62306-2 TEC | Alldatasheet
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APPLIANCES / / / MAGNET WIRE TERMINATION MAGNET WIRE TERMINALS AND TERMINATION SYSTEMS MAG-MATE terminals, SIAMEZE terminals, AMPLIVAR terminals and splices, and cluster blocks
Magnet Wire Terminals and Termination Systems Catalog 82221 Table of Contents Standard MAG-MATE Terminals Slim Line MAG-MATE Terminals Mini MAG-MATE Terminals SIAMEZE Terminals Wire-to-Wire T www.te.com/appliancesDimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change.
Magnet Wire Terminals and Termination Systems Catalog 82221 Table of Contents AMPLIVAR Splices AMPLIVAR Terminals Cluster Blocks MTM Crimpband Splices - NOT RECOMMENDED FOR NEW DESIGNS RTM Crimpband Splices - NOT RECOMMENDED FOR NEW DESIGNS Power Splice www.te.com/appliancesDimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change.
Magnet Wire Terminals and Termination Systems Catalog 82221 Table of Contents Application Tooling MPT Additional Data www.te.com/appliancesDimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change.
S imultaneously terminates two magnet wires of the same size in one terminal (for splicing or bi-filing ) Various lead wire attachment options available Available in strip form for semi-automatic or fully automatic insertions Available in l oose piece form for hand tool insertions Varnish resist tab terminals are available for special
applications
H igh speed, fully automated integrated systems provide uniform terminations reliably at the lowest possible applied cost C lean metal-to-metal interface produces stable, gas-tight electrical terminations free of oxides and other contaminants R ecognized under the C omponent R ecognition P rogram of U nderwriters Laboratories Inc., F ile N o. E 13288,Vol. 1, S ec 29 TE offers a full selection of Standard MAG-MATE Insulation Displacement Crimp (IDC) terminals for magnet wire terminations. MAG-MATE terminals are available in poke-in, poke-in tab, splice, crimp wire barrel, solder post, quick connect tab, pin and receptacle styles. Standard MAG-MATE terminates magnet wire ranging from 34-12 AWG [0.16 -2.05 mm ]. Each IDC slot size terminates a range of up to four consecutive magnet wire sizes. Two magnet wires with the same diameter can be terminated in one terminal except as noted. According to TE specifications MAG-MATE cavities are either integrated into coil bodies or specially designed cavity housings. The magnet wires are precisely positioned in the plastic cavity slots. The MAG-MATE Inserter cuts the terminals from the strip and places the terminals over the magnet wire into the plastic cavities. During this operation, small stripping shoulders in the IDC slot remove the film insulation from the magnet wire. Residual spring energy in the terminal causes the side walls of each IDC slot to function as opposing cantilever beams. This constant pressure results in an intimate metal-to-metal interface, providing a reliable, long-term connection. Wiping action between the wire and terminal removes oxides or other contaminants present on both the conductor and the terminal slot side walls, producing a clean, stable, gas-tight electrical termination. The MAG-MATE Inserter may be used as a semi-automatic bench machine or integr o t n i d e t a production lines for fully-automatic applications. Standard MAG-MATE Terminals R *Contact TE Engineering for guidance regarding aluminum Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued) Standard MAG-MATE Interconnection System How the System Operates Trim Blade This part cuts off the excess magnet wire and the wire support at the front of the cavity. Insertion Finger The insertion finger is part of the MAG-MATE Inserter. It pushes the terminal that was sheared from the carrier strip through the inserter “tube” into the positioned cavity. Contact Various wire attachments in three different sizes,.187, .300,.500 cavity height (see tables). IDC Slot In different sizes for magnet wire diameters from 34-12 AWG [0.16-2.05 mm]. Strain relief slots available for high vibration applications. Stripping Shoulders During the insertion process, these shoulders strip the film insulation from the magnet wire in four areas. Locking Barbs Terminal retention is secured in the cavity by four locking barbs. Plastic Cavity Integration of plastic cavities into final unit must be in accordance with TE Application Specifications. Consulting TE is required for design in. Cavity Slot for Wire The width has to be in accordance with the wire size (see Application Specifi- cation). Magnet Wire The magnet wire is positioned down into the plastic cavity slots. Wire Support Block The block supports the magnet wire during the cutting process. The magnet wire is cut flush to the cavity front side. Support Anvil The anvil supports the wire during the insertion process. Termination Sequence A = Prepare B = Insert C = Finish Trim Blade Insertion Finger Poke-In Contact Plastic Cavity Magnet Wire Support Anvil Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued) Test Results Standard and Slim Line MAG-MATE products have been submitted to the following tests without significant millivolt increase: Mini MAG-MATE products have been submitted to the following tests in addition to those listed without significant millivolt increase: Vibration— 10-55-01- Hz traversed in 1 minute at .06 inches total excursion; 2 hours in each of 3 mutually perpendicular directions. Industrial Gas with Chlorine— 1000 exposure to 200 ppb each of sulphur dioxide, nitrogen dioxide, hydrogen sulphide and 50 ppb chlorine. Humidity— Temperature Cycling 10 cycles between 25°C and 65°C at 95% RH Heat Age— 33 days at 118°C Current Cycling— 480 cycles with each cycle consisting of 15 minutes “ON” followed by 15 minutes “OFF” Thermal Shock— 25 cycles with each cycle consisting of 30 minutes at 125°C followed by 30 minutes at -65°C ) e r i W r e p p o C ( s e l c y C t n e r r u C s v e c n a t s i s e R) e r i W r e p p o C ( k c o h S l a m r e h T s v e c n a t s i s e R Test Current produces 100°C Magnet Wire Operating Temperature Current Rating Curves The diagram shows the temperature rise of the contact, depending on the magnet wire size being applied. Product Specifications describe technical performance characteristics and verification tests. They are intended for the Design, Test and Quality Engineer. Standard .187 and .300 MAG-MATE Terminals Standard .500 Box MAG-MATE Terminals Slim Line MAG-MATE Terminals Mini MAG-MATE Terminals 108-2012 108-2053 108-1484 108-2016 Note: For all applications, TE recommends that samples of the magnet wire to be used be submitted for engineering evaluation. T(C)
15 AWG
16 AWG
19 AWG
22 AWG
24 AWG
26 AWG
27 AWG
30 AWG
33 AWG
I (A) [ 7.62 mm ] I2 Current Leads E2 Voltage 0 10 0 25 15 25 Milliohms Milliohms Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued)
300 Box Poke-In T erminals
POKE-IN SYSTEM: SOLID WIRE CONNECTION POKE-IN SYSTEM: STRANDED LEAD WIRE AND POKE-IN TAB CONNECTION Tin plated brass Typical Cavity Size 2 (See page 23) 34-33 63662-1.010 3.40 x 0.5020-18 0.5-0.9 .135 x .020 0.25 62431-1 .135 x .020 0.30 1217234-1 .135 x .020 0.30 62429-1 .135 x .020 0.41 62935-1 .135 x .020 3.40 x 0.50 0.41 63658-1 .135 x .020 3.40 x 0.50 0.41 62420-1 .135 x .020 3.40 x 0.5020 2 0.81 20-18 0.5-0.9 .016 0.41 63591-1 .135 x .020 3.40 x 0.5019-17 0.41 62833-1 .135 x .020 0.30 63786-1 .135 x .020 0.30 1217011-1 .135 x .020 0.30 1217368-1 .135 x .020 0.41 63789-1 Copper Magnet Wire Range AWG mm Type Lead Wire Range3 5 AWG mm2 Stock Thickness Mating Tab Strip Part Number* A
300 Box
B 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Singlemagnet wireonly; 22 AWG [0.64 mm] orlargerunless otherwisenoted. 3 Solid orovercoatedstranded lead wire only. Product will also accept Poke-In T ab T erminalsh own on page 7. 4 Strain relief slot for high vibration applications. 5 See page 7 for mating tab options. * Recognized under theComponent Program of Underwriters Laboratories, Inc. A .300 [ 7.62 ] .118 [ 3.00 ] .135 [ 3.43 ] B .300 [ 7.62 ] .118 [ 3.00 ] .135 [ 3.43 ] SOLID WIRE SOLID WIRE LOCKS IN “V” NOTCH POKE-IN MAGMATE Terminal POKE-IN MAGMATE Terminal POKE-IN TAB Terminal POKE-IN TAB Terminal POKE-IN TAB Tab locks into edges of leaf Locking Grooves Magnet Wire MAGMATE Terminal MAGMATE Terminal Solid Lead Wire Cavity Magnet WireCavity Cavity Cavity Solid Lead Wire Stranded Lead Wire Stranded Lead Wire Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Part Number*Type A 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG[0.64 mm] or larger unless otherwise noted. 3 See page 7 for mating tab options. * Recognized under theComponent Program of Underwriters Laboratories, Inc. B 35-32 0.14-0.20 33-30 0.18-0.265 30-26 0.265-0.40 26-21.52 0.40-0.67 19.5-172 0.91-1.13 33-30 0.18-0.265 30-26 0.265-0.40 226-22 0.40-0.63 222-19.5 0.63-0.85 219.5-17 0.85-1.12 3Mating Tab .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 .135 x .020 3.40 x 0.50 Stock Thickness .010 0.25 .010 0.25 .013 0.32 .016 0.41 .016 0.41 .016 0.41 .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 964341-2 C
433 Box
.110 x .020 [2.8 mm x 0.5 mm] or .110 x .032 [2.8 mm x 0.8 mm] D .187 x .020 [4.8 mm x 0.5 mm] or .187 x .032 [4.8 mm x 0.8 mm] AWG mm Copper Magnet Wire Range1 Stock Thickness Strip Part Numbere r u t a e Fe p y T 33-30 0.18-0.265 w/o Dimple Dimple .013 0.32 1-964114-1 964114-1 30-26 0.265-0.40 w/o Dimple Dimple .013 0.32 1-964108-1 964108-1 26-22 0.40-0.63 w/o Dimple Dimple .013 0.32 1-928854-1 928854-1 0.63-0.85 w/o Dimple Dimple .013 0.32 1-964106-1 964106-122-19.5 .013 0.32 1 - 4 7 5 0 4 7 1e l p m i D5 6 2 . 0 - 8 1 . 01 3 - 3 3 .013 0.32 1 - 2 5 2 4 6 9e l p m i D o / w7 5 . 0 - 0 4 . 03 2 - 6 2 .013 0.32 2 1 - 0 1 1 4 6 9e l p m i D o / w0 8 . 0 - 0 6 . 0 0 2 - 5 . 2 2 .013 0.32 2 1 - 1 1 1 4 6 9e l p m i D o / w3 1 . 1 - 0 9 . 07 1 - 9 1 .013 0.32 1 1 - 4 3 2 4 3 5 1e l p m i D o / w2 1 . 1 - 0 9 . 07 1 - 9 1 Standard MAG-MATE Terminals (Continued) A .300 [ 7.62 ] .118 [ 3.00 ] .135 [ 3.43 ] B C D .300 [ 7.62 ] .118 [ 3.00 ] .135 [ 3.43 ] .135 [ 3.43 ] .125 [ 3.20 ] .433 [ 11.00 ] .433 [ 11.00 ] .125 [ 3.20 ] .135 [ 3.43 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued)
300 Box Poke-In Terminals
(Continued) Material Tin plated brass Typical Cavity Size 2 (See page 23) Note: Note: DC Type Copper Magnet Wire Range AWG mm
1 Stock
A B 1217691-1.016 0.410.36-0.4027-26 3.40 x 0.50 .135 x .020 3.40 x 0.50 .016 0.41 1217690-1 23.5-22 2 0.54-0.64 .135 x .020 3.40 x 0.50 .016 0.41 1217689-1 3.40 x 0.50 .016 0.41 1217688-1 30-27 0.25-0.36 .135 x .020 3.40 x 0.50 .016 0.41 1217221-1 27-23 0.36 -0.57 .135 x .020 3.40 x 0.50 .016 0.41 63632-1 223-20 0.57-0.81 .135 x .020 3.40 x 0.50 .016 0.41 1217533-1 19-17 0.91-1.15 .135 x .020 3.40 x 0.50 .016 0.41 1742347-1 27-23 19-17 0.36-0.57 0.91-1.15 0.8-0.9 .135 x .020 3.40 x 0.50 .016 0.41 63975-1 4Mating Tab 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG[0.64 mm] or larger. 3 Strain relief slot for high vibration applications. 4 See page 7 for mating small tab options. * Recognized under theComponent Program of Underwriters Laboratories, Inc.
500 Box Poke-In Terminals
(See page 23) Strip Part Number Copper Magnet Wire Range AWG mm D
500 Box
C 19-17 0.91-1.15 .016 0.41 1217068-1 16-15 1.29-1.45 .016 0.41 1217067-1 0.41 1217358-1 21-19.5 0.72-0.86 .016 0.41 1217357-1 19-17 0.91-1.15 .016 0.41 1217356-1 17-16 1.15-1.29 .016 0.41 1742203-1 16-15 1.29-1.45 .016 0.41 1217355-1 23-19.5 0.57-0.86 1217069-1.016 0.41 1.61-1.83 .016 0.41 1217579-114-13 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. 3 Strain relief slot for high vibration applications. Stock ThicknessType .300 [ 7.62 ] .118 [ 3.00 ] .455 [ 11.56 ] .300 [7.62] .118 [3.00] .135 [3.43] .281 [ 7.14 ] .118 [ 3.00 ] .505 [ 12.83 ].505 [ 12.83 ] .281 [ 7.14 ] .118 [ 3.00 ] Special cavity required for Tri-slot splice terminal. See Application Spec. 114-2046. Mating poke-in tab 1217324-1 (See Type H, Page 7) Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued) Material Tin plated brass E D CA .203 [ 5.28 ] .275 [ 6.98 ] .312 [ 7.92 ] B .135 [ 3.43 ] .135 [ 3.43 ] .312 [ 7.92 ] .275 [ 6.98 ] .323 [ 8.20 ] Type Stock Thickness Strip Part Number Lead Wire Size1 2AWG mm 62895-1* 63410-1 1742828-1 62896-1* 63218-1 62897-1* 63775-1 62898-1* Ins. O.D. .040-.060 1.02-1.52 .060-.100 1.52-2.54 .060-.100 1.52-2.54 .090-.140 2.29-3.56 .090-.140 2.29-3.56 .118 MAX. 3.00 MAX. .118 MAX. 3.00 MAX. .063-.090 1.60-2.30 .063-.090 1.60-2.30 63397-1 1 Stranded, fused stranded or solid lead wire. 2 Can be selectively bentinsideapplicator. With support flanges, can only be used in combination with modified cavity IA-84-5157
3 Can be selectively bentinsideapplicator, Non-locking
4 Can be selectively bent inside applicator. Non-locking;use with housing * Recognized under the Component Program of UnderwritersLaboratories, Inc. Note:All tab terminals accept stranded, fused stranded or solid lead wire. E 90° Down 18-14 0.8-2.0 .018 0.46 1742125-1 22-18 0.3-0.9 .018 0.46 63364-1 A 90° Up B 90° Up w/Ins. Sup. C Straight D Straight w/Ins. Sup. .018 0.46 .020 0.51 .018 0.46 .018 0.46 .018 0.46 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .018 0.45 .018 0.45 .018 0.45 .018 0.45 22-18 22-18 18-14 22-18 18-14 22-18 18-14 22-17 22-17 20-17 20-17 0.3-0.9 0.2 0.3-0.9 0.8-2.0 0.3-0.9 0.8-2.0 0.3-0.9 0.8-2.0 0.3-1.0 0.3-1.0 0.5-1.0 0.5-1.0 281622-2 281623-2 964101-2 964290-1 Optional Slot for #20 AWG [0.8 mm] Dia. Solid Copper Diode Slot .135 [ 3.43 ] .520 [ 13.21 ] .255 [ 6.48 ] .312 [ 7.92 ] .208 [ 5.28 ] .135 [ 3.43 ] .135 [ 3.43 ] .255 [ 6.48 ] .405 [ 10.29 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
.135 [ 3.43 ] .197 [ 5.00 ] .315 [ 8.00 ] .106 [ 2.70 ] K .490 [ 12.45 ] .250 [ 6.35 ] .200 [ 30.48 ] .150 [ 3.81 ] .135 [ 3.43 ] L M F I J .370 [ 9.40 ] .110 [ 2.79 ] .245 [ 6.22 ] .285 [ 7.24 ].347 [ 8.81 ] .540 [ 13.72 ] Standard MAG-MATE Terminals (Continued) Type Mag-Mate Terminal with M extended Leaf-Spring Stock Thickness .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 Copper Magnet Wire Range AWG mm 33-30 0.18-0.265 30-26 0.265-0.40 22.5-20 0.60-0.80 19.5-17 0.85-1.12 Strip Part Number 1740603-1 1740698-2 1534110-1 969125-1* 1418686-1 *Single magnet wire Poke-In Tab Terminals Material Tin plated brass Pre-Tin plated brass Material Pre-tinned copper alloy MAG-MATE Terminals with extended leaf-spring F 90° Down w/Ins. Sup. I Flag - 300 Box only J Flag - 500 Box only K Bridge Contact L PCB Contact 1742410-1 1742211-1 63458-1 1217406-1 1217324-1 1987199-1 24-20 22-18 18-14 20-16 18-14 0.2-0.5 0.3-0.9 0.8-2.0 0.5-1.4 0.8-2.0 .048-.078 1.22-1.98 .060-.100 1.52-2.54 .090-.140 2.29-3.56 .080-.120 2.03-3.05 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 1217041-1 Note:All tab terminals accept stranded, fused stranded or solid leadwire. Type Stock Thickness Strip Part Number Lead Wire Size1 2AWG mm Ins. O.D. Note:Special cavity is required,contact TE connectivity for information. .312 [ 7.92 ] .340 [ 8.64 ] .135 [ 3.43 ] .41 [ 10.3 ] .55 [ 13.9 ] .136 [ 3.45 ] .120 [ 3.05 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued) .300 [7.62] Series Box Typical Cavity Size 2 (See page 23) Note: C Tab Receptacle Terminals Material Tin plated phos. bronze Note: Stock Thickness Strip Part NumberMating TabCopper Magnet Wire Range AWG mm Type C
185 Box
32-31 0.20-0.23 .070 x .020 1.78 x 0.51 .010 0.25 1217538-1 30-28 0.25-0.32 .070 x .020 1.78 x 0.51 .010 0.25 1217457-1 29-28 0.29-0.32 .070 x .020 1.78 x 0.51 .010 0.25 1217458-1 28-27 0.32-0.36 .070 x .020 1.78 x 0.51 .010 0.25 1742781-1 1 Two magnetwires may be terminated in the same slot if diameters are equal. .345 [8.76] .185 [4.70] .110 [2.79] .070 [1.78] Special cavity required. Contact TE Engineering for details. Special cavity required for Tri-slot splice terminal. See application SPEC 114-2046 BA A B 1 - 3 7 9 7 1 2 10 2 - 2 2 .016 0.410.64-0.81 27-23 0.36-0.57 18 0.8-0.9 219-17 0.91-1.15 325-22 0.45-0.64 18 0.8-0.9 223.5-20 0.54-0.81 .016 0.41 .016 0.41 19-17 0.91-1.15 .020 0.51 28-24 0.32-0.51 .016 0.41 1217858-1 1742159-1 23-202 0.57-0.81 .016 0.41 1217853-1 1217613-1 1217209-1 Stock Thickness Strip Part Number Copper Magnet Wire Range AWG mm Type 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Singlemagnet wireonly; 22 AWG[0.64 mm] or larger. 3 Single solid or fused stranded lead wire only. 4 Special cavityrequired for1742159-1. .300 [ 7.62 ] .120 [ 3.05 ] .455 [ 11.56 ] .120 [ 3.05 ].135 [ 3.43 ] .300 [ 7.62 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued) A B
187 Box F-Crimp Terminals
.187 [4.75] Series Box Typical Cavity Size 1 (See page 23) Copper Magnet Wire Range AWG mm Type Stock Thickness Strip Part Number Lead Wire Range3 2AWG mm Ins. O.D. A
187 Box
B
187 Box F-Crimp
w/Ins Sup. 1.80 -2.23 .012 0.30 63856-1 0.30 0.30 1217146-1 0.30 62609-1 62610-14 0.30 63036-1 0.25 63039-1 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. 3 Stranded, fused stranded or solid leadwire. 4 Strip rereeled to feed through mini-applicator to crimp lead wire first, magnet wire termination is secondary operation. .090 [ 2.29 ] .467 [ 11.86 ] .187 [ 4.75 ] .070 [ 1.78 ]
300 Box F-Crimp Terminals
.300 [7.62] Series Box Typical Cavity Size 2, when “C” dimension is .120 [3.05] (See page 23) Typical Cavity Size 6, when “C” dimension is .070 [1.78] (See page 23) Type C 0.18-0.23 0.23-0.32 30-27 0.25-0.36 28-24 0.32-0.51 27-24 0.36-0.51 27-23 0.36-0.57 25-22 0.45-0.64 22-20 2 0.64-0.81 19-172 0.91-1.15 Dim. C .070 1.78 .120 3.05 .070 1.78 .070 1.78 .120 3.05 .120 3.05 .070 1.78 .120 3.05 .070 1.78 .120 3.05 .120 3.05 Lead Wire Range3 AWG 22-18 24-20 22-18 24-20 24-20 24-20 22-18 24-20 22-18 24-20 22-18 2mm 0.3-1.0 0.2-0.6 0.3-1.0 0.2-0.6 0.2-0.6 0.2-0.6 0.3-1.0 0.2-0.6 0.3-1.0 0.2-0.6 0.3-1.0 Stock Thickness .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .012 0.30 .016 0.41 .012 0.30 .016 0.41 .016 0.41 Strip Part Number 63235-1 63420-1 63236-1 1742614-1 62992-1 63641-1 63237-1 62459-1 63690-1 62458-1 63504-1 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Singlemagnet wireonly; 22 AWG[0.64 mm] or larger. 3 Stranded, fused stranded or solid lead wire. C .090 [ 2.29 ] .070 [ 1.78 ] .187 [ 4.75 ].360 [ 9.14 ] .300 [ 7.62 ] .480 [ 12.19 ] .135 [ 3.43 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued)
300 Box Posted PCB
Tin over copper plated brass Typical Cavity Size (See page 23) Type C—Cavity Size 2 Type D—Cavity Size 6 CB Copper Magnet Wire Range AWG mm Type Strip Part Number Dim. L Stock Thickness Tab Section Mag Wire B C PCB Post Shallow Box 33-31 0.18-0.23 .540 13.72 .010 0.25 .010 0.25 63253-1 31-28 0.23-0.32 .540 13.72 .010 0.25 .010 0.25 62928-1* 29-26 0.29-0.40 .540 13.72 .012 0.30 .012 0.30 62958-1* 27-23 0.36-0.57 .460 11.68 .016 0.41 .016 0.41 63659-1 22-20 2 0.64-0.81 .460 11.68 .016 0.41 .016 0.41 63660-1 219-17 0.91-1.15 .460 11.68 .016 0.41 .016 0.41 63661-1 219-17 0.91-1.15 .570 14.48 .016 0.41 .016 0.41 1742708-1 33-31 0.18-0.23 .475 12.07 .020 0.51 .012 0.30 1217302-1
1 Two magnetwires may be terminated in the same terminal slot
if diameters are equal. 2 Single magnet wire only. * Recognized under the Component Program of Underwriters Laboratories, Inc. Note:PC Boardhole size .050[1.27]. L .042 [ 1.07 ] .300 [ 7.62 ] .070 [ 1.78 ].135 [ 3.43 ] Multi-Spring Solderless Terminal Material Tin over Copper Alloy Cavity Size Application Spec. 114-74109 with 114-74109-5 A Multi-Spring Solderless PCB Tab Terminal Copper Magnet Wire Range AWG mm 19.5-172 0.85-1.12 26-22.5 0.40-0.63 29.5-26 0.265-0.40 33-29.5 0.18-0.265 Stock Thickness Tab Section Dim L .583 14.80 .583 14.80 .583 14.80 .583 14.80 .583 14.80 .031 0.80 .031 0.80 .031 0.80 .031 0.80 .031 0.80 Mag Wire Section .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 Strip Part Number 1247003-2 1247002-2 1247004-2 1247001-2 1247000-2 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. 22 awg [0.63 mm] and larger. Note:PC Board hole size .057 [1.45]. A L .300 [ 7.62 ] .132 [ 3.35 ] .120 [ 3.05 ] L .300 [ 7.62 ] .135 [ 3.43 ] .120 [ 3.05 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
A MAG-MATE Contact RAST 5D B MAG-MATE Edge Leaf Contact Standard MAG-MATE Terminals (Continued) Stock Thickness .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 Copper Magnet Wire Range AWG mm 33-30 0.18-0.265 30-26 0.265-0.40 26-22 0.40-0.63 22-20 0.63-0.80 20-17 0.85-1.12 Cavity Size Type Stock Thickness .013 0.32 Copper Magnet Wire Range AWG mm 33-30 0.18-0.265 Cavity Size MAG-MATE Edge Leaf Terminal Material Unplated brass Cavity 411-18517 Material Pre-tinned brass Brass Cavity 411-18517 1-1987143-1 Strip Part Number 1394429-2 1394430-2 1394431-2 1394432-2 1394433-2 Strip Part Number A B Note:Special cavity required. Contact TE Connectivity for information : Special cavity required. Contact TE Connectivity for information .64 [ 16.2 ] .12 [ 3.0 ] .31 [ 7.8 ] 7.6 16.2 3.15 Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances Note
A L B Standard MAG-MATE Terminals (Continued)
187 Box Posted PCB
(See page 23) Copper Magnet Wire Range AWG mm Type Stock Thickness Strip Part Number Dim. L A 33-31 0.18-0.23 63565-1.010 0.25 .267 6.78 .010 0.25 .330 8.38 62938-1 30-28 0.25-0.32 .267 6.78 .012 0.30 63160-1 .287 7.29 .012 0.30 63818-1 .330 8.38 .012 0.30 62430-1 27-25 0.36-0.46 .330 8.38 .012 0.30 62438-1 224-22 0.51-0.64 .287 7.29 .012 0.30 63819-1 .330 8.38 .012 0.30 62439-1 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only.
