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| Application Specification Standard Timer Connectors NOTE 114-49003 27 OCT 08 Rev G i All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2_. Figures and illustrations are for identification only and are not drawn to scale. 1. INTRODUCTION This specification covers the requirements for application of Standard Timer Connectors used with timing mechanisms on washers and other major appliances requiring timed operation cycles. The connector consists of a plug housing and Generation I, II, or III Timer Control Terminals. The housing is available in 2, 4, 7, 10, 18, and 24 positions (or circuits) and is designed with an internal terminal locking lance. The 18- and 24-position housings are color-coded for use in left-hand (white) or right-hand (black) applications. The housings feature locking tabs or latches to help secure mated housings. The terminals must be terminated using an automatic machine. Each terminal features a locking lance that engages the housing when properly inserted into the terminal cavity. These housings with these terminals mate with housings containing 3.180.51 mm [.125.020 in.] blade tab receptacle contacts. When corresponding with Tyco Electronics Personnel, use the terminology provided in this specification to facilitate your inquiries for information. Basic terms and features of this product are provided in Figure 1. Housings (Ref) Timer Control Terminals 4-Position Plug Wire End Generation I Insulation Wire Barrel Barrel Mating Face Locking Lance Slot Locking Lance Generation II Generation III Terminal Cavity Locking Tab Locking 18-Position Left-Hand Plug 7-Circuit Motor Plug Lance Latch (2 Places) Latch (2 Places) Figure 1 E2008 Tyco Electronics Corporation, Harrisburg, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at All International Rights Reserved TE logo and Tyco Electronics are trademarks. 1 of 10 LOC B www.tycoelectronics.com *Trademark. Other products, logos, and company names used are the property of their respective owners. Standard Timer Connectors 2. REFERENCE MATERIAL 2.1. Revision Summary Revisions to this application specification include: S Updated document to corporate requirements S Added new information to table in Figure 3 114-49003 2.2. Customer Assistance Reference Product Base Part Number 521135 and Product Code 1192 are representative of Standard Timer Connectors. Use of these numbers will identify the product line and expedite your inquiries through a service network established to help you obtain product and tooling information. Such information can be obtained through a local Tyco Electronics Representative or, after purchase, by calling PRODUCT INFORMATION at the number at the bottom of page 1. 2.3. Drawings Customer Drawings for product part numbers are available from the service network. If there is a conflict between the information contained in the Customer Drawings and this specification or with any other technical documentation supplied, the information contained in the Customer Drawings takes priority. 2.4. Specifications Application Specification 114-2145 provides product description and application requirements for the mating housings containing blade contacts. Product Specification (108-series) provides product performance and test information. Documents available which pertain to this product are: 108-1067 108-1271 108-1271-1 108-1271-2 Timer Connector Terminal Timer Connector with Lanceless .125 Blade Receptacle Timer Connector with .125 Blade Receptacle Timer Connector with .125.020-inch Blade Receptacle 2.5. Instructional Material Instruction Sheets (408-series) provide product assembly instructions or tooling set-up and operation procedures and Customer Manuals (409-series) provide machine setup and operating procedures. Documents available which pertain to this product are: 408-3295 408-7424 408-8040 408-9332 408-9514 408-9816 408-10142 409-5128 409-5842 409-5852 409-5878 409-5884 Preparing Reel of Contacts for Application Tooling Checking Terminal Crimp Height or Gaging Die Closure Heavy Duty Miniature Quick-Change Applicators (Side-Feed Type) Extraction Tool 454983-1 Extraction Tool 844751-1 Handling of Reeled Products Extraction Tool 1976096-1 Basic AMP-O-LECTRIC* Model "K" Terminating Machine 471273-[ ] AMP-O-LECTRIC Model "G" Terminating Machine 354500-[ ] AMPOMATOR* CLS III-G Lead-Making Machine AMPOMATOR CLS IV+ Lead-Making Machine ADUZI* Lead-Making Machine 662700-[ ] 3. REQUIREMENTS 3.1. Storage A. Reeled Terminals When using reeled terminals, store coil wound reels horizontally and traverse wound reels vertically. 2 of 10 Tyco Electronics Corporation Rev G Standard Timer Connectors 114-49003 B. Shelf Life The terminals and housings should remain in the shipping containers until ready for use to prevent deformation or damage to product. The products should be used on a first in, first out basis to avoid storage contamination that could adversely affect connector performance. C. Chemical Exposure Do not store product near any chemical listed below as they may cause stress corrosion cracking. Alkalies Amines Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Sulfur Compounds Tartrates D. Ultraviolet Light Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housings. 