporation
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfur Nitrites Tartrates
D. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housings.
3.2. Special Characteristics
These Audio/Microphone connectors include a panel mounted receptacle connector and a free--hanging plug
connector. The receptacle connector consists of a receptacle housing and the specified number of socket
contacts. The housing features a locking collar, two locking tab entry slots, an antirotation key, and four
mounting fins.
The plug connector consist of a plug insert, a plug body, and the specified number of pin contacts. The insert
features two cable strain relief collets, a locking latch, an alignment groove, and an engagement groove. The
body features two locking tabs, a latch slot, a detent, and a flexible cable guard.
Each receptacle has a polarizing groove and each plug insert has a polarizing rib to ensure proper mating.
Contact cavities are numbered on the BACK of each connector to provide circuit identification. See Figure 1.
3.3. Panel Mounting Requirements
Audio/Microphone Connectors are designed for a combination of free--hanging and rear panel mount
application. For dimensions and layout design, refer to Figure 2.
Figure 2
17.78
[.700]
1.02 [.040]
3.18 [.125]
Panel Thickness
1.47--1.78
[.058--.070]
3.4. Wire Selection and Preparation
A. Type
The wire size range for Audio/Microphone Connectors is 18 through 28 AWG and may be solid or
stranded.
Contacts which accept a wire size range of 18--20 AWG are special large conductor contacts which only fit into
customer--supplied audio/microphone connectors.
B. Preparation
Prior to stripping the discrete wires, remove 20.65 mm [.813 in.] of the cable jacket.
NOTE
i
NOTE
i
Audio/Microphone Connectors 114- 10011
Rev B4 of 11 Tyco Electronics Corporation
The discrete wires must be stripped to the dimension provided in Figure 3.
Do not nick, scrape, or cut the wire conductor during the stripping operation.
Strip Length
Wire
Insulation
Discrete Wire
INSULATION WIRE SIZE
,
STRIP WIRE BARREL INSULATION BARREL
I
N
S
U
L
A
T
I
O
N
DIAMETER
W
I
R
E
S
I
Z
E
,
AWG
S
T
R
I
P
LENGTH CRIMP HEIGHT CRIMP WIDTH CRIMP HEIGHT CRIMP WIDTH
1
8
3.18--3.94D
[.125--.155] 0.97--1.07
2.03--2.54
18 3.56--4.32[
[.140--.170]
0
.
9
7
1
.
0
7
[.038--.042]
1.52--1.75 2.74--3
2
.
0
3
2
.
5
4
[.080--.100]
2
0
3.18--3.94D
[.125--.155] 0.81--0.91
1
.
5
2
1
.
7
5
[.060--.069]
ADJUSTABLE
(
B
S
h
d
2
.
7
4
3
[.108--.118]
20 3.56--4.32[
[.140--.170]
0
.
8
1
0
.
9
1
[.032--.036] (Barrel Should
Grip Insulation
W
t
h
o
u
t
C
u
t
t
n
g
22 0.64--0.74
[.025--.029]
W
t
h
ou
t
C
u
t
t
ng
Into It)
0.91--1.37
[.036--.054] 24 3.58--4.34U
[.141--.171]
0.521--0.660
[.0205--.0260]
1.27--1.52
[.050--.060]
1.45--1.7
[.057--.067]
[
0
3
6
0
5
]
2
6
2
8
[
]
0.51--0.61
[
0
5
0
0
6
0
]
[
0
5
0
6
]
26--28
0
.
5
1
0
.
6
1
[.020--.024]
DAutomatic Machine Crimp Dimensions, [Hand Tool Crimp Dimensions, UBoth Machine and Hand Tool Crimp Dimensions
Figure 3
3.5. 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.
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.
A typical receptacle contact as it should appear after crimping is shown in Figure 4. These requirements apply
equally to the pin contact.
A. 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.
CAUTION
!
CAUTION
!
Audio/Microphone Connectors 114- 10011
Rev B 5 of 11Tyco Electronics Corporation
B. Crimp Length
For optimum crimp effectiveness, the crimp must be within the area shown in Figure 4. 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 10.
C. Bellmouths
Front and rear bellmouths shall be evident and conform to the dimensions given in Figure 4.