187 Box Tab Terminals
(See page 23) Copper Magnet Wire Range AWG mm Type Dim. L Tab Size Strip Part Number Stock Thickness Tab Section Mag Wire B 30-28 63702-1.110 x .020 0.30 .020 0.51 .432 10.97 .110 x .020 2.79 x 0.51 .012 0.30 .020 0.5129-27 0.29-0.36 .432 10.97 1217196-1 .110 x .020 2.79 x 0.51 .012 0.30 .020 0.5130-28 0.25-0.32 .512 13.00 160810-2 .110 x .020 2.79 x 0.51 .012 0.30 .020 0.5127-25 0.25-0.32 .512 13.00 160809-2 10 x .020 2.79 x 0.51 .012 0.30 .020 0.5124-22 0.25-0.32 .512 13.00 160897-2 .012 0.3030 0.25 .550 14.00 .071 x .025 1.80 x 0.63 .025 0.63 1217405-1 29-27 0.29-0.36 .012 0.30 .700 17.78 .059 x .032 1.50 x 0.81 .032 0.81 1742605-1 25-22 2 0.46-0.64 .012 0.30 .700 17.78 .059 x .032 1.50 x 0.81 .032 0.81 1217013-1 1 Two magnetwires may be terminated in the same terminal if diameters are equal. 2 Single magnet wire only. L .090 [ 2.29 ] .070 [ 1.78 ] .187 [ 4.75 ] .050 [ 1.27 ] .187 [ 4.75 ] .090 [ 2.29 ] .070 [ 1.78 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued)
300 Box Tab Terminals
(See page 23) Type A 20 0.79 31 0.23 Dim. L .750 19.05 .895 22.73 .870 22.10 Tab Size .063 x .025 1.60 x 0.63 .063 x .025 1.60 x 0.63 .062 x .032 1.57 x 0.81 Stock Thickness Tab Section Mag Wire .016 0.41 .025 0.63 .025 0.63 .016 0.41 .032 0.81 .010 0.25 Strip Part Number 63965-1 21217595-1 63810-1 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Tinsel wire only. TypicalCavity Size 2 when “C” dimension is.120[3.05] (See page 23) TypicalCavity Size 6 when “C” dimension is.070[1.78] (See page 23) B 33-31 63806-1.125 x .020 0.30 .020 0.51 .070 1.78 .125 x .020 3.17 x 0.51 .012 0.30 .020 0.51 .070 1.7831-28 0.23-0.32 63807-1 .125 x .020 3.17 x 0.51 .012 0.30 .020 0.51 .070 1.7827-24 0.36-0.50 63808-1 2 0.72 .120 3.05 .118 x .030 3.00 x 0.76 .030 0.76 63463-1.016 0.41 19.5 2 0.86 .120 3.05 .118 x .030 3.00 x 0.76 .030 0.76 63216-1.016 0.41 Type Copper Magnet Wire Range AWG mm 1 Dim. C Tab Size Stock Thickness Tab Section Mag Wire Strip Part Number 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. A .135 [ 3.43 ] .120 [ 3.05 ] L .300 [ 7.62 ] C .300 [ 7.62 ] L .120 [ 3.05 ].132 [ 3.35 ] Material Tin plated brass Typical Cavity Size 2 (See page 23) C Tab Section Mag WireTab SizeDim.1 L Copper Magnet Wire Range AWG mmType 33-31 1217746-1.118 x .020 0.25 .020 0.51 .585 14.86 27-23 0.36-0.57 .118 x .020 3.00 x 0.51 .010 0.25 .020 0.5130 -28 0.25-0.32 .585 14.86 1217745-1 .020 0.5118 Lead 1.02 .585 14.86 .118 x .020 3.00 x 0.51 63974-1.016 0.41 .020 0.51 219-17 0.91-1.15 .585 14.86 .118 x .020 3.00 x 0.51 63972-1.016 0.41 .020 0.51 223-20 0.57-0.81 .775 19.68 .125 x .020 3.17 x 0.51 63899-1.016 0.41 .020 0.5127-23 0.36-0.57 .775 19.68 .125 x .020 3.17 x 0.51 1742167-1.016 0.41 .020 0.51 14.86 .118 x .020 3.00 x 0.51 1217593-1.016 0.41 .020 0.5125-22 2 0.45-0.64 .585 14.86 .118 x .020 3.00 x 0.51 1217596-1.016 0.41 .020 0.51 .585 14.86 .125 x .020 3.17 x 0.51 63489-1.016 0.41 .118 x .020 3.00 x 0.51 .020 0.51 .585 14.86 63973-1.016 0.41 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Singlemagnet wire only; 22 AWG[0.64 mm] or larger. B C .870 [ 22.1 ] .300 [ 7.62 ] .135 [ 1.78 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued) Pin Receptacle Terminals Material A: Tin plated brass B: Unplated brass Typical Cavity Size 2 (See page 23) Type Copper Magnet Wire Range AWG mm Mating Pin Dia. Strip Part Number 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 20.5 AWG[0.76 mm] or larger. A Pin Receptacle B Pin Receptacle 30-27 1394403-10.25-0.36 .079 2.00 221-18 0.72-1.00 .150 3.80 .150 3.80 .150 3.80 .150 3.80 1394639-1 26-23 0.40-0.57 .150 3.80 1394638-1 .079 2.00 2 1 - 6 7 4 4 9 3 10 0 . 1 - 2 7 . 08 1 - 1 2 .079 2.00 1 - 5 7 4 4 9 3 17 5 . 0 - 0 4 . 0 3 2 - 6 2
3 Single magnet wire only
.013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 1740417-1 1740419-1 1740418-1 30-27 321-18 26-23 0.25-0.36 0.72-1.00 0.40-0.57 A .748 [ 19 ] .132 [ 3.35 ] .120 [ 3.05 ] .300 [ 7.62 ] B .30 [ 7.6 ] .75 [ 19 ] .138 [ 3.5 ] .12 [ 3.0 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
C BA D Standard MAG-MATE Terminals (Continued) Pin I/O Terminals Material Tin plated brass .300 [7.62] Series Box Styles A, B and C Typical Cavity Size 2 (See page 23) .500 [12.7] Series Box Style D Typical Cavity Size 4 (See page 23) Type Copper Magnet Wire Range AWG mm
1 Strip
Dia. 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Singlemagnet wire only; 22 AWG[0.64 mm] or larger. A B Offset Pin-R.H. C Offset Pin-L.H. D 27-23 63722-1.010 0.25 .010 0.250.36-0.57 .060 1.52 .010 0.25 .010 0.2533-31 0.18-0.23 .048 1.22 63443-1 .010 0.25 .010 0.2533-31 0.18-0.23 .048 1.22 63444-1 .010 0.25 .010 0.2531-28 0.23-0.32 .048 1.22 63569-1 .010 0.2527-23 0.36-0.57 .048 1.22 .016 0.25 63570-1 .010 0.2525-22 2 0.45-0.64 .048 1.22 .016 0.41 63788-1 27-23 0.86-1.15 .090 2.29 .016 0.41 .016 0.41 63278-1 22-20 0.64-0.81 .090 2.29 .016 0.41 .016 0.41 63277-1 .135 [ 3.43 ] .060 [ 1.52 ] .120 [ 3.05 ] .789 [ 20.29 ] .300 [ 7.62 ] .048 [ 1.22 ] .668 [ 16.76 ].300 [ 7.62 ] .120 [ 3.05 ] .120 [ 3.05 ] .120 [ 3.05 ] .120 [ 3.05 ] .300 [ 7.62 ] .048 [ 1.22 ] .660 [ 16.76 ] .090 [ 2.29 ] .500 [ 17.7 ] .280 [ 7.11 ] .860 [ 21.84 ] .120 [ 3.05 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued)
110 Series
(See page 23) Note: Type Copper Magnet Wire Range AWG mm
1 Tab
A .110[2.79] FASTON Tab 4.5B 3.4C Poke-In Combination Tab 30-27 63777-1.020 0.51 .012 2.79 x 0.51 .020 0.51 .110 x .020 0.41 63746-1 .020 0.51 .110 x .020 2.79 x 0.5123-20 2 0.45-0.64 .016 0.41 63486-1 .020 0.51 .110 x .020 0.51 63145-1 .020 0.51 .110 x .020 0.41 63827-1 .020 0.51 .110 x .020 2.79 x 0.51 0.41 1217783-1 .020 0.51 .110 x .020 0.30 63062-1 .020 0.51 .110 x .020 2.79 x 0.51 225-22 0.45-0.64 .012 0.30 63063-2 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal.
2 Single mag
net wire only; 22 AWG [0.64 mm] orlarger. 3 Poke-In feature accepts 20-18 AWG [0.5-0.8 mm2] Solid or overcoated stranded lead wire or 90° Poke-In tab. 4 Afterinsertion intoplasticcavity, tabportion must be bent over45°-90° orpotted in to preventpullout when mating receptacle isdisconnected. 5 Strainrelief slot for highvibrationapplications. .625 [ 15.88 ] .120 [ 3.05 ] .135 [ 3.43 ] .300 [ 7.62 ] .110 [2.79] Tab Terminals mate with compatible FASTON receptacles. Request Catalog 82004. .625 [ 15.88 ] .300 [ 7.62 ] .135 [ 3.43 ] .120 [ 3.05 ] .310 [ 7.87 ] .660 [ 16.76 ] .120 [ 3.05 ] .135 [ 3.43 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued) A
187 Series
(See page 23) Type A—Cavity Size 2 1Type Copper Magnet Wire Range AWG mm Dim. L Tab Feature Tab Size Stock Thickness Tab Section Mag. Wire Section Strip Part Number A .187 [4.75] FASTON Tab 33-31 30-27 27-23 22-202 220-18 19-17 0.18-0.23 0.25-0.36 0.36-0.57 0.57 0.64-0.81 0.81-1.02 0.91-1.15 .630 16.00 .630 16.00 .630 16.00 .630 16.00 .630 16.00 .630 16.00 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .010 0.25 62513-1* .660 16.76 Hole .187 x .020 4.75 x 0.51 .020 0.51 .012 0.30 63584-1 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .012 0.30 62512-1* Dimple .187 x .032 4.75 x 0.81 .032 0.81 .012 0.30 62678-1 Hole .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 63665-1 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 263273-1 11742160-1 Hole .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 63670-1 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 462904-1 Hole .187 x .032 4.75 x 0.81 .032 0.81 .016 0.41 1217128-1 Dimple .187 x .032 4.75 x 0.81 .032 0.81 .016 0.41 1217065-1 Hole .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 63663-1 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 62511-1* .630 16.00 .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 63776-1 .660 16.76 Hole .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 63585-1 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 62514-1* .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 63461-1 Hole .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 63664-1 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. 3 Afterinsertion intoplastic cavity, tab portion must be bent over45°-90° or potted in to preventpullout when mating receptacle is disconnected. 4 Single bare copper wire only. * Recognized under the Component Program of Underwriters Laboratories, Inc. † These part numbers are available upon special request; contact TE Engineering for details.Chart continued on next page 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Singlemagnet wireonly; 22 AWG[0.64 mm] or larger. 3 Poke-In feature accepts20-18 AWG[0.5-0.8 mm2] solid, fused stranded lead wire or 90° poke-in tab terminal. 4 Afterinsertion intoplastic cavity, tabportion must be bent over 45°-90° or potted in to prevent pullout when mating receptacle is disconnected. Type 1 Copper Magnet Wire Range AWG mm Dim. L Tab Feature Tab Size Stock Thickness Strip Part NumberMag. Wire Section Tab Section B Poke-In Combination Tab 3.4 33-31 0.81-0.23 .630 16.00 Hole .187 x .020 4.75 x 0.51 .020 0.51 63018-1.010 0.25 227-22 0.35-0.63 .630 16.00 Hole w/o Hole .187 x .020 4.75 x 0.51 .020 0.51 316300-4 2-316300-7 .016 0.41 22-19 0.64-0.89 .630 16.00 Hole w/o Hole .187 x .020 4.75 x 0.51 .020 0.51 316300-5 2-316300-8 .016 0.41 19-17 0.90-1.15 .630 16.00 Hole w/o Hole .187 x .020 4.75 x 0.51 .020 0.51 316300-6 2-316300-9 .016 0.41 217-16 1.20-1.30 .630 16.00 Hole .187 x .020 4.75 x 0.51 .020 0.51 6-316300-7.016 0.41 (See page 23) Type B—Cavity Size 2 Note:.187 [4.75] Tab Terminals mate with compatible FASTON receptacles. Request Catalog 82004. B Hole or Dimple L .120 [ 3.05 ] .300 [ 7.62 ] .135 [ 3.43 ] .120 [ 3.05 ] .135 [ 3.43 ] .310 [ 7.87 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Chart continued on next page BA Hole or Dimple 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Singlemagnet wireonly; 22 AWG[0.64 mm] or larger. 3 Strainrelief slot for highvibrationapplications. † These partnumbers are available uponspecial request;contact TE Engineering fordetails. (Continued) Material Tin plated brass Typical Cavity Size (See page 23) Type A—Cavity Size 5 Type B—Cavity Size 5 A Dim. L Tab Feature Tab Size Stock Thickness Strip Part NumberMag. Wire Section Tab Section 27-23 219-17 0.36-0.57 0.91-1.15 .630 16.00 .630 16.00 33-31 0.18-0.23 .630 16.00 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .010 0.25 63108-1 31-28 0.23-0.32 .630 16.00 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .010 0.25 62743-1 30-27 0.25-0.36 .630 16.00 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .012 0.30 63109-1 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 63107-1 16.00 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 1217004-1 218 lead 20.80-0.92 mm .630 16.00 .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 1217592-1 Hole .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 63782-1 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 62888-1 222-20 0.64-0.81 .630 16.00 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 63429-1 23-20 2 0.57-0.81 .630 16.00 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 63340-1 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 1217493-1 Standard MAG-MATE Terminals (Continued) .187 [ 4.75 ] L .300 [ 7.62 ] Dimple .120 [ 3.05 ] .135 [ 3.43 ] .135[ 3.43 ] .120 [ 3.05 ] .300 [ 7.62 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
B A (Continued) Strip Part Number Stock Thickness Mag. Wire Section Tab Section Tab SizeTab Feature Dim. L Copper Magnet Wire Range AWG mm Type 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. 3 Afterinsertion intoplasticcavity, tabportion must be bent over45°-90° orpotted in to preventpullout when matingreceptacle isdisconnected. 4 Strainrelief slot for highvibrationapplications. 3.4 B 17.5-16 22-20 19-17 1.09-1.29 0.64-0.81 0.91-1.15 .830 21.08 .830 21.08 .830 21.08 22-20 0.64-0.81 .830 21.08 Hole .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 1742819-1 19-17 0.91-1.15 .830 21.08 Hole .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 1742820-1 16-15 1.29-1.45 .830 21.08 Hole .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 63996-1 Hole .187 x .032 4.75 x 0.81 .020 0.51 .032 0.81 1217090-1 Hole .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 63995-1 Hole .187 x .032 4.75 x 0.81 .020 0.51 .032 0.81 1217339-1 Hole .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 63983-1 27-23 0.36-0.57 .830 21.08 Hole .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 1217042-1 14.5-13 2 1.54-1.83 .830 21.08 Hole .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 1217902-1 Dimple .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 63353-1 16-15 1.29-1.45 .830 21.08 Hole .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 63762-1 Hole .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 63666-1 Hole .187 x .032 4.75 x 0.81 .020 0.51 .032 0.81 1217075-1 Hole .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 63427-1 Hole .187 x .020 4.75 x 0.51 .020 0.51 .020 0.51 63667-1 Standard MAG-MATE Terminals (Continued) .187 [ 4.75 ] HoleL .505 [ 12.83 ] .120 [ 3.05 ] .281 [ 7.14 ] Material Tin plated brass Typical Cavity Size (See page 23) Type A—Cavity Size 4 Type B—Cavity Size 4 Hole or Dimple .120 [ 3.05 ] .280 [ 7.11 ] .505 [ 12.83 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Chart continued on next page CA B
250 Series
(See page 23) Type A—Cavity Size 2 Type B—Cavity Size 5 Type C—Cavity Size 3 Note: Type 1 Copper Magnet Wire Range AWG mm Dim. L Tab Feature Tab Size Mag. Wire Section Tab Section Stock Thickness Strip Part Number A .250 [6.35] FASTON Tab 19-17 0.91-1.15 .750 19.05 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .020 0.51 1742398-1 22-20 0.64-0.81 .750 19.05 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 1217924-1 27-23 0.36-0.57 .750 19.05 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 62652-1* 28-24 0.32-0.51 .750 19.05 Hole .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 63607-1 30-27 0.25-0.36 .750 19.05 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .012 0.30 62651-1* 33-31 0.18-0.23 .750 19.05 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .010 0.25 62600-1* B Narrow Body Latch Type C Wide Body Latch Type 219-17 0.91-1.15 .750 19.05 Hole .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 63614-1 222-20 0.64-0.81 .750 19.05 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 63601-2 27-23 0.36-0.57 .750 19.05 Hole Dimple .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 63571-1 63128-1 30-27 0.25-0.36 .750 19.05 Dimple Hole .250 x .032 6.35 x 0.81 .032 0.81 .012 0.30 63132-1 63499-1 30-28 0.25-0.32 .750 19.05 Hole .250 x .032 6.35 x 0.81 .032 0.81 .012 0.30 1217152-1 31-28 0.23-0.32 .750 19.05 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .012 0.30 63403-2 33-31 10.18-0.23 .750 19.05 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .010 0.25 63026-1 33-31 0.18-0.23 .750 19.05 Hole .250 x .032 6.35 x 0.81 .032 0.81 .010 0.25 63309-1 30-27 0.25-0.36 .750 19.05 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .012 0.30 63027-1. 223-20 0.57-0.81 .750 19.05 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 1217870-1 27-23 0.36-0.57 .750 19.05 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .016 0.41 1217860-1 * Recognized under theComponent Program of UnderwritersLaboratories, Inc.
1 Two magnetwires may be terminated in the same
terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64 mm] orlarge
3 Afterinsertion intoplasticholder, tabportion must be
bent over 45°-90° or potted in to prevent pullout when mating receptacle is disconnected. Standard MAG-MATE Terminals (Continued) .250 [6.35] tab terminals mate with compatible FASTON receptacles. Request Catalog 82004. L Hole or Dimple .300 [ 7.62 ] .120 [ 3.05 ] .135 [ 3.43 ] LDimple L .300 [ 7.62 ].300 [ 7.62 ] Hole or Dimple .120 [ 3.05 ] .120 [ 3.05 ] .135 [ 3.43 ] .135 [ 3.43 ] Locking Latch (2) Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
(Continued) Material Tin plated brass Typical Cavity Size (See page 23) Type A—Cavity Size 4 Type B—Cavity Size 4 Type AWG mm Copper Magnet Wire Range Dim. L Tab Feature Tab Size Mag. Wire Section Tab Section Stock Thickness Strip Part Number 214-13 1.61-1.83 .952 24.18 212 2.05 .952 24.18 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .020 0.51 63425-1 214-13 1.61-1.83 .952 24.18 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .020 0.51 63465-1 16-15 1.29-1.45 .952 24.18 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .020 0.51 63064-1 19-17 0.91-1.15 .952 24.18 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .020 0.51 62923-1 22-20 0.64-0.81 .952 24.18 Hole .250 x .032 6.35 x 0.81 .032 0.81 .020 0.51 63495-1 19-17 0.91-1.15 .952 24.18 Hole .250 x .032 6.35 x 0.81 .032 0.81 .020 0.51 63464-3 16-15 1.29-1.45 .952 24.18 Hole .250 x .032 6.35 x 0.81 .032 0.81 .020 0.51 63459-2 22-20 0.64-0.81 .952 24.18 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .020 0.51 63155-1 Dimple .250 x .032 6.35 x 0.81 .032 0.81 .020 0.51 63460-1 Hole .250 x .032 6.35 x 0.81 .032 0.81 .020 0.51 63816-1 1 Two magnetwires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only. 3 Afterinsertion intoplasticholder, tabportion must be bent over 45°-90° or potted in to prevent pullout when mating receptacle isdisconnected. Standard MAG-MATE Terminals (Continued) L L .120 [ 3.05 ] .280 [ 7.11 ] .500 [ 12.7 ] .500 [ 12.7 ] .120 [ 3.05 ] .280 [ 7.11 ] Hole or Dimple Hole or Dimple Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued) Typical Plastic Cavity —Poke-In Tab MAG-MATE Terminals —Standard MAG-MATE.187 [4.75] Box Height Terminals —Standard MAG-MATE.300 [7.62] Box Height Terminals —Standard MAG-MATE.500 [12.7] Box Height Terminals —Standard MAG-MATE .300 [7.62] Box Height Latch-In Terminals Narrow Body —Standard MAG-MATE .300 [7.62] Box Height Latch-In Terminals Wide Body 114-2050 114-2069 114-2046 114-2066 114-2067 114-2094 Application Specifications describe requirements for using the product in its intended application and or crimping information. They are intended for the Packaging and Design Engineer and the Machine Setup Person. Technical Documents Cavity Size 1 187 [4.75] Box MAG-MATE (Application Spec. 114-2069) Cavity Size 2 .300 [7.62] Box MAG-MATE (Application Spec. 114-2046) Cavity Size 3 .300 [7.62] Box Latch-In MAG-MATE Wide Body (Application Spec. 114-2094) Cavity Size 4 .500 [12.70] Box MAG-MATE (Application Spec. 114-2066) Cavity Size 5 .300 [7.62] Box Latch-In MAG-MATE, Narrow Body (Application Spec. 114-2067) Cavity Size 6 .300 [7.62] Box MAG-MATE (Application Spec. 114-2046) Plastic cavities, designed to TE specifications, may be molded as part of the coil bobbin or attached to a lamination stack in the area of the magnet wire coil. Each cavity is a rectangular box with two narrow slots on opposing walls and a plastic post or anvil extending upward from the bottom surface. During or after the winding process, the magnet wire is placed across the plastic cavities and into the slots, either manually or by coil winding equipment. Unraveling is prevented by a slight friction fit, suitable bend or by wrapping the magnet wire around a tie-off post. During insertion, two insulation displacing terminal slots strip the film insulation from the magnet wire producing a stable electrical termination. The plastic anvil supports the magnet wire, helping to prevent it from being dragged down when the terminal is inserted. Terminal retention is secured in the plastic cavities by either locking barbs or locking latches in addition to locking barbs for quick disconnect FASTON tab terminals. Excess magnet wire is trimmed flush with the outside of the plastic cavity by a shear blade traveling with the terminal insertion ram. The sheared wire end can be tucked inside the plastic cavity, if necessary, by cutting the wire off before the terminal is fully seated allowing the terminal to drag the severed end of the wire into the pocket inside the cavity. TE will provide design and mold engineering resources to manufac- ture any specifically designed MAG-MATE cavity housing. Manufacture only according to TE Specification. Illustrations shown are for reference only. They are not a purchased item. .215 [ 5.46 ] Min. .235 [ 5.97 ] Min. .355 [ 9.08 ] Min. Note: The MAG-MATE typical plastic cavities shown above are for reference only. They are not a purchased item. Refer to appropriate TE application specification for details. .355 [ 9.08 ] Min. .235 [ 5.97 ] Min. .355 [ 9.08 ] Min. .355 [ 9.08 ] Min. .205 [ 5.21 ] Min. .215 [ 5.46 ] Min. .235 [ 5.97 ] Min. .150 [ 3.81 ] Min. .175 [ 4.45 ] Min. .550 [ 13.97 ] Min. .375 [ 9.53 ] Min. .300 [ 7.62 ] Min. .215 [ 5.46 ] Min. .150 [ 3.81 ] Min. .355 [ 9.08 ] Min. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Standard MAG-MATE Terminals (Continued) .375 [ 9.53 ] Min. .270 [ 6.86 ] .115 [ 2.92 ] Min. Min. Typical Plastic Cavities Reference Application E T A M - G A M i n i ME T A M - G A M e n i L m i l S Spec. 114-2147 Reference Application Spec. 114-2047 Technical Documents Application Specifications describe requirements for using the product in its intended application and or crimping information. They are intended for the Packaging and Design Engineer and the Machine Setup Person. 114-2140—Slim Line MAG-MATE Terminals Technical Documents Application Specifications describe requirements for using the product in its intended application and or crimping information. They are intended for the Packaging and Design Engineer and the Machine Setup Person. 114-2047—Mini MAG-MATE Terminals Illustrations shown are for reference only. They are not a purchased item. Manufacture only according to TE Specification. .375 [ 9.53 ] Min. .225 [ 5.71 ] Min. .250 [ 6.35 ] Min. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
TE offers a full selection of 187 and 250 Series Faston and posted PCB Slim Line MAG-MATE Tab insulation displacement (IDC) termi- nals for magnet wire terminations. Slim Line MAG-MATE terminals with a single IDC slot terminate 33-17 AWG [0.18 to 1.15 mm]. Each IDC slot terminates a range of up to four consecutive magnet wire sizes. Two magnet wires with the same diameter can be terminated in one terminal. Except as noted. MAG-MATE cavities are either integrated into coil bodies or especially designed cavity housings. The magnet wires are precisely positioned in the plastic cavity slots. The MAG-MATE Inserter cuts the terminals from the strip and places the termi- nals over the magnet wire into the plastic cavities. During this operation, small stripping shoulders in the IDC slot remove the film insulation from the magnet wire. Residual spring energy in the terminal causes the side walls of each IDC slot to function as opposing cantilever beams. This constant pressure results in an intimate metal-to-metal interface, providing a reliable, long- term connection. Wiping action between the wire and terminals removes oxides or other contaminants present on both the conductor and the terminal slot side walls, producing a clean, stable, gas-tight electrical termina- tion. fully-automatic applications. Product Facts R Terminates all magnet wire film insulations Eliminates need for pre-stripping conductors Eliminates need to post-insulate terminations Excess magnet wire is automatically trimmed during the termination process 187 and 250 Series Faston Tab and posted PCB Tab terminals available Terminates 33-17 AWG [0.18-1.15 mm ] magnet wire Simultaneously terminates two magnet wires of the same size in one terminal from 33-23 AWG [0.18-0.57 mm ] Available in strip form for semi-automatic or fully automatic insertions High speed, fully automated integrated systems provide uniform terminations reliably at the lowest possible applied cost Clean metal-to-metal interface produces stable, gas-tight electrical termina- tions free of oxides and other contaminants Recognized under the Component Recognition Program of Underwriters Laboratories Inc., File No. E13288 Slim Line MAG-MATE Terminals Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
L Hole or Dimple B L Hole or Dimple A 1217516-1 Type AWG Copper Magnet Wire Range1 Dim. L Stock Thickness Section Mag.WireTab Section Tab SizeTab Feature Material Tin plated brass 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64] or larger. 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64] or larger. 33-31 30-28 27-24 23-20 19-172 Hole Dimple .187 x .020 4.75 x 0.51 .020 0.51 .012 0.30 63710-2 63738-2 1 - 6 6 6 7 1 2 1e l o H.187 x .032 4.75 x 0.81 .032 0.81 .012 0.30 Hole Dimple .187 x .020 4.75 x 0.51 .020 0.51 .012 0.30 63711-2 63737-2 Hole Dimple .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 63712-2 63736-2 1217497-1Plain .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 .760 19.31 .630 16.00 .630 16.00 .630 16.00 .630 16.00 63713-2 63735-2 Hole Dimple .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 Hole .187 x .032 4.75 x 0.81 .032 0.81 .016 0.41 Hole Dimple .187 x .020 4.75 x 0.51 .020 0.51 .016 0.41 63714-2 63734-2 .630 16.00 A .187 [4.75] FASTON Tab 0.57-0.81 0.91-1.15 mm 0.18-0.23 0.25-0.32 0.36-0.51 (Slim Line MAG-MATE Terminals Continued) Wire Range1 Dim. L Stock Thickness Mag.Wire Section Tab Section Tab SizeTab Feature Strip Part Number 63719-2 63741-2 63718-2 63742-2 63717-2 63743-2 23-20 19-17 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. 2 Single magnet wire only; 22 AWG [0.64] or larger. Type AWG mm Copper Magnet Wire Range1 Dim. L Stock Thickness Mag.Wire Section Tab Section Tab SizeTab Feature 33-31 30-28 27-24 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 63716-2 63744-2 .032 0.81 .012 0.30 .012 0.30 .016 0.41 .016 0.41 .016 0.41 .032 0.81 .032 0.81 .032 0.81 .032 0.81 Hole Dimple Hole Dimple Hole Dimple Hole Dimple Hole Dimple .752 19.10 .752 19.10 .752 19.10 .752 19.10 .752 19.10 B .250 [6.35] FASTON Tab 0.57-0.81 0.91-1.15 0.18-0.23 0.25-0.32 0.36-0.51 Strip Part Number 63720-2 63740-2 33.5-30 0.17-0.25 29.5-26 0.27-0.40 26-22 0.40-0.63 22-20 0.63-0.81 C .040 [1.00] PCB Tab 1534684-1 1534685-1 1534686-1 .024 0.60 .024 0.60 .013 0.32 .024 0.60 .013 0.32 1740829-1 1534687-1 .040 x .024 .040 x .024 .024 0.60 .013 0.32 .013 0.32 .024 0.60 .013 0.32 .323 8.20 .323 8.20 Embossment Embossment Embossment Embossment .040 x .024 1.00 x 0.60Embossment .323 8.20 .323 8.20 .323 8.20 .040 x .024 1.00 x 0.60 1.00 x 0.60 1.00 x 0.60 1.00 x 0.60 .040 x .024 C .135 [ 3.43 ] .016 [ 0.41 ] .020 [ 0.51 ] .032 [ 0.81 ] .250 [ 6.35 ] .135 [ 3.43 ] .132 [ 3.45 ] .0125 [ 0.32 ] .0322 [ 8.20 ] .016 [ 0.41 ] .187 [ 4.75 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Slim Line MAG-MATE Terminals (Continued) Offset Tab Terminals Mater l l a i Tin Plated Brass 63888-1 63903-1 Diode SizeType AWG Copper Magnet Wire Range1 mm Stock Thickness Mag.Wire Section Tab Section Strip Part Number 33-31 33-31 .059 x .032 1.50 x 0.81 .059 x .032 1.50 x 0.81 0.032 0.81 0.032 0.81 0.012 0.30 0.012 0.30 #20 0.8 #22.5 0.6 .725 18.42 .725 18.42 0.18-0.23 0.18-0.23 A Combination Diode Slot/Tab Dim. L Tab Size 1 Two magnet wires may be terminated in the same terminal slot if diameters are equal. Applications where I/O Tab spacing must be less than IDC connection spacing Example: automotive accessory coils A L .032 [ 0.81 ] .139 [ 3.53 ] .059 [ 1.50 ] .135 [ 3.43 ] .220 [ 5.59 ] .013 [ 0.33 ] Posted PCB Terminals Multi-Spring Solderless Terminal Material Tin Plated Copper Alloy Cavity Size Application Spec. Contact TE Engineering B .289 [ 9.33 ] .132 [ 3.35 ] .013 [ 0.32 ] L
1 Two magnet wires may be terminated in the same terminal slot
if diameters are equal. 2 Single magnet wire only. 22 awg [0.63 mm] and larger. Note:PC Board hole size .057[1.45] Type Copper Magnet Wire Range1 Stock Thickness AWG 33-29.5 29.5-26 26-22.5 22.5-19.5 19.5-172 Mag.Wire Section .013 0.32 .013 0.32 .013 0.32 .013 0.32 .013 0.32 Tab Section .031 0.81 .031 0.81 .031 0.81 .031 0.81 .031 0.81 Dim. L .583 14.80 .583 14.80 .583 14.80 .583 14.80 .583 14.80 B Multi-Spring Solderless PCB Tab Terminal mm 0.63-0.85 0.85-1.12 0.18-0.265 0.265-0.40 0.40-0.63 2120746-2 2120745-2 2120744-2 2120743-2 Strip Part Number 2120747-2 Slim Line MAG-MATE Terminals Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Slim Line MAG-MATE Terminals (Continued) Type A MAG-MATE Terminal with MQS Pins Copper Magnet Wire Range AWG mm 33-30 331 0.256-0.40 0.40-0.561 30-26 30-26 0.256-0.40 0.40-0.56 26-22 26-23 0.40-0.63 0.40-0.56 22-20 0.63-0.80 20-17 0.85-1.12 Posted PCB Solder Terminals Material Unplated brass 1-1987222-1 1-1987223-1 1-1987224-1 1-1987225-1 1-1987226-1 Strip Part Number Stock Thickness Varied thickness Varied thickness Varied thickness Varied thickness Varied thickness
1 For double magnet wires
A Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
R Terminates all fine gauge magnet wire film insulations Eliminates need to pre-strip conductors Eliminates need to post insulate terminations Terminates 52-30 AWG [0.02-0.25 mm ] diameter copper magnet wire Poke-In leaf style accepts overcoated stranded or solid lead wire Available in strip form for semi-automatic or fully automatic insertions High speed, fully automated integrated systems provide uniform terminations and reliability at the lowest possible applied cost Recognized under the Component Recognition Program of Underwriters Laboratories Inc, File No. E13288 TE offers Mini MAG-MATE poke-in, crimp wire barrel, post and quick disconnect tab insulation displacement (IDC) termi- nals for fine gauge magnet wire terminations. Mini MAG-MATE terminals are designed to terminate 52-30 AWG [0.02-0.25 mm] diameter copper magnet wire. Poke-in leaf terminals accept overcoated stranded or solid lead wire. The terminal design uses the AMPLIVAR serrated burr technology to penetrate the film insulation of copper magnet wire. Mini MAG-MATE cavity pockets, designed to TE specifications, include a wire receiving slot and wire tie-off post that is either integrated into coil bodies or specially designed cavity housings. The magnet wire is wrapped around the tie-off post and placed across the cavity slot. After the coil is wound, the finish end of the magnet wire is dressed through the second cavity slot and tied to its tie-off post. The Mini MAG-MATE Inserter shears the terminal from the carrier strip and inserts the terminal into the cavity by a dual ram insertion mechanism. As the unexpanded terminal approaches the bottom of the cavity, the upper ram stops. The lower ram continues to push to a prescribed depth to expand the terminal and complete the termination process. The fully seated terminal fits squarely into the cavity,while the serrated leg of the terminal cams against the pre-positioned magnet wire to penetrate the film insula- tion and provide a stable electrical termination. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Mini MAG-MATE Terminals (Continued) Termination Complete A Poke-In Terminal Material .010 [0.25] tin plated brass Lead Wire RangeType
1 Stock Thickness
1 - 1 8 7 2 6— 1 - 0 8 7 2 6— 1 - 6 0 6 2 6— 1 - 3 1 6 3 6—— — — 63795-12 2 - 4 4 8 3 6—— 2 A Lead Wire Poke-In B Tab Poke-In C Skinny Mini 52-42 44-36 38-30 52-42 44-36 38-30 0.02-0.06 0.05-0.13 0.10-0.25 0.02-0.06 0.05-0.13 0.10-0.25 22-18 22-18 22-18 0.3-0.9 0.3-0.9 0.3-0.9 .060 x .020 1.52 x 0.51 .060 x .020 1.52 x 0.51 .060 x .020 1.52 x 0.51 0.010 0.25 0.010 0.25 0.010 0.25 0.010 0.25 0.010 0.25 0.010 0.25 0.010 0.25 0.010 0.25 0.010 0.25 0.010 0.25 0.010 0.25 0.010 0.25 1.00 x 0.51 0.010 0.25 0.010 0.25 1 Solid or overcoated stranded lead wire only. 2 Radius on beam leaf tip. B C L .345 [ 8.76 ] .047 [ 1.20 ] Lower ram stops Sheared post and excess wire to scrap chute Lower ram continues Upper ram stops Wire Wire tie-off post Split ram Wire .138 [ 3.51 ] .060 [ 1.52 ] .345 [ 8.76 ] .060 [ 1.52 ] .345 [ 8.76 ] .138 [ 3.51 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Mini MAG-MATE Terminals (Continued) Posted Terminal FASTON Tab Terminals 63675-4 Type Copper Magnet Wire Range Tab Size Stock Thickness Strip m mG W A Part Number 63778-1 Type Copper Magnet Wire Range Lead Wire Range Stock Thickness Strip AWG mm AWG mm 2 Crimp Barrel Mag Wire Part Number C Crimp WireBarrel Terminal A Type Copper Magnet Wire Range Post Size Stock Thickness e r i W g a M t s o Pm mG W A Post Mag Wire Strip Part Number Material Tin over premilled brass Material Tin over premilled brass A PCB Post 38-30 0.10-0.25 .024 x .020 0.62 x 0.51 0.020 0.51 0.010 0.25 B B .187 [4.75] FASTON Tab C Crimp Wire Barrel 1217529-138-30 0.10-0.25 .187 x .020 4.75 x 0.51 .020 0.51 .010 0.25 44-36 0.05-0.13 .187 x .020 4.75 x 0.51 .020 0.51 .010 0.25 63199-1 10.010 0.25 0.010 1 Wire and insulation barrel reversed so lead wire exits over magnet wire termination area. Material Tin plated brass .060 [ 1.52 ] .138 [ 3.51 ] .169 [ 4.29 ] .540 [ 13.72 ] .060 [ 1.52 ] .138 [ 3.51 ] .690 [ 17.53 ] .138 [ 3.51 ] .060 [ 1.52 ] .620 [ 15.75 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