D. Cutoff Tab
The cutoff tab shall be cut to the dimensions shown in Figure 4.
E. Burrs
The cutoff burr shall not exceed the dimensions shown in Figure 4.
F. Wire Barrel Flash
The wire barrel flash shall not exceed the dimensions shown in Figure 4 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 4.
I. Wire Barrel Seam
The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam.
Figure 4
0.13 [.005]
Max. Burr
Cutoff Tab 0.25
[.010] Max
0.25 [.010] Max.
Wire Barrel
Flash
View A
Section X- X
Wire Barrel
Crimp Height
Cutoff Tab Must Be
Visible -- See View A
X
X
No Damage or Distortion to the
Contact or the Locking Lance
Conductor Extension
0.51 [.020] Max
Wire Insulation and
Conductors Must Both
BeVisibleinThisArea
Rear Bellmouth
0.18--0.30 [.007--.012]
Wire
Barrel Flash
Front Bellmouth
0.20 [.008] Max
Effective Crimp Length
Wire Barrel Seam
Wire Barrel
Crimp Width
Audio/Microphone Connectors 114- 10011
Rev B6 of 11 Tyco Electronics Corporation
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 5.
Figure 5
Front of
Contact
(Pin or Socket)
0_
Wire Barrel
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 6.
Figure 6
NOTE: Angles are drawn for clarification only and are not to scale.
Datum Line 0.25 [.010] Max
0.25 [.010] Max
2. Side to Side
The side--to--side bending of the contact may not exceed the limits provided in Figure 7.
Periodic inspections must be made to ensure crimped contact formation is consistent as shown.
NOTE
i
Audio/Microphone Connectors 114- 10011
Rev B 7 of 11Tyco Electronics Corporation
Figure 7
0.25 [.010] Max
0.25 [.010] Max
3.6. Housings
Housings are available in 4, 5, or 6 circuit positions for your production requirements. Figure 8 shows the
housing configurations. The housings are made from black thermoplastic.
Figure 8
4--Position 5--Position 6--Position
Numbered Cavities
Mounting Fins
Antirotation Key
Locking Tab
Entry Slot
Audio/Microphone Connectors 114- 10011
Rev B8 of 11 Tyco Electronics Corporation
3.7. Assembly Procedures
Instruction Sheet 408--7819 provides specific assembly procedures. Figure 9 shows how the product fits
together. Insertion Tool 91002--[ ] may be used to help insert terminated wires and contacts into the housings if
needed. Refer to Instruction Sheet 408--7347.
Figure 9
Panel
Locking Tab
Detent
Cable
Discrete Wires
Alignment Groove
Entire Length of Collets
Must Grip Cable Jacket
Polarizing Rib
Contacts Inserted Into
Back of Plug Insert
Plug
Insert
Mounting
Fins
After Mating,
Turn Clockwise
to Tighten
Locking Tab Slot
3.8. Repair/Replacement
If a damaged contact is apparent before the contacts are inserted into the housing, cut the wire in back of the contact
and reterminate the wire end. If contacts or housing are damaged after insertion, the wire must be cut directly in back
of the housing and reterminated with new contacts and housing. See Section 5, TOOLING.
Contacts are not repairable once a termination has been made. Any defective contact should be removed and
replaced with a new one. Damaged contacts can be removed from the housing by using Extraction Tool
91136--1. Refer to Instruction Sheet 408--7859 for extraction procedures.
4. QUALIFICATION
Audio/Microphone Connectors are not required to be agency approved.
CAUTION
!
Audio/Microphone Connectors 114- 10011
Rev B 9 of 11Tyco Electronics Corporation
5. TOOLING
Figure 10 provides tool part numbers and instructional material related to wire size.
Tyco Electronics Tool Engineers have designed machines for a variety of application requirements. For assistance in
setting up prototype and production line equipment, contact Tyco Electronics Tool Engineering through your local Tyco
Electronics Representative or call the Tooling Assistance Center number at the bottom of page 1.
SHand Crimping Tool
Hand crimping tools that accommodate the full wire size range are designed for prototype and
low--volume applications such as repair of damaged contacts.