R Product Facts Terminates all copper magnet wire film insulations Eliminates need for pre-stripping conductors Moving Beam contact design connects a wide range of magnet wire sizes with a single terminal Standard range terminals connect 34-18 AWG [0.16-1.0 mm] magnet wire Fine range terminals connect 36-27 AWG [0.13-0.38 mm ] magnet wire Medium range terminals connect 23-12 AWG [0.56-2.03 mm ] magnet wire Excess magnet wire is automatically trimmed during the termination process Available in strip form for semi-automatic or fully automatic insertions Loose piece terminals available for manual tool insertions High-speed automatic coil winding machine termina- tions provide uniform reliability at the lowest possible applied cost Clean metal-to-metal interface produces stable, gas-tight electrical termina- tions free of oxides and other contaminants Recognized under the Component Program of Underwriters Laboratories Inc.,File No. E13288 TE offers a full selection of SIAMEZE insulation displacement (IDC) terminals for interconnect- ing copper magnet wires, lead wires, and other components. The SIAMEZE insulation displacement (IDC) terminal technology eliminates the need to strip the film insulation from copper magnet wires and lead wires. Terminals are available in wire-to-wire, Lead Lok, quick disconnect tabs, posts, pin and receptacle terminals. Available with either Moving Beam contacts whereby a single terminal connects toa very wide range of magnet wire sizes, or a Compliant Beam for contacting two magnet wires of the same diameter in one terminal for splicing or bi-filar applica- tions. Tab terminals are available with single barbs or multiple retention barbs for higher retention. According to TE specifica- tions SIAMEZE cavities are either integrated into coil bodies or specially designed cavity housings. The magnet wires are positioned in the “U”shaped slots. The SIAMEZE terminal Inserter cuts the terminals from the strip and places the terminals over the magnet wire into the plastic cavities. During this operation the small stripping devices penetrate the film insulation from the magnet wire. Residual spring energy in the terminal causes the side walls of the IDC slot to function as opposing cantilever beams. This constant pressure results in an intimate metal-to-metal interface, providing a reliable, long-term connection. The wiping action between the wire and terminals remove all oxides or other contaminants present on both the conductor and the terminal slot side walls, producing a clean, stable, gas-tight electrical termination. The SIAMEZE terminal Inserter may be used as a semi-automatic bench machine or integrated in production lines for fully-automatic applica- tions. SIAMEZE Terminals Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Cavity Specifications - Provide dimensional design guidelines & criteria for a cavity to be used with a SIAMEZE IDC terminal. The appropriate Cavity Specification number is shown on the following pages adjacent to the terminal number. As a general reference, overall dimensions are shown at the end of this section. Product Specifications ( These describe the performance characteristics and verification tests ) 108-2085 Standard Range SIAMEZE Insulation Displacement 108-2293 High Temperature Standard Range SIAMEZE Insulation Displacement 108-2244 Fine Range SIAMEZE Insulation Displacement 108-2239 Medium Range SIAMEZE Insulation Displacement 108-2316 Heavy Range SIAMEZE Insulation Displacement Application Specifications ( These describe the requirements for using the product in its intended application ) 114-13166 Standard and Fine Range SIAMEZE Insulation Displacement 114-13210 Medium and Heavy Range SIAMEZE Insulation Displacement Lead Lok Terminals Product Facts Provides perpendicular and parallel lead wire strain relief retention forces in excess of 20 lbs (90 N). Inserter automatically positions and secures lead wire during insertion Manual, semi-automated, fully automated systems allow for lead wire termina- tion Accepts #18 - #22 [0.3mm 2-0.8 mm 2 ] AWG solid or stranded lead wire with .115 [2.92 ] max.insulation diameter No lead wire stripping required TE features the Lead Lok strain relief terminal system that provides optimum lead wire retention when used in conjunction with SIAMEZE insulation displacement terminals. After the one-step insertion of SIAMEZE wire-to- wire terminals into TE specified plastic cavities, the application is ready for the secondary lead wire attach- ment. The lead wire is manually positioned over the magnet wire terminated SIAMEZE wire-to-wire terminal. The Lead Lok Inserter cuts the Lead Lok terminals from the strip and places the terminal over the lead wire in the plastic cavities. During this operation, the lead wire is automatically seated, the insulation pierced and the exposed solid or stranded conductor is terminated in the IDC slot of the SIAMEZE wire-to-wire terminal. Residual spring energy in the terminal causes the side walls of the IDC slot to function as opposing cantilever beams. This constant pressure results in an intimate metal-to-metal interface, providing a reliable, long termconnection. Perpendicular and parallel lead wire strain relief retention forces in excess of 20 lbs are achieved. The Lead Lok Inserter may be a secondary station in the SIAMEZE Wire-to- Wire semi-automatic bench machine. Information regarding terminal insertion equipment may be found in Magnet Wire Termi- nation Overview #138516. SIAMEZE Terminals (Continued) SIAMEZE Terminals Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
SIAMEZE Terminals (Continued) SIAMEZE Interconnection System How the System Operates Magnet Wire The magnet wire is positioned in “U” slot manually or automatically by coil winding equipment. Terminal Insertion Finger The terminal insertion finger is part of the SIAMEZE Inserter. It pushes the terminal that was sheared from the carrier strip through the“tube” into the cavity. Contact Various wire attachments in standard, fine, mediumand heavy duty terminals are available (See tables). IDC Slot The IDC slot in the terminal will terminate a wide range of magnet wire sizes. Stripping Burrs During the insertion process, these burrsstrip the film insulation from the magnet wire. Retention Barbs Terminal retention is provided in the cavity by single or multiple locking barbs. Plastic Cavity Design must comply with TE connectivity specifications(for cavity drawing numbers see tables). ConsultingTE is required for design in. Cavity Slot for Wire The width has to be in accord ance with the wire size (see cavity drawings). Wire Cutoff Block The wire cutoff block supports the magnet wire during the trimming process. The magnet wire is cut plain to the cavity front side. Trim Blade The trim blade cuts the excess magnet wire and the wire cutoff block at the front of the cavity. Terminal Insertion Complete The magnet wire termina- tion is complete when the terminal is fully seated in the cavity. Test Results SIAMEZE products have been submitted to the following tests without significant millivolt increase: Current Cycling— 250 cycles with each cycle consisting of 15 minutes “ON” followed by 15 minutes “OFF” Thermal Shock—
25 Cycles -40°C to +125°C,
25 Cycles -40°C to +175°C
Humidity— Temperature Cycling 10 cycles between 25°C and 65°C at 80 to 100% RH Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
HOW TO CONNECT MULTIPLE MAGNET WIRES OR OTHER COMPONENTS Lead Lok Insertion Finger The Lead Lok insertion finger pushes the Lead Lok that was sheared from the carrier strip and positions the Lead Lok and lead wire into the IDC slot. Lead Lok Terminal The Lead Lok terminal provides maximum lead wire retention in the cavity. Retention Barbs The Lead Lok multiple barbs provide retention in the cavity. Lead Wire Stranded, solid and bonded lead wire with 105°C PVC insulation can be used. Contact TE Engineering for other lead wires and insulation under consider- ation. IDC Slot The IDC slot will pierce the lead wire during insertion. Lead Wire Insertion Complete The lead wire termination is complete when the Lead Lok is fully seated in the cavity. Bussed High Carry SIAMEZE Plastic Cavity Bussed cavity pocket designs are available for double or triple bussed terminals. Bussed High Carrier Terminals Bridging of two SIAMEZE terminals that is accom- plished by leaving the carrier strip between two adjacent terminals intact. SIAMEZE Terminals (Continued) Magnet Wire Magnet wire may be equal or differ in size for bi-filar applications. SIAMEZE Terminals Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
A Moving Beam 1601421 18-34 27–36 18-34 18-34 18-34 27–36 12-23 1.02-0.16 1.02-0.16 1.02-0.16 0.36–0.13 1.02–0.16 0.36-0.13 2.06-0.56 B Wire Specific8 C High Carrier D High Carrier Specific E Medium Range F Lead Lok 1601421 1601436 618-22 618-22 618-22 16-20 18-22 0.8-0.3 0.8-0.3 0.5 0.8 0.8-0.3 0.5 1.3-0.5 0.8-0.3 1601000-1 1601000-25 1601117-1 4-1601000-12 4-1601000-22,5 4-1601117-12 1601056-1 4-1601056-12 2-1601056-11 2-1601117-11 1601074-112-1601074-1 4-1601074-12 1601046-112-1601046-1 24-1601046-1 36-1601046-1 48-1601046-1 1601136-112-1601136-1 1601140-112-1601140-1 24-1601136-1 36-1601136-1 1601237-112-1601237-1 24-1601237-1 36-1601237-1 4-1601140-1 1601421 1601433 1601440 1601433 1601440 1601433 1 Reversed Reeled—Consult TE drawing for orientation. 2 Loose Single. 3 Loose Bussed (Bridged) Double. 4 Loose Bussed (Bridged) Triple. 5 Finish is Post Plated Tin over Copper (Consult TE drawing for specifics). 6 Lead wire may be stranded, solid or bonded with 105°C PVC insulation. Contact TE Engineering when using other types of insulation. 7 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 8 Wire Specific terminals have a top contact designed to penetrate difficult Lead Wire Insulation (e.g Irradiated types). SIAMEZE Terminals (Continued) .146 [ 3.71 ] .300 [ 7.62 ] .300 [ 7.62 ] .300 [ 7.62 ] .300 [ 7.62 ] .020 [ 0.51 ] .020 [ 0.51 ] .020 [ 0.51 ] .020 [ 0.51 ] .146 [ 3.71 ] .146 [ 3.71 ] .146 [ 3.71 ] .280 [ 7.11 ] .550 [ 13.97 ] .025 [ 0.46 ] .150 [ 3.81 ] .250 [ 6.35 ] .032 [ 0.81 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
2,1 A B C D Type Recommended Pocket5 mm Copper Magnet Wire Range AWG L Dim. Mating Tab Size Part Number Reeled Loose A Wire2Blade In Line B Wire2Blade High Carrier In Line C Wire2Blade In Line Medium Range D Wire2Blade Off Line Medium Range 1601425 1601426 1601436 1601437 18-34 18-34 15-23 15-23 1.02-0.16 1.02-0.16 1.47-0.56 1.47-0.56 .300 7.62 .300 7.62 .550 13.97 .310 7.87 .020 0.51 .020 0.51 .032 0.81 .032 0.81 1601075-1 12-1601075-1 1601196-1 12-1601196-1 1601137-2 2-1601137-2 1601075-26 2-1601075-21,6 2-1601075-31,7 1601232-27 2-1601232-21,7 1,6 24-1601075-1 4-1601075-22,6 4-1601196-12 6-1601196-13 8-1601196-14 4-1601232-22,7 4-1601137-22,6 1 Reverse Reeled –Consult TE drawing for orientation. 3 Loose Bussed (Bridged) Double. 5 Magnet wire 30 AWG [0.25] and smaller also requires a wrap post per Specification 1601447. 7 Finish is Post Plated Tin over Nickel (Consult TE drawing for specifics). 2 Loose Single. 4 Loose Bussed (Bridged) Triple. 6 Finish is Pre Plated Tin (Consult TE drawing for specifics). 8 Overall Height of terminal does not include inserted Blade (Tab). Receptacle Terminals (Wire to Blade) Type E Round Pin L [ 2.13 ] [ 0.51 ] Dia. [ 3.71 ] E Pin Terminals Round Pin Recommended Pocket2 1601424 Copper Magnet Wire Range AWG mm L Dim. Pin Dia. Part Number Reeled Loose 18-34 1.02-0.16 .718 18.24 .084 2.13 1601077-1 2-1601077-11 4-1601077-13 1 Reverse Reeled –Consult TE drawing for orientation. 2 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 3 Loose piece single. SIAMEZE Terminals (Continued) Material Brass Material Brass .300 [ 7.62 ] .146 [ 3.71 ] .020 [ 0.51 ] .280 [ 7.11 ] .032 [ 0.81 ] .032 [ 0.81 ] .480 [ 12.19 ] .310 [ 7.87 ] .550 [ 13.97 ] .300 [ 7.62 ] .020 [ 0.51 ] .146 [ 3.71 ] SIAMEZE Terminals Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
L L A B C Part Number Reeled Loose D E F Post Terminals Material Brass Type Recommended Pocket7 Copper Magnet Wire Range A PC Tab 1601424 B Extended PC Tab D Long Narrow Blade Mult-Barb C Long Narrow Blade E Medium Width Blade Mult-Barb F Medium Width Blade Medium wire range 1601425 1601431 1601425 1601475 1601438 12-23 18-34 L Dim. .345 8.7618-34 29** 27-36 27-36 18-34 18-34 18-34 27-36 0.56-2.06 0.36-0.13 1.02-0.16 1.02-0.16 1.02-0.16 0.36-0.13 1.02-0.16 0.36-0.13 1.02-0.16 0.29 AWG mm Tab Size .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .040 x .020 1.02 x 0.51 .047 x .032 1.20 x. 0.81 .059 x .032 1.50 x. 0.81 .059 x .032 1.50 x. 0.81 .059 x .032 1.50 x. 0.81 .059 x .032 1.50 x. 0.81 .071 x .025 1.80 x 0.64 .059 x .032 1.50 x 0.81 .118 x .020 3.00 x 0.51 .118 x .025 3.00 x 0.64 .130 x .032 3.30 x 0.81 .405 10.29 .345 8.76 .345 8.76 .456 11.57 .485 12.32 .485 12.32 .754 19.16 .669 17.00 .756 19.21 .904 22.96 1.005 25.53 .974 24.74 .805 20.45 .533 13.54 .952 24.18 .872 22.15 293214-1 1601138-1 1 Reverse Reeled –Consult TE drawing for orientation. 3 Finish is Post Plated Tin (Consult TE drawing for specifics). 5 Finish is Post Plated Tin over Nickel (Consult TE drawing for specifics). 7 Magnet wire 30 AWG [0.25] and smaller also requires a wrap post per Specification 1601447 2 Loose Piece Single. 4 Finish is Post Plated Tin over Copper (Consult TE drawing for specifics).
6 Finish is Pre Plated Tin (Consult TE drawing for specifics)
** Compliant contact can connect 2 wires of the same diameter. 1601009-4 2-1601009-41,5 1601214-25 2-1601214-21,5 1601155-35 2-1601155-31,5 1601120-45 2-1601120-41,5 1601095-24 2-1601095-22,4 1601041-35 2-1601041-31,5 1601128-35 2-1601128-31,5 1601110-26 2-1601110-21,6 1601099-25 2-1601099-21,5 1601063-26 2-1601063-21,6 1601037-26 2-1601037-21,6 1601066-26 2-1601066-21,6 1601104-26 2-293214-11 2-1601104-21,6 1601243-23 2-1601243-21,3 1601119-26 2-1601119-21,6 2-1601138-11 4-1601009-42,5 4-1601155-32,5 4-1601214-22,5 4-1601120-42,5 4-1601095-22,4 4-1601041-32,5 4-1601128-32,5 4-1601110-22,5 4-1601099-22,5 4-1601063-22,6 4-1601037-22,6 4-1601066-22,6 4-1601104-22,6 4-1601243-22,3 4-1601119-22,6 4-1601138-12 SIAMEZE Terminals (Continued) .146 [ 3.71 ] .146 [ 3.71 ] .146 [ 3.71 ] .146 [ 3.71 ] .146 [ 3.71 ] .280 [ 7.11 ] .032 [ 0.81 ] .020 [ 0.51 ] .020 [ 0.51 ] .020 [ 0.51 ] .020 [ 0.51 ] .020 [ 0.51 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
B L C L A L 110 Series (2.8 mm wide) FASTON Tab Terminals Material Brass Type Recommended Pocket8 Copper Magnet Wire Range AWG mm L Dim.Thickness Part Number Loose A Single Barb B Single Barb Low Transition C Multi-Barb 1601425 1601431 1601425 18-34 27-36 18-34 18-34 1.02-0.16 1.02-0.16 1.02-0.16 0.36-0.13 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .032 0.81 .032 0.81 .020 0.51 .020 0.51 .032 0.81 .032 0.81 .032 0.81 1.240 31.50 1.240 31.50 .630 15.99 .655 16.63 .655 16.63 1.195 30.35 .945 24.00 .925 23.50 .846 21.49 .846 21.49 .640 16.26 .640 16.26 1 Reverse Reeled-Consult TE drawing for orientation. 2 Loose Piece Single. 3 Finish is Post Plated Tin over Nickel (Consult TE drawing for specifics). 4 Finish is Post Plated Tin (Consult TE drawing for specifics). 5 Finish is Pre-Plated Tin over Copper (Consult TE drawing for specifics). 6 Finish is Pre-Plated Tin (Consult TE drawing for specifics). 7 No hole in Tab. 8 Magnet wire 30 AWG [0.25] and smaller also requires a wrap post per Specification 1601447. Reeled 1601005-1 1601045-1 1601073-1 1601039-1 1601133-2 6,7 2-1601133-21,6,7 1601112-26,7 2-1601112-21,6,7 1601064-17 2-1601064-11,7 1601039-26 2-1601039-21,6 2-1601039-11 1601194-23,7 2-1601194-21,3,7 1601097-36,7 2-1601097-31,6,7 2-1601073-11 1601059-17 2-1601059-11,7 2-1601045-11 1601204-26,7 2-1601204-21,6,7 2-1601005-11 4-1601005-12 4-1601204-22,6,7 4-1601045-12 4-1601059-12,7 4-1601073-12 4-1601097-32,6,7 4-1601194-22,3,7 4-1601039-12 4-1601039-22,6 4-1601064-12,7 4-1601112-22,6,7 4-1601133-22,6,7 SIAMEZE Terminals (Continued) .146 [ 3.71 ] .146 [ 3.71 ] .020 [ 0.51 ] .020 [ 0.51 ] .146 [ 3.71 ] .020 [ 0.51 ] SIAMEZE Terminals Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
L L L L L A B C D E 187 Series (4.75 mm wide) FASTON Tab Terminals Material Brass (except High Temp listed below) Type Recommended Pocket8 Copper Magnet Wire Range AWG mm Thickness L Dim. Part Number Reeled Loose A Single Barb B Single Barb Short Pocket C Multi-Barb D Multi-Barb Short Profile E Multi-Barb .187/.250 Profile 1601425 1601434 1601425 1601427 1601425 18-34 18-34 18-34 20-23 18-34 18-34 1.02-0.16 1.02-0.16 1.02-0.16 0.58-0.81 1.02-0.16 18-34 1.02-0.16 1.02-0.16 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .020 0.51 .032 0.81 .032 0.81 .032 0.81 .032 0.81 .020 0.51 .032 0.81 .032 0.81 .020 0.51 .020 0.51 .020 0.51 .805 20.45 .655 16.64 .655 16.64 0.571 14.50 0.492 12.50 .655 16.64 .745 18.92 .655 16.64 .655 16.64 .625 15.88 0.832 21.14 .791 20.09 .655 16.64 .618 15.70 .985 25.02 .590 14.99 .505 12.83 .605 15.37 1601011-1 1601013-1 1601035-1 1601142-1 1601020-1 SIAMEZE Terminals (Continued) 2-1601006-21,5 1601006-25 2-1601011-11 2-1601018-21,5,6 1601018-25,6 2-1601033-21,5,6 1601033-25,6 2-1601021-21,5,6 1601021-25,6 2-1601013-11 3-1601072-25,6 2-1601068-21,5,6 1601068-25,6 2-1601174-21,5,6 1601174-25,6 2-1601035-11 2-1601035-21,5 1601035-25 2-293029-11,5 293029-15 2-1601142-11 2-1601058-21,5,7 1601058-25,7 2-1601226-11,3,6 1601226-13,6 2-1601020-11 2-1601020-21,5 1601020-25 2-1601049-21,5 1601049-25 4-1601006-22,5 4-1601011-12 4-1601018-22,5,6 4-1601033-22,5,6 4-1601021-22,5,6 4-1601013-12 4-1601072-22,5,6 4-1601068-22,5,6 4-1601174-22,5,6 4-1601035-12 4-1601035-22,5 4-1601142-12 4-1601058-22,5,7 4-1601226-12,3,6 4-1601020-12 4-1601020-22,5 4-1601049-22,5 1 Reverse Reeled-Consult TE drawing for orientation. 3 High Temperature Copper Alloy. 5 Finish is Pre Plated Tin (Consult TE drawing for specifics). 7 Extra Short Tab-Does not meet UL & NEMA length requirements. Compliant contact can connect 2 wires of the same diameter 2 Loose Piece Single. 4 Finish is Post Plated Tin (Consult TE drawing for specifics). 6 No hole in Tab., 8 Magnet wire 30 AWG [0.25] and smaller also requires a wrap post per Specification 1601447. .146 [ 3.71 ] .020 [ 0.51 ] .146 [ 3.71 ] .020 [ 0.51 ] .146 [ 3.71 ] .020 [ 0.51 ] .146 [ 3.71 ] .020 [ 0.51 ] .146 [ 3.71 ] .020 [ 0.51 ] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
L L L B CA SIAMEZE Terminals (Continued) 250 Series (6.3 mm wide) FASTON Tab Terminals Material Brass Type Recommended Pocket6 Copper Magnet Wire Range AWG mm L Dim. Tab Feature Tab Size Reeled Part Number Loose 4-1601161-1 4-1601159-1 4-1601115-1 4-1601028-1 4-1601118-23 4-1601002-23 4-1601028-23 4-1601061-23 4-1601139-23 4-1601052-22 A Multi-Barb B Single Barb Medium Range C Single Barb Heavy Range 1601435 1601438 1601425 27-36 18-34 12-23 12-20 16-17 14-15 1.60-1.40 1.27-1.15 2.03-0.8 2.03-0.56 1.02-0.16 0.36-0.13 .745 18.92 .745 18.92 .805 20.45 1.281 32.53 .778 19.76 .885 22.48 .885 22.48 .885
22.48 Hole
Hole .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 .250 x .032 6.35 x 0.81 1601028-1 1601115-1 1601159-1 1601161-1 1601118-2 2-1601118-21,3 1601002-23 2-1601002-21,3 1601028-23 2-1601028-21,3 2-1601028-11 284937-17 2-284937-11,7 1601061-23 2-1601061-21,3 1601052-22,4 2-1601052-21,2,4 1601139-23 2-1601139-21,3 2-1601115-11 2-1601159-11 2-1601161-11 1 Reverse Reeled –Consult TE drawing for orientation. 2 Finish is Pre-Plated Tin over Copper (Consult TE drawing for specifics). 3 Finish is Pre-Plated Tin (Consult TE drawing for specifics). 4 Double Carrier Strip. 5 Two magnet wires may be terminated in the same slot if diameters are equal. 6 Magnet wire 30 AWG [0.25 mm] and smaller also requires a wrap post per drawing 1601447. 7 Hole size and position complies with DIN standard. .146 [ 3.71 ] .020 [ 0.51 ] .280 [ 7.12 ] .032 [ 0.81 ] .315 [ 8.00 ] .032 [ 0.81 ] SIAMEZE Terminals Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
[ 7.75 ] Min. [ 2.63 ][ 7.01 ] Min. Min. .380 [ 9.65 ] Min. .104 [ 2.63 ] Min. .496 [ 12.60 ] Min. [ 8.38 ] Min. [ 2.95 ][ 7.01 ] Min. Min. SIAMEZE Terminals (Continued) Typical Plastic Cavity Pockets Note: Plastic cavities, designed to TE specifications, may be molded as part of the coil bobbin or attached to a lamination stack in the area of the magnet wire coil. Each cavity is a rectangular box with two narrow slots on opposing walls and a plastic cutoff or tie-off post. During or after the winding process, the magnet wire is placed across the plastic cavities and into the slots, either manually or by coil winding equipment. Unraveling is prevented by a slight friction fit, suitable bend or by wrapping the magnet wire around the wrap post. During insertion, the insulation displacing terminal slot strip the film insulation from the magnet wire producing a stable electrical termination. Terminal retention is retained in the plastic cavities by single or multiple barbs (Refer to Product Spec for force requirements). Excess magnet wire is trimmed flush with the outside of the plastic cavity by a shear blade traveling with the terminal insertion ram. TE can provide design and mold engineering resources to manufacture most specifically designed SIAMEZE cavity housings. Cavity Specification 1601421 Cavity Specification 1601424 Cavity Specification 1601425 Cavity Specification 1601431Cavity Specification 1601427Cavity Specification 1601426 * Minimum dimension with Lead Lok slot. The overall dimensions shown on these pages are for general reference only. For design purposes refer to the TE Cavity Specification. .204 [ 5.18 ] Min.* .276 [ 7.01 ] Min. .276 [ 7.01 ] Min. .104 [ 2.63 ] Min. .104 [ 2.63 ] Min. .270 [ 6.86 ] Min. .380 [ 9.65 ] Min. .276 [ 7.01 ] Min. .380 [ 9.65 ] Min. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Wrap Post Specification 1601447 Cavity Specification 1601475 Cavity Specification 1601433 Min. Cavity Specification 1601434 Cavity Specification 1601435 Cavity Specification 1601436 Cavity Specification 1601437 Cavity Specification 1601438 Typical Plastic Cavity Pockets (Continued) * Minimum dimension with Lead Lok slot. Cavity Specification 1601440 Cavity Specification 1601432 SIAMEZE Terminals (Continued) .104 [ 2.63 ] Min. .380 [ 9.65 ] Min.* .204 [ 5.18 ] Min. .490 [ 12.60 ] Min. .276 [ 7.01 ] Min. .380 [ 9.65 ] Min. .116 [ 2.95 ] Min. .446 [ 11.33 ] Min. .535 [ 13.59 ] Min. .630 [ 16.00 ] Min. .135 [ 3.44 ]Min. .410 [ 10.41 ] Min. .580 [ 14.72 ] .050 [ 1.27 ] Min. .050 [ 1.27 ] Min.* .204 [ 5.18 ] Min. .716 [ 18.19 ] Min. .380 [ 9.65 ] Min. .350 [ 8.89 ] .135 [ 3.44 ]Min. .135 [ 3.44 ] Min. .410 [ 10.41 ] Min. .520 [ 13.21 ] Min. .135 [ 3.44 ] Min. .276 [ 7.01 ] Min. .116 [ 2.95 ] Min. .353 [ 8.97 ] Min. .473 [ 12.01 ] Min. .293 [ 7.44 ] SIAMEZE Terminals Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Compression crimp eliminates cold solder points, weld burns and wire embrittlement usually connected with thermal-type terminations Excellent tensile strength— vibration resistant Provides a superior electrical connection that is free of many contaminants such as stripper residue and solder flux Precision formed, strip-fed splices terminated in automatic machines for high production rates per hour High termination rates, low wire consumption and the elimination of rejects caused by solder flux or heat damage results in the lowest applied costs Precisely controlled crimp termination helps eliminate human error for maximum reliability Splice up to 3 magnet wires together with stranded lead in one barrel Motor windings and connections Coil connections Transformer windings and connections Solid wire connections Lighting ballasts Power supplies Starters and alternators TE Connectivity offers a full selection of AMPLIVAR splices that are specifically designed to terminate magnet wire to itself or in combination with standard solid or stranded lead wire. AMPLIVAR splices have machined, sharp edged serrations inside the crimp barrels. These serrations, made by a special production process, pierce the insulating layer of magnet wires in a manner that provides a large contact area. In a one-step operation the magnet wire is automatically multiple ring-stripped of its insulation as it is forced into the serrations during the precisely controlled crimp. The resulting termination produces a high tensile strength, air-sealed connection that is as resistant to corrosion as the insulated conductor. As many as three magnet wires can be terminated simultaneously in one splice. In addition, copper or aluminum magnet wire, or a combination of both, can be terminated. When required, copper or aluminum magnet wire can Section AA be combined with standard, pre-stripped solid or stranded lead wires. Depending on your specific application, AMPLIVAR splices are available in 5, 7 and 9 serration versions for terminations in the 100 to 22,000 CMA range as well as miniature and subminiature designs for terminations in the 100 to 1850 CMA range. The crimping of AMPLIVAR splices is done by semi- automatic crimping machines for high output per hour production rates. Stranded Wire on top Magnet Wire on bottom Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
AMPLIVAR Splices (Continued) Technical Features Applicable Types of Wire — Cu, Al (Solid) together or in combination with stranded lead wire Wire Size Range — from 300 to 13,000 CMA (0.1 mm 2 to 6.6 mm2) Terminal Base Material — Brass, phosphor bronze Surface Finish — plain and tin plated except where noted Temperature Range — –65°C to +150°C Rated Current — according connected wire size Rated Voltage — according terminated winding Test Results The AMPLIVAR products have been subjected to the following tests without significant millivolt losses. Temperature Cycling — 25 cycles with each cycle consisting of 30 minutes at +125°C followed by 30 minutes at –65°C Heat Age — 96 hours at +150°C Thermal Shock — 25 cycles with each cycle consisting of 30 minutes at +150°C followed by 30 minutes at –65°C Salt Spray — 96 hours at +35°C with a 5% salt solution spray Humidity — 96 hours at 90–95% relative humidity and +40°C Current Cycling — 10,000 cycles with each consisting of 3 minutes on and 3 minutes off at a current (25 A) which establishes a wire temperature AMPLIVAR Splices Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
AMPLIVAR Splices (Continued) 1. All magnet wires must be placed in the bottom of the wire barrel before crimping. If lead wire is to be crimped in the same termination, it should be placed on top of the magnet wires. 2. Wire barrels are designed to accept a maximum of three insulated magnet wires plus stranded lead wires. 3. The ratio of magnet wire diameters crimped in any wire barrel should not exceed 2:1. This ratio is approximately a range from the largest to the smallest magnet wire of six sizes. 4. The sum of the circular mil area (CMA) of the magnet wires and any lead wires should not exceed the capacity of the splice. 5. The sum of the diameters of the individual magnet wires plus twice the terminal stock thickness must be equal to or less than the crimp width. 1. Use 9-serration splices, tin plated when terminating aluminum magnet wire or combinations with aluminum magnet wire. 2. Use 9-serration splices for hermetic and severe environment applications. 3. Use splices identified with an asterisk [*] when terminating 7-serration 26 AWG [0.40 mm] or smaller wires and 9-serration 28 AWG [0.32 mm] or smaller wires. 4. Calculate the total CMA of the magnet wires plus any lead wires to be terminated. Always use the coated magnet wire for CMA (see pages 90–91). 5. Calculate the total magnet wire diameters (see pages 90 and 91). 6. Select a splice for trial calculations. It should have the proper CMA range. Plating finish should be considered at this time. 7. Calculate the sum of the magnet wire diameters plus two splice stock thicknesses. If this total is less than the crimp width of the splice selected, it may be used. If the total is greater than the crimp width, a splice with a greater crimp width must be selected. Consult TE for special wide tooling recommendations. E xample: Selection of a pigtail splice to terminate the following wires: One 28 AWG [0.32 mm] copper magnet wire. One 22 AWG [0.64 mm] aluminum magnet wire. One 18 AWG [0.8–0.9 mm 2] 19-strand copper lead wire. Calculate the total CMA (Procedure 4): 28 AWG [0.32 mm] coated magnet wire = 185 CMA 22 AWG [0.64 mm] coated magnet wire = 708 CMA 18 AWG [0.8–0.9 mm2] stranded lead wire = 1608 CMA A M C 1 0 5 2 =l a t o T Calculate the sum of the magnet wire diameters (Procedure 5): 28 AWG [0.32 mm] coated magnet wire = .0136 [0.35] 22 AWG [0.64 mm] coated magnet wire = .0266 [0.68] ] 3 0 . 1 [ 2 0 4 0 . =l a t o T Select a terminal for trial calculations. Splice No. 62305-2, page 47 (Procedure 6): 0 0 3 – 0 0 6 =e g n a r A M C ] 1 4 . 0 [ 6 1 0 . =s s e n k c i h t k c o t S ] 9 7 . 2 [ 0 1 1 . =h t d i w p m i r C 9-serration, tin plated for aluminum magnet wire (Procedure 1). Splice identified with asterisk [*] for 28 AWG [0.32 mm] (Procedure 3). Calculate the sum of the magnet wire diameters plus two splice stock thicknesses (Procedure 7): .0722 [1.84] is less than the splice crimp width of .110 [2.79]; therefore, Part No. 62305-2 may be used. 114-2002 AMPLIVAR 7- serration pigtail splices 114-2003 AMPLIVAR 9- serration pigtail splices 114-2005 AMPLIVAR subminiature thru splices 114-2006 AMPLIVAR subminiature pigtail splices 114-2009 AMPLIVAR 5- serration thru splices 114-2016 AMPLIVAR miniature pigtail splices 6. Magnet wire of 26 AWG [0.40 mm] or smaller should be used with 7-serration splices having “shallow serrations,” and magnet wire of 28 AWG [0.32 mm] or smaller should be used with 9-serration splices having “shallow serrations” (part numbers identified with asterisk [*] are in the tabular data on the following technical pages). 7. Magnet wire of 20 AWG [0.81 mm] or larger having an insulation thickness heavier than “single film coated,” should not be used with splices having “shallow serrations” (those part numbers marked with an asterisk [*] in the tabular data on the following technical pages). 8. When aluminum magnet wire is used, splices and terminals must be tin plated. 9. Consult TE for splice and terminal selection and recommendations for all non-standard applications. General Application Guidelines To assist you in obtaining the optimum AMPLIVAR product termination, the following guidelines are recommended: Suggested Splice Selection Procedure Use the following guide to help you to determine the proper splice for your application: Technical Documents Application specifications describe requirements for using the product in its intended application and or crimping information. They are intended for the packaging and design engineer and the machine setup person. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
AMPLIVAR Splices (Continued)
9 Serrations —
(Plus All 7 Serration Facts) Splice length is increased on larger CMA splices for improved performance Serration depths are varied within the splice to give optimum electrical/ mechanical performance on all wire sizes Serration sidewall angles are varied to allow better wire stripping and serration fill Flat bottom of splice helps keep magnet wires on bottom as required during crimping Magnet wires 28 AWG [0.32 mm] and larger may be terminated without requiring shallow serrations Additional serrations enhance stability of crimp
7 Serrations —
Taper on both crimper and anvil improves flex life of termination Longer “flat” on tooling improves electrical performance (.125 vs. .080 [3.18 vs. 2.03]) Radius on wire entry end of splice helps prevent nicking wires and improves mechanical performance Serrations are offset to sheared end to place additional serrations in “electrical” portion of crimped splice Splice CMA ranges are overlapped so that two splices are available for any given CMA AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part mm2 r e b m u NL h t d i W s s e n k c i h T A M C . a i D d i l o S *These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller. 1 Flat bottom. AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part mm2 r e b m u NL h t d i W s s e n k c i h T A M C . a i D d i l o S *These splices are recommended for applications using wire size 28 AWG [0.32 mm] or smaller. 1 Special high force application equipment required. AMPLIVAR Splices Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
AMPLIVAR Splices (Continued)
5 Serrations —
Wide range of thru splice s Serrations centered in splic e to achieve optimu m electrical and mechanica l performance in a thru splic e CMA range accepts a wid e variety of wire sizes an d combinations Type AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part mm2 r e b m u NL h t d i W s s e n k c i h T A M C . a i D d i l o S * These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller. 1 Increased terminal pitch. 2 Increased U-diameter. BA L Crimp bellmouth provides retention in circular cavity slot in bobbin AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part mm2 r e b m u NL h t d i W s s e n k c i h T A M C . a i D d i l o S *These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
AMPLIVAR Splices (Continued) Miniature Splice — Pigtail Type Product Facts The miniature AMPLIVAR splice was developed for crimping thinner copper magnet wires having a diameter between .003 and .016 [0.08 and 0.40 mm] and has to be connected with a stranded conductor The diameter of one conductor strand should not exceed the magnet wire diameter to be applied Subminiature Splice — Thru or Pigtail Type Product Facts The compactness of these splices makes them ideal for use in small subfractional motors, transformers, relays, solenoids, indicator lamps and small appliance terminations These splices provide the same reliability as the larger AMPLIVAR splices AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part mm2 r e b m u NL h t d i W s s e n k c i h T A M C . a i D d i l o S AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part mm2 r e b m u NL h t d i W s s e n k c i h T A M C . a i D d i l o S L Serration depths are varied within the splice to give optimum electrical / mechanical performance on all wire sizes Flat bottom of splice helps keep magnet wires on bottom as required during crimping AWG/ Wire Range Wire Range Stock Crimp Dim. Material Part mm2 r e b m u NL h t d i W s s e n k c i h T A M C . a i D d i l o S *These splices are recommended for applications using wire size 26 AWG [0.40 mm] or smaller. 1 Flat bottom. AMPLIVAR Splice Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Ring tongue terminals available for 2 to 3/8 stud diameters FASTON tab terminals accept .125 [3.18], .187 receptacle terminals FASTON receptacle terminals accept .187 [4.75] and .250 [6.35] tab terminals FASTON stator receptacle accept .250 x .032 [6.35 x 0.81] tab terminal Pin receptacle terminals accept .062 [1.57] and .090 [2.29] diameter pins Motor windings Transformers Power supplies Starters and alternators AMPLIVAR magnet wire terminals are designed to terminate copper and/or aluminum magnet wire. Terminals are insulation displacing; therefore, magnet wires do not require a separate prestripping operation. The unique wire barrel design, with serrations and burrs, produces a superior metal-to-metal compression crimp with excellent tensile strength. Terminals are available in a variety of ring tongue, FASTON straight, flag and stator receptacles and tab quick-disconnect style terminals. Direct connection to magnet wire eliminates the need for separate stranded wire terminal connection to input/output devices. Matched with automated application tooling allows high production rates for stripform terminals. Product specifications describe the product qualification test results completed by TE for consideration of product use in a specific application. They are intended for the Design and Product Reliability Engineer. 108-16000 — AMPLIVAR ring tongue terminals 108-1718 — A MPLIVAR .125 blade terminals [Type A] 114-2145 AMPLIVAR .125 Blade Terminals 114-2146 AMPLIVAR FASTIN-FASTON Series 187 Tab Terminals 114-2070 AMPLIVAR FASTON Series
250 Tab Terminals
.250 Straight Receptacle Terminals 114-2152 AMPLIVAR Flag FASTON Series 187 & 250 Receptacle Terminal 114-2080 AMPLIVAR Pin Receptacle Terminals [Type A] 114-2128 AMPLIVAR Stator Receptacle with FASTON Mating End Technical Documents Application Specifications describe requirements for using the product in its intended application and or crimping information. They are intended for the Packaging and Design Engineer and the Machine Setup Person. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
AMPLIVAR Terminals (Continued) Ring Tongue Terminals Wire Size Range 29–22 AWG [0.287–0.643 mm] Type Insulation Hole Stud Stock Material Dimensions Part Dia. Range Dia. Size Thk. W L E C Number Wire Size Range 23–19 AWG [0.574–0.912 mm] Type Insulation Hole Stud Stock Material Dimensions Part Dia. Range Dia. Size Thk. W L E C Number Wire Size Range 22–18 AWG [0.643–1.024 mm] Type Insulation Hole Stud Stock Material Dimensions Part Dia. Range Dia. Size Thk. W L E C Number Wire Size Range 20–16 AWG [0.813–1.29 mm] Type Insulation Hole Stud Stock Material Dimensions Part Dia. Range Dia. Size Thk. W L E C Number Wire Size Range 18–14 AWG [1.024–1.628 mm] Type Insulation Hole Stud Stock Material Dimensions Part Dia. Range Dia. Size Thk. W L E C Number 1High conductivity copper-tin-zinc alloy. A B C D E G .243 [6.15] F .243 [6.15] Wire Range 17–13.5 AWG [1.151–1.78 mm] Type Insulation Hole Stud Stock Material Dimensions Part Dia. Range Dia. Size Thk. W L E C Number *Available on request Wire Size Range 14–12 AWG [1.628–2.05 mm] or (2) 15 AWG [1.45 mm] Type Insulation Hole Stud Stock Material Dimensions Part Dia. Range Dia. Size Thk. W L E C Number AMPLIVAR Terminals Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
AMPLIVAR Terminals (Continued) Wire Range (2) 17 AWG [1.51 mm] or (2) 15 AWG [1.45 mm] Type Insulation Hole Stud Stock Material Dimensions Part Dia. Range Dia. Size Thk. W L E C Number .150-.190 B or (2) 2.92 .150-.190 or (2) 2.92 Wire Range (1) 18 AWG [1.024 mm] and (1) 20.5 AWG [0.768 mm] Type Insulation Hole Stud Stock Material Dimensions Part Dia. Range Dia. Size Thk. W L E C Number Wire Range 16–13.5 AWG [1.29–1.78 mm] Type Insulation Hole Stud Stock Material Dimensions Part Dia. Range Dia. Size Thk. W L E C Number Wire Range 14.5 AWG [1.539 mm] Type Insulation Hole Stud Stock Material Dimensions Part Dia. Range Dia. Size Thk. W L E C Number Wire Range (2) 13 AWG [1.83 mm] Type Insulation Hole Stud Stock Material Dimensions Part Dia. Range Dia. Size Thk. W L E C Number H J K M N Stud Retaining Terminals Alternator Eyelet Terminal Wire Size Range 13–11 AWG [1.83–2.3 mm] Type Insulation Hole Stud Stock Material Dimensions Part Dia. Range Dia. Size Thk. W L E C Number 45° 45° L .388 [9.85] .376 [9.55] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
AMPLIVAR Terminals (Continued) Type Wire Range Material Dim. Part AWG mm 2 L Number B 27-23 0.1-0.2 Tin Plated Brass .935 63484-12 23.75 24-21 0.2-0.4 Tin Plated Brass .935 61440-3† 23.75 22-16 0.3-1.4 Tin Plated Brass 1.015 62447-1 A 25.78 15-13 1.6-2.6 Tin Plated Brass .935 61442-3† 23.75 15-12 1.6-3.0 Tin Plated Brass 1.015 62445-125.78 2 Varnish resist coating. † These part numbers are available upon special request, contact TE engineering for details.
187 Series FASTON Tabs1
A = .020 [0.51] B = .032 [0.81]
250 Series FASTON Tabs1
.032 [0.81] Wire Range Material Part Quick-Change AWG mm2 Number Applicator3 14-12 2.0-3.0 Tin Plated Brass 62922-12 466510-1 2 Varnish resist coating. 3 Quick-change applicator for AMP-O-LECTRIC machine 565435-5. For AMPOMATOR machine and other machines not listed, contact TE. BA 1Mates with FASTON receptacles. See Catalog 82004.
125 Series Blade
A = .013 [0.33] B = .020 [0.51] Mates with power blade receptacle terminals 61603-1, 61604-1, 770642-1 and 1217039-1 Housings Contact TE engineering for housing options available .810 [20.57] .125 [3.18] .020 [.508] .330 [8.38] .940 [23.88].125 [3.18] .020 [.508] .370 [9.40] BA Type Magnet Wire Range Material Material Part AWG mm 2 Solid Dia. CMA Thickness Number Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
AMPLIVAR Terminals (Continued) Wire Range Material Dimensions Part AWG mm 2 W L E T Number
250 Series FASTON
.016 [0.41] Mates with FASTON tabs. See catalog 82004. Magnet Wire Range Insulation Mating Material Material Part Applicator CMA mm 2 Dia. Diameter Tab Thk. Thickness Number No. 567451-22 1.30-2.00 0.51 Tin Plated Brass 0.41 63623-21 (2) 26 (2) 0.45 (2) 20 (2) 0.88 2.55-3.55 Tin Plated Brass 60384-2 1 4 . 01 5 . 0 5 5 . 3 - 5 5 . 2 18-14 or .120-.170 or .032 .016 3.05-4.30 1 4 . 01 5 . 0 0 3 . 4 - 5 0 . 39 1 ) 2 ( 1 4 . 01 5 . 0 0 3 . 4 - 5 0 . 39 1 ) 2 (
1 Low insertion force
2 Quick-change applicator for AMP-O-LECTRIC machine 565435-5. .690 [17.53] .290 [7.37] .280 [7.11] (Continued) Stock Thickness .032 [0.81] Mates with FASTON receptacles. See Catalog 82004. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
AMPLIVAR Terminals (Continued) Pin Receptacles Stock Thickness .016 [0.41] Type Wire Range Insulation Material Dimensions Part AWG mm 2 Dia. Range W Max. L C Number BA
187 Series FASTON Flag
.016 [0.41] Magnet Wire Range Insulation Mating Material Material Part Applicator CMA mm 2 Dia. Diameter Tab Thk. Thickness Number No. 1 4 . 01 5 . 0 2 0 . 1 - 1 5 . 0 1 4 . 01 8 . 0 2 0 . 1 - 1 5 . 0 1 4 . 01 5 . 0 2 0 . 1 - 1 5 . 0 1 4 . 01 5 . 0 2 0 . 1 - 1 5 . 0 1 4 . 01 8 . 0 2 0 . 1 - 1 5 . 0 1 Standard applicator for AMP-O-LECTRIC Model G splice terminator No. 356462-2. 2 Quick-change applicator for AMP-O-LECTRIC Model G splice terminator No. 356462-1. .045 [1.14] .240 [6.10] .4.35 [11.05].232 [5.89]
250 Series FASTON Flag
.018 [0.45] Insulation Diameter .100-.120 2.54-3.05 .100-.120 2.54-3.05 .075-.125 1.90-3.18 .110-.150 2.79-3.81 Material Thickness 0.0157 0.4 0.0157 0.4 0.0157 0.4 0.0157 0.4 Magnet wire range CMA mm 2 Dia. 500-1900 — 1000-2700 1500-4220 4000-8500 Part Number 1742881-1 1742882-1 1742977-1 1742979-1 Mating Tab Thk. 6.35 0.81 6.35 0.81 6.35 0.81 6.35 0.81 1 Quick-change applicator for AMP-O-LECTRIC Model G splice terminator No. 356462-1. .125 [3.16] .305 [7.75] .530 [13.46] .318 [8.09] Applicator No. 1855633 1855634 1855680 1855681 .070 [1.78] .305 [7.75] .600 [15.24] .300 [7.62] Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
AMPLIVAR Terminals (Continued) Stator Terminal — Receptacle .250 x .032 [6.35 x 0.81] Stator Terminal with Receptacle .250 x .032 [6.35 x 0.81] Plastic Cavity Production only according to TE Specifications (contact TE engineering for details). For design and material selection TE engineering has to be contacted before decision. The terminal is separated from the strip and placed automatic- ally into the cavity. Wire Clamping Barrel The magnet wire is positioned via posts into the AMPLIVAR crimp barrel and fixed inside clamping barrel. AMPLIVAR Terminal Crimp The application equipment crimps the AMPLIVAR product connection and cuts the extending clamping barrel in one operation. Additional versions upon request. Application tooling for production line integrating available upon request.