SApplicator
Applicators are designed for the full wire size range of strip--fed, precision formed contacts, and provide
for high volume, heavy duty, production requirements. The applicators can be used in bench or floor
model power units.
Each applicator is shipped with a metal identification tag attached. DO NOT remove this tag or disregard the
information on it. Also, a packet of associated paperwork is included in each applicator shipment. This information
should be read before using the applicator; then it should be stored in a clean, dry area near the applicator for future
reference. Some changes may have to be made to the applicators to run in all related power units. Contact the Tooling
Assistance Center number located at the bottom of page 1 for specific changes.
SPower Units
A power unit is an automatic or semi--automatic device used to assist in the application of a product.
Power unit includes the power source used to supply the force or power to an applicator.
The Model “K” AMP--O--LECTRIC Terminating Machine PN 565435--5 has been superseded by the Model “G”
Terminating Machine PN 354500--1 (409--5842) for new applications. For existing applications, the Model “K” is still
recommended because of the large number of installed machines.
SInsertion Tools
Insertion Tools are designed for contacts crimped to small fragile wire. They are designed to stabilize the
contact during insertion.
SExtraction Tools
Extraction Tools are designed to release the locking lance inside the connector housing without
damaging the housing or contacts.
INSULATION
DIAMETER
WIRE SIZE,
AWG
APPLICATOR
(DOCUMENT)
POWER UNIT
(DOCUMENT)
HAND TOOL
(DOCUMENT)
680402--1 (408--8040) 217500--[ ] (409--5866)
2.03--2.54
1
8
2
0
6
8
0
4
0
2
2
(
4
0
8
8
0
4
0
)
565435--5 (409--5128) 90715--1
2
.
0
3
2
.
5
4
[.080--.100] 18--20 680402--2
(
408--8040
)
354500--1 (409--5842)
9
0
7
1
5
1
(408--4392)
680402--3 (408--8040) 354500--[ ] (409--5842)
(
)
4
6
6
6
4
4
3
(
4
0
8
8
0
4
0
)
565435--5 (409--5128)
0.91--1.37
2
2
2
8
466644--3
(
408--8040
)
354500--1 (409--5842) 90363--1
0
.
9
1
1
.
3
7
[.036--.054] 22--28 466644--4 (408--8040) 354500--[ ] (409--5842)
9
0
3
6
3
1
(408--7901)
466966--1 (409--5855) 854040--3 (409--5855)
(
)
Figure10(cont’d)
NOTE
i
NOTE
i
NOTE
i
Audio/Microphone Connectors 114- 10011
Rev B10 of 11 Tyco Electronics Corporation
Figure 10 (end)
Hand Crimping Tool
90715--1 (408--4392) or
90363--1 (408--7901)
Typical Heavy Duty
Mini--Applicator
(408--8040)
AMP--O--LECTRIC Model “K”
Terminating Machine 565435--5
(409--5128)
AMP--O--LECTRIC Model “G”
Terminating Machine 354500--1
(409--5842)
Insertion Tool
91002--1 and --2
(408--7347)
Extraction Tool
91136--1 (408--7859)
AMP--O--MATIC
Stripper--Crimper Machine
854040--3 (409--5855)
AMPOMATOR CLS IV
Lead--Making Machine
217500--[ ] (409--5866)
Audio/Microphone Connectors 114- 10011
Rev B11 of 11Tyco Electronics Corporation
6. VISUAL AID
Figure 11 shows a typical application of an Audio/Microphone Connector. 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.
FIGURE 11. VISUAL AID
NO CONDUCTOR
WIRES SHOWING IN
WIRE BARREL SEAM
WIRE CONDUCTORS AND
INSULATION BOTH VISIBLE
IN THIS AREA
CONDUCTOR ENDS
MUST BE VISIBLE
MATING END MUST
NOT BE DAMAGED
BELLMOUTHS MUST
BE VISIBLE
MAKE SURE RECEPTACLE
HOUSING IS SECURE ON PANEL
PLUG AND RECEPTACLE
CONNECTOR MUST NOT
BE DAMAGED
PULL LIGHTLY ON
WIRE TO MAKE
SURE CONTACTS
ARE SEATED
MAKE SURE BOTH CONNECTORS
CONTAIN SAME NUMBER OF
POSITIONS