250 Series Stator
Receptacles —
7 Serrations
.070 [1.78] .860 [21.84] .300 [7.62] .305 [7.75] Magnet Wire Range Mating Tab Stock Crimp Material Part AWG mm 2 Solid Dia. CMA Thickness Thickness Width Number Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Connects to sealed hermetic headers Versions available to accept header pins Impervious to many oils and refrigerants Insulation compatibility Housings available to accept standard and reversed header p in layouts High-performance electrical and mechanical contact High-impact resistant Assemblies accept pins from one side only to prevent reversed polarity High-speed application of pin receptacle terminals with automatic terminating machines and quick-change applicators for high volume production rates at the lowest installed cost Recognized under the Component Program of Underwriters Laboratories Inc., File N o. E28476 Cluster blocks feature high impact resistance to shock and abuse, and long-life performance in the presence of oils and refrigerants. Since the connectors accept pins from only one side, the danger of reversing polarity at the time of installation is prevented. The one-piece housings are molded from thermoplastic polyester. The connector accepts 2.29 [.090] and 3.18 [.125] diameter pin sizes in either standard or reverse pin layouts. Housings accept both lead wire and AMPLIVAR direct connect pin receptacle Accepts Lead wire range 18–16 AWG [0.8–1.4 mm2] and AMPLIVAR product versions accept up to 3 copper or aluminum magnet wires without the need to remove insulation Housing versions available for compressor interior and exterior terminals. These are precision formed and available on reels for highspeed application. High retention pin recepta- cle terminals are available to provide optimum terminal retention hous- ings. TE features cluster blocks that offer manufacturers of air conditioning and refrigeration products a low-cost, fully insulated, quick-connect means for electrically connecting sealed hermetic header pins on compressors. Typical Assembly R Pin Receptacle Terminal (Crimped to Wire) PRODUCT SPECIFICATIONS: 108-2008,108-5205 &108-5541 APPLICATION SPECIFICATIONS: 114-2019 & 114-5235 Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Cluster Blocks 2.29 [.090] Pin Size (Lead Wire and Direct Connect) Housings K W H L C W H K L E .090 ± .001 [2.29 ± 0.03] Pin Dia. 3 Plcs. .530 [13.46] .229 [5.82] .459 [11.66] Dia. Pin Location B C and D .108 [2.74] .108 [2.74] .090 ± .001 [2.29 ± 0.03] Pin Dia. 4 Plcs. .108 [2.74] .108 [2.74] .324 [8.23] .683 [17.35] .324 [8.23] .324 [8.23] Dia. Pin Location E D A K H W L B 1.Interior use designates that the material can be subjected to refrigerants and lubricants often found in a compressor. Consult TE Connectivity Product specification for additional information. 2.Flammability rating UL94 V-2 Notes: 3.Flammability rating UL94 V-0 5.Flammability rating UL94 HB 4.Flammability rating UL94 V-0. Glow Wire compliant to 750°C with No Flame per IEC 60335-1. Type Header Pin Circle Dia. Dim L Dim W Dim H Dim K Part Number Notes mm / inch mm / inch mm / inch mm / inch mm / inch B 31.50 18.05 8.15 21.35 A, B & C 360050-1
3 Position
C D 31.60 22.70 9.30 21.50 D & E 171370-3 Use¹ Accepts Receptacle Style PBT Interior PBT Interior PA6+GF Exterior PBT Exterior PBT Interior PBT Exterior 13.46 [.530] 13.46 [.530] 13.46 [.530] PBT Interior PBT Interior PBT Exterior 30.48 17.65 9.70 20.40 A, B & C 2232327-1 3 30.48 17.65 9.70 20.40 A, B & C 2232327-2 PBT Exterior PA6+GF Exterior 30.48 17.65 9.70 20.40 A, B & C 2232326-1 3 30.48 17.65 9.70 20.40 A, B & C 2232326-2 30.80 17.80 7.40 20.40 A, B & C 235280-1 PBT Exterior PBT Exterior PA6+GF Exterior Pin Location A Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances 4PA6+GF Exterior 28.10 22.70 7.60 18.10 PBT Filled Exterior 4PBT Filled Exterior F 2825082-2 Economy Models
Cluster Blocks 2.29 [.090] Pin Size (Lead Wire and Direct Connect) Pin Receptacles .670 [17.02] .313 [7.95] .180 [4.57] .115 [2.92] A Lead Wire Standard Retention C Lead Wire Standard Retention .670 [17.02] .313 [7.95] .180 [4.57] .115 [2.92] B Lead Wire High Retention ED Lead Wire Standard Retention Lead Wire Standard Retention Magnet Wire Size Crimp Width Insulation Dia Crimp Width Part Number Notes mm / inch mm / inch mm / inch A 2.03 1.30 - 2.40 3.05 1599105-1 Lead Wire 0.080 .051 - .095 0.120 Standard Retention 2.79 1.50 - 2.50 3.56 62131-3 0.110 .060 - .100 0.140 2.79 2.30 - 4.30 4.57 63448-1 0.110 .090 - .170 0.180 B 2.54 2.00 - 3.80 3.30 1217264-1 Lead Wire 0.100 .080 - .150 0.130High Retention [400 - 1600] 0.090 0.06 - .100 0.140 E 1.78 Tin Plated Phos 1123655-1 2, 4 AMPLIVAR Short Barrel 0.070 .035 - .079 0.90 - 2.00 0.130 3.3 Oval Contact 2.79 2.00 - 2.90 3.81 353937-1 2, 4 0.110 .080 - .114 0.150 Tin Plated Phos Tin Plated Phos 0.77 - 2.13 [1600 - 4200] 0.11 - 0.73 [225 - 1445] Tin Plated Phos Material Tin Plated Phos Bronze¹ Bronze¹ Bronze¹ Bronze¹ Bronze¹ Bronze¹ Bronze¹ Bronze¹ Bronze¹ 0.30 - .75 [22 - 18] 0.80 - 1.3 [18 - 16] Tin Plated Phos Tin Plated Phos Tin Plated Phos 0.50 - 1.25 [20 - 16] 0.77 - 2.43 [1600 - 4800] 0.30 - 2.08 [22 - 14] Tin Plated Phos Type Lead Wire Size mm² / AWG mm² / CMA 1.May contain an equivalent copper alloy.Notes: 2.Requires extra wide type D housing. 3.Connects up to 3 Copper or aluminum magnet wires without stripping insulation. 4.Connects up to 2 copper magnets without stripping insulation. F 2,29 2.00 - 3.40 3.81 2825083-1 5Lead Wire 0.090 .080 - .134 0.150Oval Contact Economy Model Tin Plated Phos Bronze¹ 0.50 - 1.25 [20 - 16] 1.May contain an equivalent copper alloy.Notes: 2.Requires extra wide type D housing. 5.Requires extra wide type D, Economy Model housing. 3.Connects up to 3 Copper or aluminum magnet wires without stripping insulation. 4.Connects up to 2 copper magnets without stripping insulation. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances F Lead Wire Standard Retention Economy Model .180 [4.57] .083 [2.12] .590 [15.0] .276 [7.0]
Cluster Blocks 3.18 [.125] Pin Size (Lead Wire and Direct Connect) Housings .125 ± .001 [3.18 ± 0.03] Pin Dia. 3 Plcs. .530 [13.46] .229 [5.82] .459 [11.66] Dia. Pin Location A and B .125 ± .001 [3.18 ± 0.03] Pin Dia. 3 Plcs. .687 [17.45] .297 [7.55] .595 [15.12] Dia. Pin Location C and D .125 ± .001[3.18 ± 0.03] Pin Dia. 3 Plcs. .815 [20.70] .353 [8.96] .706 [17.92] Dia. Pin Location E C W L K H W H K L D E H L K W WK L H A B H L K W Type Header Pin Circle Dia. Dim L Dim W Dim H Dim K Part Number mm / inch mm / inch mm / inch mm / inch mm / inch A 44.60 19.45 11.95 31.17 A, B, C & D 360052-1 Center Forward 44.60 19.45 13.35 31.17 B 44.60 19.45 11.95 31.10 A, B, C & D 360051-1 Center Back 47.25 19.45 13.35 31.10 A, B, C & D 1217200-1 C 40.50 22.75 9.65 27.45 A, B, C & D 520995-1 Center Forward 43.95 22.75 15.60 27.45 A, B, C & D 1217186-1 17.45 [.687] 17.45 [.687] 20.70 [.815] PBT Interior PBT Interior PBT Interior PBT Interior PBT Interior Material / Use’ Accepts Receptacle Style PBT Interior PBT Interior PBT Interior13.46 [.530] 13.46 [.530] 1.Interior use designates that the material can be subjected to refrigerants and lubricants often found in a compressor. Consult TE Connectivity product specification for additional information. Notes: Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Cluster Blocks 3.18 [.125] Pin Size (Lead Wire and Direct Connect) (Continued) C AMPLIVAR Direct Connect Contact D AMPLIVAR Direct Connect Contact A Lead Wire .240 [6.1] .400 [10.16] .870 [22.1] .160 [4.06] .240 [6.1] .400 [10.16] .870 [22.1] .160 [4.06] B Lead Wire Pin Receptacles .805 [20.45] .400 [10.16] .160 [4.06] .240 [6.10] .805 [20.45] .400 [10.16] .160 [4.06] .240 [6.10] Type Lead Wire Size Magnet Wire Size mm² / CMA Crimp Width Insulation Dia Crimp Width Part Number Notes mm / inch mm / inch mm / inch A 2.79 2.30 - 3.30 3.94 62244-3 2 Lead Wire 0.110 .090 - .130 0.155 B 2.29 2.79 or 2x2.29 Max 3.56 1742657-1 2 Lead Wire 0.090 .110 or 2x.090 Max 0.140 High Retention C AMPLIVAR Direct Connect 400 - 1600 0.090 .060 - .100 0.140 Standard Retention D AMPLIVAR Direct Connect 400 - 1600 0.090 .060 - .100 0.140 High Retention 2.0 - 6.0 [14 - 10] Material Tin Plated Phos Bronze¹ Tin Plated Phos Bronze¹ Tin Plated Phos Bronze¹ Tin Plated Phos Bronze¹ Tin Plated Phos Bronze¹ Tin Plated Phos Bronze¹ Tin Plated Phos Bronze¹ Tin Plated Phos Bronze¹ Tin Plated Phos Bronze¹ Tin Plated Phos Bronze¹ Tin Plated Phos Bronze¹ 0.75 - 1.5 [18 - 16] 0.32-0.82 or 2x0.32 [22-18 or 2x22] 0.75 - 1.5 [18 - 16] mm² / AWG 2.Receptacle must be contained in a housing listed on the previous page for proper performance. 3.Stand-alone receptacle can be used with or without a housing. 4.Connects up to 3 copper or aluminum magnet wires without removing the insulation. 1.Material shown is for reference only. May contain an equivalent copper alloy.Notes: Cluster Blocks Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Made from a continuous coil of ribbon connector material Magnet wires MTM Crimpband splices have machine-piercing serrations designed for displacing magnet wire insulation. Available in brass, tin- plated brass, and copper- nickel alloy material Make parallel or pigtail connections on same machine 100% of Crimpband material is used in scrap free terminations Crimpband material coupled with appropriate toolsets accommodate specific CMA ranges Produced in TE equipment on your production floor Meets UL 486C crimp tensile requirements TE features the MTM Crimpband system that is comprised of two key features: the semi- automatic termination machine and a reel of MTM Crimpband material. In a one-step crimping operation, the machine feeds, cuts, forms and crimps the material to provide a low-cost, high reliability crimp connection. The MTM Crimpband splices are formed during the crimping process from machined longitudinal grooved material that pierces magnet wire varnish film insulation during crimping. MTM Crimpband splices are specifically designed to terminate magnet wire to itself or in combination with standard solid or stranded lead wire. Three magnet wires maximum can be terminated together with stranded lead wire in one splice. TE provides a wide range of toolset types and Crimpband splices to meet various production requirements. Depending on your specific application, MTM Crimpband splices are available in 7, 9, 11 and 13 serration versions for terminations in the 400 to 13,000 CMA range. When aluminum magnet wire is used, MTM Crimpband splices must be tin plated. Motors windings and connections Coil connections Transformer windings and connections Lighting ballasts Power supplies Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances Cut Formed Crimped This product line is not recommended for new designs, as the application machines are no longer manufactured.
MTM Crimpband Splices (Continued) Feed (Magnet Wire Connector Material) Machine feeds strip until the strip hits the wire stop. Shear (Blank Length) The strip is cut by the cutter block former bar insert tooling. Bend (Crimp Formed) The former bar drives the cut strip over the anvil, bending the cut strip into an upside down “U”. Wire (Placement) In pigtail and parallel (Thru) splices magnet wires must be placed on top of the lead wire. Crimp (Crimp Formed) The anvil retracts as the driver takes the formed strip down into the clincher. MTM Crimpband Interconnection System How the System Operates W W Blank Length DT SerrationsBurrs Lead Wire Magnet Wires on top A A Section A-A Connector Specification Code See Figure 1 and/or Legend below L 092 6R 20 T B Splice No. Example: L 092 6R 20 T B Legend Machine Basis L P G* Leased Purchase General * Customer has their own Tooling Tooling Blank Length Size Code B/L (Nom.) 032 .167 032/036 .228 036 .224 045 .246 051 .267 061 .292 061/076 .324 076 .339 076/092 .361 092 .379 092/125 .413 125 .446 125/160 .485 125/165 .506 165 .546 Note: For B/L above, .546 consult TE for tooling size code. Connector Width Code W 4R 5 Serrations .138 6R 7 Serrations .154 8R 9 Serrations .194 10R 11 Serrations .234 Material T±.002 D Thickness Dim. Serration Code Depth 12 .012 .005 14 .014 .005 16 .016 .007 20 .020 .007 25 .025 .007 UL486C Pull Out Wire Size Force Requirements AWG Underwriters Laboratory (lbs.) 26 3 24 5 22 8 20 10 18 10 16 15 14 25 12 35 10 40 Notes: To insure that the proper Crimpband splice is chosen, TE recommends the following: 1. Submit 10 samples of wire combinations and/or components to be crimped with any special requirements to your TE sales representative. 2. Pull-out force and/or millivolt drop tests will be performed to insure that the proper Crimpband material, toolset and crimp heights are recommended. 3. Tooling and testing will be documented on a Material & Tooling Sheet (M & T sheet). 4. Crimpband material quotes, tooling quotes and samples will be submitted to the customer. Material Material/FinishCode B CDA 260 Brass A CDA 725 Copper/ Nickel Alloy TB Pre-Tin over CDA 260 Brass Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances This product line is not recommended for new designs, as the application machines are no longer manufactured.
MTM Crimpband Splices (Continued)
11 Serrations
9 Serrations
T W T W AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive mm2 f e r - X r e b m u N) W ( h t d i W ) T ( . k h T e g n a R . a i D d i l o S 24-20 .020-.033 400-1100 .016 .194 Tin Plated 032/036 1601794-1 † P032/ 18-14 .040-.063 1800-4600 .020 .194 Brass 076/092 1601823-1 P076/ 18-14 .040-.063 1800-4600 .020 .194 Tin Plated 076/092 1601639-1 L076/ 16-12 .051-.078 2600-6100 .020 .194 Brass 092/125 1601833-1 P092/ 16-12 .051-.078 2600-6100 .020 .194 Tin Plated 092/125 1601677-1 L092/ 16-12 .051-.078 2600-6100 .025 .194 Brass 092/125 1601678-1 † L092/ 16-12 .051-.078 2600-6100 .025 .194 Tin Plated 092/125 1601835-1 † P092/ 141/uni22152-111/uni22152 .059-.087 3500-7500 .025 .194 Brass 125/165 1601706-1 L125/ 141/uni22152-111/uni22152 .059-.087 3500-7500 .025 .194 Tin Plated 125/165 1601707-1 L125/ 111/uni22152-9 .084-.114 7000-13000 .025 .194 Tin Plated 200/202 1601761-1 L200/ † These part numbers are available upon special request; contact TE engineering for details. AWG/ Wire Range CMA Stock Mat’l Material Toolset Part Descriptive mm2 f e r - X r e b m u N) W ( h t d i W ) T ( . k h T e g n a R . a i D d i l o S 141/uni22152-111/uni22152 .059-.087 3500-7500 .025 .234 Brass 125/165 1601842-1 P125/ 141/uni22152-111/uni22152 .059-.087 3500-7500 .025 .234 Tin Plated 125/165 1601705-1 L125/ 131/uni22152-101/uni22152 .071-.097 4500-9500 .025 .234 Brass 165/200 1601847-1 P165/ 131/uni22152-101/uni22152 .071-.097 4500-9500 .025 .234 Tin Plated 165/200 1601848-1 P165/ Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances This product line is not recommended for new designs, as the application machines are no longer manufactured.
MTM Crimpband Splices (Continued) T W AWG/ Wire Range CMA Stock Mat ’l Material Toolset Part Descriptive mm2 f e r - X r e b m u N) W ( h t d i W ) T ( . k h T e g n a R . a i D d i l o S 271/uni22152-21 .013-.028 170-800 .012 .154 Brass 032 1601800-1 P0326R12BUF 1 24-20 .020-.033 400-1100 .012 .154 Brass 032/036 1601539-1 L032/ 24-20 .020-.033 400-1100 .012 .154 Cu Ni 032/036 1601538-1 L032/ 24-20 .020-.033 400-1100 .016 .154 Brass 032/036 1601540-1 L032/ 24-20 .020-.033 400-1100 .016 .154 Tin Plated 032/036 1601793-1 P032/ 171/uni22152-131/uni22152 .042-.068 1800-4600 .016 .154 Brass 076/092 1601637-1 L076/ 16-12 .051-.078 2600-6100 .016 .154 Tin Plated 092/125 1601675-1 L092/ 16-12 .051-.078 2600-6100 .020 .154 Brass 092/125 1601832-1 P092/ 1 UF designates Ultra-Fine serrations which are recommended for applications using wire size 28 AWG [0.32 mm] or smaller. † These part numbers are available upon special request; contact TE engineering for details. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances This product line is not recommended for new designs, as the application machines are no longer manufactured.
Made from a continuous coil of “Ribbon Connector” material RTM Crimpband have grooved serrations for improved axial retention. Available in brass, tin-plate d brass and copper-nickel alloy (CA725) materia l Make parallel or pigtail connections on same machine Used for electrical and non- electrical connections. 100% of RTM Crimpband material is used in scrap free terminations Crimpband material coupled with appropriate toolsets accommodate specific CMA ranges Produced in TE equipment on your production floor Meets UL 486C crimp tensile requirements TE features the RTM Crimpband system that is comprised of two key features: the semi- automatic termination machine and a reel of RTM Crimpband material. In a one-step crimping operation, the machine feeds, cuts, forms and crimps the material to provide a low-cost, high reliability crimp connection. The RTM Crimpband splices are formed during the crimping process from milled longitudinal groove material that produce rolled, rounded serrations. They are designed to terminate pre-stripped stranded and solid wire conductors together as well as wire conductors to switch tabs, resistors, printed circuit board, flex circuit and light bulb LED and glass reed switch assemblies, etc. The flexibility of the RTM Crimpband system provides opportunity for use in custom applications for either electrical and / or mechanical connections. TE provides a wide range of toolset types and crimpband splices to meet various production requirements. Depending on your specific application, RTM Crimpband splices are available in 3, 6, 7, 8, 9, 10 14 and 20 ridge serration versions for terminations in the 170 to 13,000 CMA range. Stranded and solid wire-to- wire connections Light bulb LED assembly Switch lead assembly Resistor lead assembly Printed circuit board lead assembly Flex-film lead assembly Glass reed switch lead assembly Cut Formed Crimped Mod I Mod III Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances This product line is not recommended for new designs, as the application machines are no longer manufactured.
RTM Crimpband Splices (Continued) Feed (Ribbon Connector Material) Machine feeds strip until the strip hits the wire stop. Shear (Blank Length) The strip is cut by the cutter block former bar insert tooling. Bend (Crimp Formed) The former bar drives the cut strip over the anvil, bending the cut strip into an upside down “U”. Wire (Placement) Pigtail and parallel (Thru) splice terminations are made on the same machine. Crimp (Crimp Formed) The anvil retracts as the driver takes the formed strip down into the clincher. RTM Crimpband Interconnection System How the System Operates Legend Machine Basis L P Leased Purchase Tooling Blank Length Size Code B/L (Nom.) 032 .167 032/036 .228 036 .224 045 .246 051 .267 061 .292 061/076 .324 076 .339 076/092 .361 092 .379 092/125 .413 125 .446 125/160 .485 125/165 .506 165 .546 Note: For B/L above, .546 consult factory for tooling size code Connector W N Width Dim. No. of Code Ridges B .076 3 C .138 6 D .154 7 E .185 8 F .216 9 G .234 10 H .247 10 L .086 3 M .330 14 N .500 20 P .114 5 Material T±.002Thickness Dim.Code 12 .012 16 .016 18 .018 20 .020 22 .022 24 .024 25 .025 Material Material/FinishCode B CDA 260 Brass A CDA 725 Copper/ Nickel Alloy TB Pre-Tin over CDA 260 Brass TCRS 1010 Cold Rolled Steel, Tin Plated SS 301 or 302 Stainless Steel ST Stainless Steel, Tin Plated UL486C Pull Out Wire Size Force Requirements AWG Underwriters Laboratory (lbs.) 26 3 24 5 22 8 20 10 18 10 16 15 14 25 12 35 10 40 Notes: To insure that the proper Crimpband splice is chosen, TE recommends the following: 1. Submit 10 samples of wire combinations and/or components to be crimped with any special requirements to your TE sales representative. 2. Pull-out force and/or millivolt drop tests will be performed to insure that the proper Crimpband material, toolset and crimp heights are recommended. 3. Tooling and testing will be documented on a Material & Tooling Sheet (M & T sheet). 4. Crimpband material quotes, tooling quotes and samples will be submitted to the customer. W W Blank Length T Ridges Lead Wires A A Section A-A Connector Specification Code See Figure 1 and/or Legend below Size Width Thickness L 092 F 20 TCRS Splice No. Example: L 092 F 20 TCRS Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances This product line is not recommended for new designs, as the application machines are no longer manufactured.
RTM Crimpband Splices (Continued)
20 Ridges
T W AWG/ Wire Range CMA Stock Mat ’l Material Toolset Part Descriptive mm2 f e r - X r e b m u N) W ( h t d i W ) T ( . k h T e g n a R . a i D d i l o S
14 Ridges
T W AWG/ Wire Range CMA Stock Mat ’l Material Toolset Part Descriptive mm2 f e r - X r e b m u N) W ( h t d i W ) T ( . k h T e g n a R . a i D d i l o S † These part numbers are available upon special request; contact TE engineering for details.
10 Ridges
T W AWG/ Wire Range CMA Stock Mat ’l Material Toolset Part Descriptive mm2 f e r - X r e b m u N) W ( h t d i W ) T ( . k h T e g n a R . a i D d i l o S 111/uni22152-9 .084-.114 7000-13000 .020 .234 Brass 200/202 1601853-1 P200/ 111/uni22152-9 .084-.114 7000-13000 .025 .234 Brass 200/202 1601769-1 L200/ † These part numbers are available upon special request; contact TE engineering for details. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances This product line is not recommended for new designs, as the application machines are no longer manufactured.
RTM Crimpband Splices (Continued)
9 Ridges
T W AWG/ Wire Range CMA Stock Mat ’l Material Toolset Part Descriptive mm2 f e r - X r e b m u N) W ( h t d i W ) T ( . k h T e g n a R . a i D d i l o S
8 Ridges
T W AWG/ Wire Range CMA Stock Mat ’l Material Toolset Part Descriptive mm2 f e r - X r e b m u N) W ( h t d i W ) T ( . k h T e g n a R . a i D d i l o S 24-20 .020-.033 400-1100 .012 .185 Cu Ni 032/036 1601553-1 L032/ 111/uni22152-9 .084-.114 7000-13000 .024 .185 Brass 200/202 1601768-1 L200/
7 Ridges
T W AWG/ Wire Range CMA Stock Mat ’l Material Toolset Part Descriptive mm2 f e r - X r e b m u N) W ( h t d i W ) T ( . k h T e g n a R . a i D d i l o S 24-20 .020-.033 400-1100 .012 .154 Brass 032/036 1601550-1 L032/ 24-20 .020-.033 400-1100 .016 .154 Cu Ni 032/036 1601551-1 L032/ 24-20 .020-.033 400-1100 .016 .154 Brass 032/036 1601797-1 P032/ 24-20 .020-.033 400-1100 .016 .154 Tin Plated 032/036 1601798-1 P032/ Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances This product line is not recommended for new designs, as the application machines are no longer manufactured.
RTM Crimpband Splices (Continued)
7 Ridges (Continued)
T W AWG/ Wire Range CMA Stock Mat ’l Material Toolset Part Descriptive mm2 f e r - X r e b m u N) W ( h t d i W ) T ( . k h T e g n a R . a i D d i l o S † These part numbers are available upon special request; contact TE engineering for details. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances This product line is not recommended for new designs, as the application machines are no longer manufactured.
RTM Crimpband Splices (Continued) T W AWG/ Wire Range CMA Stock Mat ’l Material Toolset Part Descriptive mm2 f e r - X r e b m u N) W ( h t d i W ) T ( . k h T e g n a R . a i D d i l o S 171/uni22152-13 .042-.068 1800-4600 .016 .154 Brass 076/092 1601642-1 L076/ 16-12 .051-.078 2600-6100 .020 .154 Cu Ni 092/125 1601680-1 L092/ 16-12 .051-.078 2600-6100 .020 .154 Brass 092/125 1601681-1 L092/ 16-12 .051-.078 2600-6100 .020 .154 Tin Plated 092/125 1601682-1 092/ 141/uni22152-111/uni22152 .059-.087 3500-7500 .018 .154 Tin Plated 125/165 1601709-1 L125/ 141/uni22152-111/uni22152 .059-.087 3500-7500 .020 .154 Cu Ni 125/165 1601710-1 L125/ 141/uni22152-111/uni22152 .059-.087 3500-7500 .020 .154 Brass 125/165 1601711-1 L125/ 141/uni22152-111/uni22152 .059-.087 3500-7500 .020 .154 Tin Plated 125/165 1601712-1 L125/ 131/uni22152-101/uni22152 .071-.097 4500-9500 .020 .154 Brass 165/200 1601532-1 G165/ 111/uni22152-9 .084-.114 7000-13000 .016 .154 Brass 200/202 1601764-1 L200/ 111/uni22152-9 .084-.114 7000-13000 .020 .154 Cu Ni 200/202 1601765-1 L200/ 111/uni22152-9 .084-.114 7000-13000 .020 .154 Brass 200/202 1601852-1 P200/ 111/uni22152-9 .084-.114 7000-13000 .020 .154 Tin Plated 200/202 1601766-1 L200/ † These part numbers are available upon special request; contact TE engineering for details. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances This product line is not recommended for new designs, as the application machines are no longer manufactured.
RTM Crimpband Splices (Continued)
6 Ridges
T W AWG/ Wire Range CMA Stock Mat ’l Material Toolset Part Descriptive mm2 f e r - X r e b m u N) W ( h t d i W ) T ( . k h T e g n a R . a i D d i l o S 24-20 .020-.033 400-1100 .012 .138 Tin Plated 032/036 1601548-1 L032/ 24-20 .020-.033 400-1100 .016 .138 Brass 032/036 1601549-1 L032/ 20-15 .033-.057 1100-3200 .016 .138 Brass 061/076 1601597-1 L061/ 20-15 .033-.057 1100-3200 .016 .138 Tin Plated 061/076 1601599-1 L061/ 20-15 .033-.057 1100-3200 .018 .138 Brass 061/076 1601600-1 † L061/ 171/uni22152-13 .042-.068 1800-4600 .016 .138 Brass 076/092 1601640-1 L076/ † These part numbers are available upon special request; contact TE engineering for details. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances This product line is not recommended for new designs, as the application machines are no longer manufactured.
RTM Crimpband Splices (Continued) AWG/ Wire Range CMA Stock Mat ’l Material Toolset Part Descriptive mm2 f e r - X r e b m u N) W ( h t d i W ) T ( . k h T e g n a R . a i D d i l o S 24-20 .020-.033 400-1100 .012 .076 Cu Ni 032/036 1601542-1 L032/ 24-20 .020-.033 400-1100 .012 .076 Brass 032/036 1601795-1 P032/ 24-20 .020-.033 400-1100 .016 .076 Brass 032/036 1601545-1 L032/ 24-20 .020-.033 400-1100 .016 .076 Tin Plated 032/036 1601546-1 L032/ 24-20 .020-.033 400-1100 .018 .076 Brass 032/036 1601547-1 † L032/ 20-15 .033-.057 1100-3200 .016 .076 Tin Plated 061/076 1601596-1 L061/ † These part numbers are available upon special request; contact TE engineering for details.
3 Ridges
T W Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances This product line is not recommended for new designs, as the application machines are no longer manufactured.
Compression crimp eliminates cold solder points, weld burns and wire enbrittlement usually connected with thermal-type terminations Precisely controlled crimp termination helps eliminate human error, for maximum reliability Excellent tensile strength, up to 90 lbs axial retention, vibration resistant Provides a superior electrical connection that is free of many contaminates such as stripper residue and solder flux 8000 - 38,000 CMA nominal capacity Accepts up to six magnet wires and two standard solid or stranded lead wires Superior test results: low resistance, high stability High termination rates, low wire consumption and the elimination of rejects caused by solder flux or heat damage results in the lowest applied costs TE features the Power Splice terminal that is specifically designed to terminate a wide range of lead and magnet wire combinations. The splice contains two cavities that separate and cradle magnet wire and stripped lead wires prior to crimping. The outer saddle accepts up to six-magnet wire allowing for a CMA range of 15,000 to 30,000. The inner saddle accepts pre-stripped lead wires that total up to 10,900 CMA. In a one step automatic operation, the magnet wire film insulation is multiple ring-stripped as it is forced into the serrations while the lead wire is simultaneously terminated during the precisely controlled crimp. The outer saddle has machined, sharp edges made by a special production process that pierces the insulating layer of the magnet wire in a manner that provides a large contact area. The resulting termination produces a high tensile strength, air sealed connection that is as resistant to corrosion as the insulated conductor with up to 90 lbs axial retention. As many as six magnet wires can be terminated simultaneously in one splice in combination with up to two pre-stripped standard solid or stranded lead wire. A semi-automatic machine provides high output per hour terminations. Hermetic/Compressor motors Squirrel cage DC motors Capacitor start motors Gear & Traction motors Power supplies Liner, Torroid & RF transformers Circuit breakers & welders Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Power Splice (Continued) Magnet wire insulation piercing serrations Inner saddle for lead wire (CMA 4,200-10,900) Outer saddle accepts up to 6 magnet wires (CMA 15,000-30,000) #20 AWG minimum Magnet wires smaller than #18 AWG (1.0 mm) are placed here Direction of Feed .408 [10.36] .430 [10.92] Max. Cut-off .385 [9.78].430 ± .010 [10.92 ± 0.25] .118 [3.00] R .060 [1.52] R .024 [0.61] .296 [7.52] Part Number 111-000-001 Type Magnet Wire Range Lead Wire Range Part Number CMA CMA Reeled A 15,000-30,000 4200-10,900 1601953-1 1 1 Total combined CMA not to exceed 38000. .375 [9.53] .408 [10.36] .425 [10.80] Power Splice Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Worldwide Leadership in Wire and PCB Manufacturing Products Leadership demands commitment and TE is committed to meeting manufacturing needs worldwide with technology, products and systems, and service. Application Tooling of TE Connectivity TE has long been recognized as a leader in providing the tools for wire har- ness and printed circuit manufacturing. There’s a good reason. Our products are designed to meet and anticipate our customers’ ever-changing require- ments and built to the highest quality standards, for longest, most productive performance lifetimes. Whatever your production volume and job mix, we can the tools to get it done. With a full range of tooling from hand tools to high volume, fully auto- mated systems, TE is able to meet most manufacturing demands worldwide. It’s an ability that comes from our experience with manufacturers large and small, giving us a unique view of the trends and challenges in wire harness and PCB manufacturing. It all derives from our commitment to your manufacturing challenges, giving you the advantage in your marketplace. This catalog is just a sampling of the types of solutions that will make your job easier, faster, more productive and more profitable. Make tooling, assembly equipment, and service from TE part of your thinking, now and as you grow into the future. TE Connectivity Service and Support Few suppliers can match TE customer service and support. From helping you select the tooling for your requirements to maintenance and repair and ana- lyzing your operation for maximum productivity, our worldwide capabilities and experience will make a real in your production and bottom line. ProductionChek Service — In a consultative role, our field engineer will meet with you to determine your objectives and known production issues, then observe and record in detail each step in your operation. Based on this infor- mation, the engineer will be able to make recommendations for improvement, typically in people, process or equipment. Tool Repair and Certification — Our field engineers will set up, certify, and repair application tooling on site or recommend our factory-level service. Flexible plans, including options for premium access to parts and service, will keep your PCB assembly automation equipment running at peak performance. For additional maintenance services, the TE Technical Support Center is dedi- cated to providing the answers you need, toll-free at 1-800-522-6752. Support contracts are available for preventive maintenance, training, emergency situa- tions and other specific requirements. For more information regarding the products and services shown in this brochure, visit our website at www.tooling.te.com Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
The Power Splice Machine and applicator from TE provides reliable pigtail splice termination of magnet wire and solid or stranded lead wire. This machine can terminate pigtail splices consisting of up to two solid or stranded copper lead wires in wire size from 10-14 AWG and having a Circular Mil Area (CMA) of 4,100 - 11,000. The splice will simultaneously accept combinations of multiple copper magnet wires in a range of 11-20 AWG. The total CMA range Magnet Wire Crimp Application Equipment MAG-MATE and AMPLIVAR splices and terminals are available in a wide range of configurations to meet most magnet-wire termination needs. All provide high reliability with minimal wire preparation. TE Connectivity a wide variety of magnet-wire termination solutions for thru splicing, pigtail splicing and coil termination. AMPLIVAR Product Terminator (APT) Machines The new APT 5A magnet wire pigtail splice machine a fast, system, with no need to strip mag-wire insulation. Simply place the wires in the target area and depress the foot switch. The machine automatically shears the splice or Direct Connect contact from the strip, crimps it, shears excess wire, and advances the next splice or contact into position. APT bench machines are available in two versions: the 5A with automatic precision adjustment controlled by the crimp quality monitor (CQM) and the 5E with manual precision adjustment. Using CQM, the APT 5A provides 100% inspection and automatic adjustment of crimp height. If a questionable crimp is detected, visual and audible alarms alert the operator. The lower cost, manual adjust APT 5E is a simpler version with the advan- tage of faster set-up times but without CQM capability. Power Splice Machine Not CE approved, contact engineering for quotation. for lead wire and magnet wire is 4,000 to 40,000. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Magnet Wire Crimp Application Equipment AMPLIVAR Terminator for Parallel and End Connections Primarily sold in Europe. The machine was developed for processing magnet wire connections. versions for end-feed and side-feed contacts are available. The design takes into account that the motor windings and coils can be supplied directly to the connectors. The exposed crimp position permits precise handling. In case of end connections the projecting magnet wires are cut AMPLIVAR splices and terminals are specifically designed to terminate magnet wires or in combination with standard solid or stranded wire. In a one-step operation the magnet wire is automatically multiple ring stripped of its insulation as it is forced into the serrations during the precisely controlled crimping operation. As many as three magnet wires can be terminated, simultaneously in one splice. Nearly the entire AMPLIVAR splice program can be applied with this machine in combination with suitable applicators. The comprehensive range of manu facturing possibilities demands a specific machine and applicator combination. AMP-O-LECTRIC Model G Terminator with Thru-Splice Applicator Not CE Approved. Applying thru-splices is fast and when you have access to both sides of the applicator for placing and holding the wires. The AMP-O-LECTRIC model G splice terminator with a standard G splice applicator provides front and rear access to maximize production cy. It provides full guarding for operator safety and is available with or without a Crimp Quality Monitor. Request catalog 889021 for more information. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Crimpband Application Tooling Not CE approved, contact engineering for quotation. TE solderless crimping systems to handle a wide range of wire connections including solid and stranded lead wire, insulated magnet wire, and component leads. Each system is comprised of continuous, serrated Crimpband material and a crimping machine. The TE solution allows the flexibility to create a shape and size, which optimizes the crimp’s electrical and mechanical performance. The TE crimping system produces a very economical and reliable intercon- nection. Utilizing a continuous crimpband material the machine will feed, cut form, and crimp your application resulting in a very strong and uniform interconnect crimp. Whether your application required a wire-to-wire, wire to components leads, wire to terminals, or magnet wire splice termination, the very flexible and dependable crimping machine will provide high-speed scrap free interconnects. Substantial increase in production interconnection rates can be realized versus traditional soldering. Not to mention it completely eliminates the noxious fumes. The mod I crimping system is used when running standard RTM and MTM crimpband product. In addition, left and right horn termination machines are available when your application requires additional working envelope. Magnet Wire Crimp Application Equipment Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances Crimpband application machines have been discontinued and are no longer offered by TE.
Magnet Wire MAG-MATE Terminal Application Equipment MPT-5 MAG-MATE Product Terminator Not CE approved, refer to Mark I, Mark II pages 83, 84. The MPT-5 is an air-operated machine with microprocessor control that inserts MAG-MATE terminals into customer-designed cavities in the coil bobbin or similar magnet-wire housing, terminating the wire for connectivity. Please note: The customer designed cavities must follow TE specification guide- lines. Termination of single, dual, triple and up to quadruple termina- tion possible depending on the application details. The machine is available in either vertical or horizontal configuration to match the customer’s application. The dual reel capability of the MPT-5 machine allows inser- tion of two MAG-MATE terminals, with the capability to alternate between inserting one and two terminals at a time. The MPT-5 is also capable of trimming excess magnet wire. The MPT-5 Terminator also has the capability to alternate between inserting 2 bridged (or commoned) terminals and 2 separated terminals. Request catalog 1308387 for more information. MAG-MATE Terminal Cavity and Fixture Design MAG-MATE terminals insert into a molded-in cavity in the coil bobbin. The bobbin is generally secured in a fixture during the insertion/termination process. TE engineers work with our customers to support cavity and fixture design, at any level. We can provide complete design of cavities and fixtures for customer’s applications, work with our customer’s engineers, or simply provide CAD models and other engineering data as needed. Consultation early in the design process allows customers maxi- mum benefit from our decades of magnet-wire experience. Product Line Integration The MPT-5 and APT IIIA Machines have the production capacity and the electronics for easy integration into automated production lines. TE Engineers work with your system integrators to assure the of TE equipment into the line’s design and assembly. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
MPT-5 S/L Machine (for SIAMEZE and Lead Lok Terminals) Not CE approved, refer to Mark I, Mark II pages 83, 84. For quick, easy and reliable termination of magnet wire, TE the MPT-5 S/L MAG-MATE product terminator — an air-operated insertion machine with microprocessor control. The MPT-5 S/L machine inserts a SIAMEZE terminal into a customer-designed cavity in the coil bobbin or similar mag-wire housing, terminating the wire for connectivity. Please note: The customer designed cavities must follow TE specification guidelines. It can insert both the SIAMEZE terminal and the Lead Lok terminal to assure your lead wire connection. The MPT-5 S/L dual reel capability and is also capable of trim- ming excess magnet wire. The dual reel capability of the MPT-5 S/L allows insertion of two SIAMEZE terminals, with the capability to alternate between inserting one and two terminals at a time. The MPT-5 S/L machine is available as a horizontal or vertical bench machine or as a discrete module for integration into automated lines. EMT — Entry Level Magnet Wire Terminator (for loose piece SIAMEZE, Lead Lok, or MAG-MATE Terminals) Not CE approved, contact engineering for quotation. The Entry Level Magnet Wire Terminator tube design is based on the proven MPT-5 system and incorporates a fine adjust mechanism for easy set-up. The floating tube bottoms on the top of the terminal cavity to create the datum for the insertion depth of the terminal. The insertion depth can be adjusted in .002” [. 05 mm] increments quickly and easily. An unobstructed view of the tube bottom permits the operator to easily load loose piece terminals. A two-handed actuation system protects the operators during the insertion process and the open architecture design allows operators to easily load and unload the stators on and o the fixture. Magnet Wire MAG-MATE Terminal Application Equipment MPT-5 S/L Entry Level Terminator Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Magnet Wire MAG-MATE Terminal Application Equipment Insertion Tools CERTI-LOK Tools Manual Arbor Press Manual Hand Tool Manual Hand Tool (for loose piece SIAMEZE, Lead Lok, or MAG-MATE Terminals)
- Inserts loose piece terminals into molded cavities
- Insertion depth is repeatable due to the hand tools design which requires the operator to fully compress the handle before it is allowed to retract
- Since tooling captures the cavities during insertion, no fixturing is needed
- Hand tools are available quickly for prototyping, repair, and/or low volume
** The manual hand tool is not compatible with every application. Please contact TE Connectivity for more information. Manual Arbor Press (for loose piece SIAMEZE, Lead Lok, or MAG-MATE Terminals)
- Inserts loose piece terminals into molded cavities
- One tip is capable of inserting the SIAMEZE wire-to-wire terminal, the lead wire and the Lead Lok terminal
- Insertion tip bottoms on the top of the cavity to provide repeatable insertion depth capability
- Customers often supply their own fixtures for prototyping or low volume requirements
- Tips, arbor presses, and CERTI-LOK hand tools are available quickly for prototyping applications requirements Hand Insertion Tools
- Inserts loose piece terminals into molded cavities
- Available quickly for prototyping application requirements
- Available for each type of MAG-MATE terminal Full Line of Crimp Tooling
- TE a full line of hand tools, bench equipment, and automatic machines to perform the wire crimps for the mating end of these MAG-MATE connections. Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Magnet Wire MAG-MATE Terminal Application Equipment MAG-MATE Inserter MK I with Pneumatic Control, Primarily sold in Europe.
- Single, dual, triple and quadruple insertion
- Module easily integrated into production lines using simple handshake signals
- Holding fixture for bobbin can be designed and built by TE
- Can apply standard MAG-MATE and SIAMEZE terminals
- Load-while-running feature increases productivity
- Cycle time: 0.9 - 1.3 s depending on terminal type
- Mechanical insertion force limiter optional MAG-MATE Inserter MK I with Electro Pneumatic Control (PLC), Primarily sold in Europe.
- Single contact
- Double contacts with or without bridge
- 2 single contacts alternately with 2 bridged contacts
- Module is easily integrated into customer’s production line using sim- ple handshake signals
- Terminations up to 4 terminals at a time as single or linked type
- Mechanical insertion force limiter optional MAG-MATE and SIAMEZE Inserter Mark II with PLC, Primarily sold in Europe. TE magnet wire terminations are a perfect connecting alternative to all soldering techniques used in a lead-free environment. Special knowledge is required to design a mass manufacturing line for insulation displacement crimps on thin lacquerd insulated wires with high yield. Design aspects of the terminal, the cavity and the machine all need to be harmonized. With the Inserter Mark II, TE can an economic solution especially for the application of MAG-MATE and SIAMEZE terminals. Mark II Inserter with PLC MK I Inserter Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Magnet Wire MAG-MATE Terminal Application Equipment MAG-MATE and SIAMEZE Inserter Mark II with PLC and Insertion Force Control, Primarily sold in Europe. This advanced insertion machine provides the features of the MAG-MATE inserter Mark II with an additional force distance control system. The machine is designed to apply multiple contacts and will be customized according to the customer or product specific requirement. The contacts can be used as single contacts or in strip form (bridge function adjusted "on-the-fly"). A gauge is available to check the adjusted insertion force and to recalibrate the insertion force control sensor. Request catalog 7-1773440-4 for more information. Pneumatic Insertion Tool for MAG-MATE Terminals, Primarily sold in Europe. The pneumatic tool for MAG-MATE terminals features a rotary insertion finger to faciliate insertion angles. This tool is designed for use in TE standard insertion machines such as P200 and P300 but can also be integrated into customized production lines or assembly cells. Pneumatic Insertion Tool Mark II Inserter with PLC and Insertion Force Control Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Magnet Wire MAG-MATE Terminal Application Equipment Customer Specific Machines This unique machine was developed to process all IDC terminals regardless of shape and configuration. The insertion head module is capable of inserting individual or multiple terminals and can be configured for dual feed, left and right hand supply reels. The servo-driven NC-Axis facilitates precisely controlled insertion with programmable ramp profile. If required, a servo driven torque motor will locate the stator/bobbin to programmable positions. Excess magnet wire and wrap post are during the insertion cycle and removed via a ventury. The cutting punches are cam actuated via our patented linear slide module. The machine is designed and built for easy maintenance. Spare parts (punches, insertion blades, trim blades, die plate inset) are easy to access and replace. Custom Built IDC Terminal Insertion Head The insertion head module is designed to be integrated into a rotary index or linear transfer line. The IDC terminal insertion can be in vertical or horizontal plane. The terminal strip feeds from the right and/or from the left, if necessary with 2 terminal configurations. Wrap posts and excess magnet wire can be removed via a trim blade. Insertion force monitoring is available as an option. The insertion head module is custom built according to your requirements. Request catalog 7-1773440-4 for more information. Cam driven linear slide module for punch actuation. n g i s e D l a c i t r e Vn g i s e D l a t n o z i r o H Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Magnet Wire Terminals and Termination Systems Catalog 82221 Technical Information –80 –112.0 9 48.2 47 116.6 85 185.0 –70 –94.0 10 50.0 48 118.4 86 186.8 –60 –76.0 11 51.8 49 120.2 87 188.6 –50 –58.0 12 53.6 50 122.0 88 190.4 –45 –49.1 13 55.4 51 123.8 89 192.2 –40 –40.0 14 57.2 52 125.6 90 194.0 –35 –31.0 15 59.0 53 127.4 91 195.8 –30 –22.0 16 60.8 54 129.2 92 197.6 –25 –13.0 17 62.6 55 131.0 93 199.4 –20 –04.0 18 64.4 56 132.8 94 201.2 –19 –02.2 19 66.2 57 134.6 95 203.0 –18 –00.4 20 68.0 58 136.4 96 204.8 –17 1.4 21 69.8 59 138.2 97 206.6 –16 3.2 22 71.6 60 140.0 98 208.4 –15 5.0 23 73.4 61 141.8 99 210.2 –14 6.8 24 75.2 62 143.6 100 212.0 –13 8.6 25 77.0 63 145.4 110 230.0 –12 10.4 26 78.8 64 147.2 120 248.0 –11 12.2 27 80.6 65 149.0 130 266.0 –10 14.0 28 82.4 66 150.8 140 284.0 –09 15.8 29 84.2 67 152.6 150 302.0 –08 17.6 30 86.0 68 154.4 160 320.0 –07 19.4 31 87.8 69 156.2 170 338.0 –06 21.2 32 89.6 70 158.0 180 356.0 –05 23.0 33 91.4 71 159.8 190 374.0 –04 24.8 34 93.2 72 161.6 200 392.0 –03 26.6 35 95.0 73 163.4 220 428.0 –02 8.4 36 96.8 74 165.2 240 464.0 –01 30.2 37 98.6 75 167.0 260 500.0 0 32.0 38 100.4 76 168.8 280 536.0 1 33.8 39 102.2 77 170.6 300 572.0 2 35.6 40 104.0 78 172.4 400 752.0 4 39.2 42 107.6 80 176.0 600 1112.0 5 41.0 43 109.4 81 177.8 700 1292.0 6 42.8 44 111.2 82 179.6 800 1472.0 7 44.6 45 113.0 83 181.4 900 1652.0 8 46.4 46 114.8 84 183.2 1000 1832.0 C = 5/9 (F – 32) F = 9/5 C + 32 Tensile Strength of Magnet Wire1 Nominal Nominal Wire Dia. Dia. Size Copper Aluminum (lbs.) (lbs.) 8 438 142 9 340 113 10 269 89 11 213 71 12 189 56 13 134 44 14 106 35 15 84 28 16 66 22 17 53 17 18 42 14 19 33 11 20 6 8 21 21 7 22 16 5 23 13 4 24 10 3 25 8 2.7 26 6 2.1 27 5 1.7 28 4 1.3 29 3 1.1 30 2 .86 31 2 .68 32 1 .55 33 1 .43 34 1 .34 35 .81 .27 36 .65 .21 37 .65 .21 38 .42 .13 39 .32 .10 40 .25 .083 41 .20 .067 42 .16 .054 43 .12 .041 44 .10 .034 45 .08 .027 46 .06 .022 47 .05 .017 48 .04 .013 49 .03 .010 50 .02 .009 51 .02 .007 52 .01 .005
1 Magnet wire tensile will change as
the psi of magnet wire changes. Note: Copper magnet wire is calculated at 33,000 psi. Aluminum magnet wire is calculated at 11,000 psi (EC grade). Magnet wire should be tensiled on each coil. After termination of the AMPLIVAR splice, the tensile strength will be 70% (min.) of the original magnet wire tensile values. www.te.com/appliances
Magnet Wire Terminals and Termination Systems Catalog 82221 Technical Information (Continued) AWG Bare Wire CMA Single Film CMA Heavy Film CMA Bare Dia. Bare Coated Dia. Single Film Coated Dia. Heavy Film Wire in. mm in. mm Coated in. mm Coated Circular Mil Area (CMA) and diameter for magnet wires (AWG wire size range 52–25 1/2) www.te.com/appliances Technical Information
Magnet Wire Terminals and Termination Systems Catalog 82221 Technical Information (Continued) Circular Mil Area (CMA) and diameter for magnet wires (AWG wire size range 25–8) AWG Bare Wire CMA Single Film CMA Heavy Film CMA Bare Dia. Bare Coated Dia. Single Film Coated Dia. Heavy Film Wire in. mm in. mm Coated in. mm Coated www.te.com/appliances
Magnet Wire Terminals and Termination Systems Catalog 82221 Technical Information (Continued) Circular Mil Area (CMA) and diameter for lead wires (AWG wire size range 30–8) Wire Strands Wire Area inSize No. Dia. (Mils) Circ. Mils 30 7 4.0 112 30 1 10.0 100 28 7 5.0 175 28 19 3.1 181 28 1 12.6 159 27 7 5.6 219 27 1 14.2 202 26 6 6.3 238 26 10 5.0 250 26 16 4.0 256 26 8 5.6 251 26 1 15.9 253 26 26 3.1 250 26 7 6.3 278 26 3 10.0 300 26 AN 12 5.0 300 25 10 5.6 314 25 8 6.3 318 25 1 17.9 320 24 10 6.3 397 24 8 7.1 403 24 16 5.0 400 24 4 10.0 400 24 1 20.1 404 24 26 4.0 416 24 13 5.6 408 24 7 8.0 448 24 56 2.8 439 24 AN 19 5.0 475 23 10 7.1 504 23 8 8.0 512 23 1 22.6 511 — 21 5.0 525 22 6 10.0 600 22 8 8.9 634 22 16 6.3 635 22 10 8.0 640 22 1 25.3 640 22 7 10.0 700 22 AN 19 6.3 754 20 10 10.0 1,000 20 1 10.0 1,024 20 26 6.3 1,032 20 7 12.6 1,111 20 AN 19 7.9 1,186 18 19 9.2 1,608 — 16 10.0 1,600 18 1 40.3 1,624 18 7 15.2 1,617 18 65 5.0 1,625 18 7 15.3 1,639 Wire Strands Wire Area inSize No. Dia. (Mils) Circ. Mils — 41 6.3 1,627 — 7 16.0 1,792 18 AN 19 10.0 1,900 18 AN 19 11.3 2,426 16 7 19.2 2,580 16 1 50.8 2,581 16 65 6.3 2,580 16 19 11.7 2,601 16 105 5.0 2,625 — 26 10.0 2,600 16 7 20.0 2,800 14 AN 19 14.2 3,831 14 37 10.5 4,079 14 7 24.2 4,099 14 19 14.7 4,106 14 1 64.4 4,109 — 41 10.0 4,100 14 105 6.3 4,167 14 168 5.0 4,200 14 84 71 4,234 — 7 25.3 4,481 12 19 17.9 6,088 12 AN 19 17.9 6,088 12 259 5.0 6,475 12 19 18.5 6,503 12 7 30.5 6,512 12 37 13.3 6,545 12 1 80.8 6,529 12 165 6.3 6,549 12 84 8.9 6,654 10 7 36.0 9,072 — 37 16.0 9,472 10 414 5.0 10,350 10 37 16.7 10,319 10 1 101.9 10,384 10 7 38.5 10,376 10 19 23.4 10,404 — 41 15.9 10,365 10 105 10.0 10,500 9 7 43.0 12,943 9 1 114.4 13,087 9 525 5.0 13,125 8 7 45.0 14,175 8 133 11.1 16,386 8 37 21.1 16,472 8 1 128.5 16,512 8 7 48.6 16,533 8 19 29.5 16,534 8 49 18.4 16,589 8 AN 133 11.3 16,982 www.te.com/appliances Technical Information
Magnet Wire Terminals and Termination Systems Catalog 82221 Terminal Stud Hole Size The chart shows sizes and dimensions of various studs and the corresponding terminal stud hole sizes used with devices. For example, with stud #5 (.125 [3.18] Diameter), use device listed for #5 stud (.129 [3.28] Hole Diameter). Terminal stud hole sizes may easily be checked by fitting sample terminal to black circle. Stud Size Minimum Terminal U.S. Cust. Metric Stud Dia. Hole Diameter 5/8" M16 .625 .651 0 5 7 ." 4 / 3 .776 7/8" M22 .875 .901 0 0 0 . 1" 1 1.026 5 2 1 . 1" 8 / 1 - 1 1.151 0 5 2 . 1" 4 / 1 - 1 1.276 Stud Size Minimum Terminal U.S. Cust. Metric Stud Dia. Hole Diameter 4 6 0 .0 6 0 .0 # 7 7 0 .3 7 0 .1 # 0 9 0 .6 8 0 .2 M2 # 3 0 1 .9 9 0 .3 # 6 1 1 .2 1 1 .4 # 9 2 1 .5 2 1 .3 M5 # 2 4 1 .8 3 1 .5 . 3 M6 # 8 6 1 .4 6 1 .4 M8 # 4 9 1 .0 9 1 .0 1 # 0 2 2 .6 1 2 .2 1 # 7 4 2 .2 4 2 .4 1 # 0 6 2 .0 5 2 .6 M" 4 / 1 3 2 3 .2 1 3 .8 M" 6 1 / 5 5 8 3 .5 7 3 ." 8 / 3 8 4 4 .7 3 4 ." 6 1 / 7 0 1 5 .0 0 5 .2 1 M" 2 / 1 Use to Select Proper Size Terminal www.te.com/appliances
Magnet Wire Terminals and Termination Systems www.te.com/appliances 41765 48 41766 48 41770 48 41899 48 41900 48 41904 48 42076 48 42119 48 42192 48 42776 48 42778 48 42779 48 42780 48 60177 55 60318 51 60319 51 60320 51 60321 51 60322 51 60323 51 60325 51 60384 54 60385 54 60752 52 61074 48 61151 52 61166 49 61440 53 61442 53 61710 52 62000 47 62001 47 62002 47 62040 47 62044 49 62069 54 62080 54 62131 59 62157 47 62194 49 62200 47 62201 47 62243 61 62244 61 62295 47 62303 47 62304 47 62305 47 62306 47 62307 47 62308 47 62309 47 62310 47 62311 47 62341 49 62381 56 4 0 2 4 2 6 4 9 2 4 2 6 62430 13 4 1 3 4 2 6 62438 13 62439 13 Part No. Page 62445 53 62447 53 62458 10 62459 10 62511 18 62512 18 62513 18 62514 18 62600 21 62606 30 62609 10 62610 10 62651 21 62652 21 62670 49 62678 18 62702 13 62743 19 62755 51 62780 30 62781 30 4 3 3 8 2 6 62835 51 62888 19 7 1 9 8 2 6 7 6 9 8 2 6 7 7 9 8 2 6 7 8 9 8 2 6 62904 18 62922 53 62923 22 62928 11 4 5 3 9 2 6 62938 13 62958 11 62992 10 63018 18 63026 21 63027 21 63036 10 63039 10 63062 17 63063 17 63064 22 63107 19 63108 19 63109 19 63128 21 63132 21 63136 54 63140 54 63145 17 63147 51 63155 22 63160 13 63165 54 63199 31 63216 14 7 8 1 2 3 6 63235 10 63236 10 63237 10 Part No. Page 63240 10 63253 11 63273 18 63277 16 63278 16 63309 21 63340 19 63353 20 7 4 6 3 3 6 7 7 9 3 3 6 63399 51 63403 21 7 0 1 4 3 6 63425 22 63427 20 63429 19 63431 49 63443 16 63444 16 63446 51 63448 59 63453 61 63454 61 63455 61 8 8 5 4 3 6 63459 22 63460 22 63461 18 63463 14 63464 22 63465 22 63480 56 63484 53 63486 17 63489 14 63495 22 63499 21 63504 10 63506 55 63561 48 63562 48 63564 48 63565 13 63569 16 63570 16 63571 21 63584 18 63585 18 4 1 9 5 3 6 63601 21 63607 21 63612 51 63613 30 63614 21 63621 49 63622 54 63623 54 6 2 3 6 3 6 63641 10 63649 51 4 8 5 6 3 6 63659 11 Part No. PageNote : This index lists all cataloged parts by base no. only. Complete part nos. (with prefixes and/or suffixes) are shown on the page(s) indicated. Part Number Index Catalog 82221
Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances 63660 11 63661 11 63662 4 63663 18 63664 18 63665 18 63666 20 63667 20 63670 18 63675 31 63690 10 63710 26 63711 26 63712 26 63713 26 63714 26 63716 26 63717 26 63718 26 63719 26 63720 26 63734 26 63735 26 63736 26 63737 26 63738 26 63740 26 63741 26 63742 26 63743 26 63744 26 63746 17 63762 20 63772 16 63775 7 63776 18 63777 17 63778 31 63782 19 63786 4 63788 16 63789 4 63795 30 63806 14 63807 14 63808 14 63810 14 63816 22 63818 13 63819 13 63827 17 63844 30 63856 10 63864 52 63870 53 63871 53 63888 27 63889 53 63899 14 63903 27 63940 55 63941 55 Part No. Page 63942 55 63964 56 63965 14 63972 14 63973 14 63974 14 63975 6 63983 20 63995 20 63996 20 160809 13 160810 13 160897 13 170063 59 171370 58 235080 58 281006 58 281622 7 281633 7 284937 41 293029 40 293214 38 316300 18 350571 52 353937 59 356462 55 360033 58 360050 58 360051 60 360052 60 466010 54 466510 53 466816 54 485044 51 485079 51 505036 52 505044 52 505071 51 505072 51 505075 51 505079 52 520995 60 521078 58 565435 53 566410 55 566411 55 567343 54 567451 54 640212 52 680353 55 880631 58 926850 5 926851 5 926852 5 928770 5 928771 5 928854 5 964101 7 964106 5 964108 5 964110 5 964111 5 Part No. Page 964114 5 964156 47 964252 5 964290 7 964337 5 964338 5 964339 5 964340 5 964341 5 969082 5 969125 8 1123655 59 1217004 19 1217011 4 1217013 13 1217029 53 1217041 8 1217042 20 1217065 18 1217067 6 1217068 6 1217069 6 1217072 53 1217073 53 1217075 20 1217090 20 1217128 18 1217146 10 1217152 21 1217172 61 1217173 61 1217174 61 1217175 61 1217176 61 1217181 60 1217186 60 1217187 60 1217196 13 1217200 60 1217209 9 1217221 6 1217234 4 1217261 60 1217262 58 1217264 59 1217302 11 1217324 8 1217339 20 1217355 6 1217356 6 1217357 6 1217358 6 1217368 4 1217384 48 1217405 13 1217406 8 1217417 55 1217457 9 1217458 9 1217493 19 1217497 26 1217516 26 Part No. Page 1217529 31 1217533 6 1217538 9 1217579 6 1217592 19 1217593 14 1217595 14 1217596 14 1217613 9 1217624 55 1217666 26 1217688 6 1217689 6 1217690 6 1217691 6 1217745 14 1217746 14 1217783 17 1217835 54 1217853 9 1217858 9 1217860 21 1217870 21 1217902 20 1217924 21 1217973 9 1247000 11 1247001 11 1247002 11 1247003 11 1247004 11 1380145 58 1394403 15 1394429 12 1394430 12 1394431 12 1394432 12 1394433 12 1394475 15 1394476 15 1394638 15 1394639 15 1418686 8 1534110 8 1534234 5 1534684 26 1534685 26 1534686 26 1534687 26 1599105 59 1601000 36 1601002 41 1601005 39 1601006 40 1601009 38 1601011 40 1601013 40 1601018 40 1601020 40 1601021 40 1601028 41 1601033 40 Part No. Page
Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances 1601035 40 1601037 38 1601039 39 1601041 38 1601045 39 1601046 36 1601049 40 1601052 41 1601056 36 1601058 40 1601059 39 1601061 41 1601063 38 1601064 39 1601066 38 1601068 40 1601072 40 1601073 39 1601074 36 1601075 37 1601077 37 1601095 38 1601097 39 1601099 38 1601104 38 1601110 38 1601112 39 1601115 41 1601117 36 1601118 41 1601119 38 1601120 38 1601128 38 1601133 39 1601136 36 1601137 37 1601138 38 1601139 41 1601140 36 1601142 40 1601155 38 1601159 41 1601161 41 1601174 40 1601194 39 1601196 37 1601204 39 1601214 38 1601226 40 1601232 37 1601237 36 1601243 38 1601421 42 1601424 42 1601425 42 1601426 42 1601427 42 1601431 42 1601432 42 1601433 42 1601434 42 1601435 42 Part No. Page 1601436 42 1601437 42 1601438 42 1601440 42 1601447 42 1601475 42 1601503 73 1601504 73 1601507 70 1601511 72 1601513 72 1601514 70 1601520 69 1601528 71 1601529 71 1601531 71 1601532 71 1601538 65 1601539 65 1601540 65 1601542 73 1601545 73 1601546 73 1601547 73 1601548 72 1601549 72 1601550 69 1601551 69 1601553 69 1601555 73 1601559 65 1601560 65 1601562 73 1601564 73 1601566 72 1601569 72 1601571 72 1601572 69 1601573 69 1601575 68 1601577 68 1601578 68 1601580 73 1601582 73 1601583 73 1601584 73 1601586 72 1601587 70 1601588 70 1601591 70 1601593 68 1601596 73 1601597 72 1601599 72 1601600 72 1601601 70 1601603 70 1601604 65 1601606 65 1601607 64 1601608 64 1601610 73 Part No. Page 1601611 73 1601612 73 1601614 72 1601617 72 1601618 72 1601619 72 1601620 70 1601623 70 1601625 70 1601628 70 1601629 70 1601630 70 1601631 70 1601632 68 1601633 68 1601635 73 1601637 65 1601639 64 1601640 72 1601642 71 1601644 65 1601646 65 1601647 65 1601649 73 1601650 72 1601651 72 1601652 72 1601654 72 1601655 70 1601656 70 1601658 70 1601660 70 1601661 70 1601664 70 1601665 70 1601667 70 1601668 70 1601669 69 1601675 65 1601677 64 1601678 64 1601680 71 1601681 71 1601682 71 1601683 65 1601687 72 1601689 71 1601691 71 1601693 71 1601694 71 1601695 71 1601705 64 1601706 64 1601707 64 1601709 71 1601710 71 1601711 71 1601712 71 1601716 65 1601717 64 1601718 64 1601719 64 Part No. Page 1601721 72 1601722 72 1601723 72 1601726 71 1601729 71 1601730 71 1601731 71 1601733 71 1601750 64 1601754 71 1601755 71 1601761 64 1601764 71 1601765 71 1601766 71 1601768 69 1601769 68 1601771 68 1601793 65 1601794 64 1601795 73 1601797 69 1601798 69 1601800 65 1601807 69 1601808 72 1601809 72 1601810 72 1601811 70 1601814 64 1601818 70 1601819 70 1601820 70 1601823 64 1601824 64 1601825 73 1601827 72 1601828 70 1601829 70 1601832 65 1601833 64 1601835 64 1601837 72 1601841 71 1601842 64 1601844 65 1601845 65 1601846 64 1601847 64 1601848 64 1601852 71 1601853 68 1601857 64 1601953 75 1718165 30 1740417 15 1740418 15 1740419 15 1740574 5 1740603 8 1740698 8 1740829 26 Part No. Page Part Number Index
Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances 1742125 7 1742159 1742160 18 1742167 14 1742203 6 1742211 8 1742347 6 1742398 21 1742410 8 1742605 13 1742614 10 1742657 61 Part No. Page 1742708 11 1742781 1742819 20 1742820 20 1742828 7 1742881 55 1742882 55 1742898 47 1742964 59 1742977 55 1742979 55 1742981 59 Part No. Page 1855633 55 1855634 1855680 55 1855681 55 1955415 58 1969357 58 1987143 12 1987199 8 1987222 28 1987223 28 1987224 28 1987225 28 Part No. Page 1987226 28 2120743 2120744 27 2120745 27 2120746 27 2120747 27 2232326 58 2232327 58 2825082 58 2825083 59 Part No. Page
Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
Magnet Wire Terminals and Termination Systems Catalog 82221 www.te.com/appliances
APPLIANCES / / / MAGNET WIRE TERMINATION te.com TE Connectivity, TE Connectivity (logo), Every Connection Counts, AMP, AMP-O-LECTRIC, AMPLIVAR, AMPOMATOR, CERTI-LOK, DYNA-CRIMP, FASTIN-FASTON, FASTON, MAG-MATE and SIAMEZE are trademarks. All other logos, products and/or company names referred to herein might be trademarks of their respective owners. The information given herein, including drawings, illustrations and schematics which are intended for illustration purposes only, is believed to be reliable. However, TE Connectivity makes no warranties as to its accuracy or completeness and disclaims any liability in connection with its use. TE Connectivity‘s obligations shall only be as set forth in TE Connectivity‘s Standard Terms and Conditions of Sale for this product and in no case will TE Connectivity be liable for any incidental, indirect or consequential damages arising out of the sale, resale, use or misuse of the product. Users of TE Connectivity products should make their own evaluation to determine the suitability of each such product for the specific application. © 2016 TE Connectivity Ltd. family of companies All Rights Reserved. 82221 06/2016 APP LET’S CONNECT We make it easy to connect with our experts and are ready to provide all the support you need. Just call your local support number or visit www.te.com/appliances to chat with a Product Information Specialist. TEChNICaL SuPPOrT te.com/support-center 1103 France 1999 226 +02-3415-4607 900 New Z P Slo