3.2. Wire Selection and Preparation The terminals will accept solid or stranded wire sizes 22 through 14 AWG. Proper strip length is necessary to properly insert the wire into the terminal. The strip length of the wire is shown in Figure 2. CAUTION Reasonable care must be taken not to nick, scrape, or cut any part of the wire during the stripping operation. ! Strip Length Insulation Note: Not to Scale Conductor TERMINAL WIRE BARREL WIDTH WIRE INSULATION DIAMETER TYPE SIZE (AWG) QTY STRIP LENGTH 20 18 16 14 18 16 18 16 14 Generation II and III 3.43-2.54 [.135 .100] [.135-.100] (1) 16 (1) 18 18 20 1 1 1 1 2 3.18 [.125] 3 18 [ 125] Max 2 1 1 1 2 2 2 2 3.12 [.123] Max 2.84 [.112] Max 2.16-3.30 [.085 .130] [.085-.130] 4.24-4.50 [.167 .177] [.167-.177] 2.16 3.18 2.16-3.18 [.085-.125] 5.21 4.44 5.21-4.44 [.205-.175] Generation I 3.30 2.67 3.30-2.67 [.130-.105] 5.46 4.7 5.46-4.7 [.215-.185] 5.08 4.32 5.08-4.32 [.200-.170] 2.84 [.112] Max Per Wire 5.08 4.32 5.08-4.32 [.200-.170] Figure 2 Rev G Tyco Electronics Corporation 3 of 10 Standard Timer Connectors 3.3. Crimp Requirements 114-49003 The terminal must be terminated according to the instructions included with the appropriate tooling. A terminal as it should appear after crimping is shown in Figure 3. CAUTION Wire insulation shall NOT be cut or broken during the crimping operation. Reasonable care should be taken to provide undamaged wire terminations. ! A. Crimp Height The crimp applied to the wire portion of the terminal is the most compressed area and is most critical in ensuring optimum electrical and mechanical performance of the crimped terminal. The crimp height must be within the dimensions provided in Figure 3. B. Crimp Length Effective crimp length shall be defined as that portion of the wire barrel, excluding bellmouths, fully formed by the crimping tool. For optimum crimp effectiveness, the crimp must be within the area shown in Figure 3. C. Bellmouths Front and rear bellmouths shall be evident and conform to the dimensions given in Figure 3. D. Cutoff Tab The cutoff tab shall be cut to the dimensions shown in Figure 3. E. Burr The cutoff burr shall not exceed the dimensions shown in Figure 3. F. Wire Barrel Flash The wire barrel flash shall not exceed the dimensions shown in Figure 3. G. Wire Insulation and Conductor Location After crimping, the wire conductor and insulation must be visible in the transition area between the wire and insulation barrels. The wire insulation shall not be crimped into the terminal wire barrel. The conductor may extend beyond the wire barrel to the maximum shown in Figure 3. H. Wire Barrel Seam The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam. I. Insulation Barrel Seam The insulation barrel seam must be fully closed with no evidence of insulation visible in the seam. 4 of 10 Tyco Electronics Corporation Rev G Standard Timer Connectors 114-49003 There are No Wire Strands Showing in Wire Barrel Seam Wire Insulation Does Not Enter Wire Barrel Insulation Support Barrel Seam is Closed with No Wire Insulation Showing End of Wire is Flush to 0.79 [.031] (Max) from End of Wire Barrel Wire Conductor and Insulation is Visible in Transition Area 0.38 [.015] Max Front Bellmouth X 0.38-0.64 [.015-.025] Rear Bellmouth X Detail A Wire Barrel 0.13 [.005] Max Burr Crimp Width See Detail A Section X-X (Refer to Table) 0.25 [.010] Max Cutoff Tab 0.13 [.005] Max Wire Barrel Flash Wire Barrel Crimp Height (Refer to Table) WIRE BARREL CRIMP TERMINAL WIRE SIZE (AWG) HEIGHT 20 18 16 Generation I 14 (2) 18 (2) 16 Generation II 18 16 14 Generation II and III (1) 16 (1) 18 (2) 20 (2) 18 Generation III 18 1.83-1.93 [.072-.076] 1.5-1.6 [.059-.063] 2.79 [.110] 2 79 [ 110] 1.8-1.9 [.071-.075] 1.37-1.47 [.054-.058] 1.52-1.62 [.060-.064] 1.83-1.93 [.072-.076] 2.29 [.090] 2 29 [ 090] 1.83-1.93 [.072-.076] 1.52-1.62 [.060-.064] 1.68-1.78 [.066-.070] 1.19-1.30 [.047-.051] 2.29 [.090] 1.27-1.37 [.050-.054] 1.37-1.47 [.054-.058] 2.29 [.090] 2 29 [ 090] 1.55-1.65 [.061-.065] WIDTH INSULATION BARREL CRIMP WIDTH 3.56 [.140] 3 56 [ 140] 4.32 [.170] 4 32 [ 170] 3.94-4.19 [.155-.165] 3 94 4 19 [ 155 165] 3.94-4.19 [.155-.165] Figure 3 Rev G Tyco Electronics Corporation 5 of 10 Standard Timer Connectors J. Twist and Roll 114-49003 There shall be no twist, roll, deformation or other damage to the mating portion of the crimped terminal that will prevent proper mating. See Figure 4. 2.08+0.05/-0.08 [.082+.002/-.003] (Overall Dimension Must Be Maintained At All Times) Correct Incorrect 10_ Max 10_ Max Figure 4 K. Straightness The force applied during crimping may cause some bending between the crimped wire barrel and the mating portion of the terminal. Such deformation is acceptable within the following limits. 1. Up-and-down -- the crimped terminal, including cutoff tab and burr, shall not be bent above or below the datum line any more than the amount shown in Figure 5. 2. Side-to-side -- the side-to-side bending of the crimped terminal may not exceed the limits provided in Figure 5. NOTE Periodic inspections must be made to ensure crimped terminal formation is consistent. i Up-and-Down 5_ Max Datum Line Side-to-Side Datum Line Note: Angles are drawn for clarification only and are not to scale. Figure 5 6 of 10 Tyco Electronics Corporation EEEEE EEEEE EEEEE 5_ Max 5_ Max 5_ Max Rev G Standard Timer Connectors 3.4. Assembly 114-49003 The terminal must be aligned with the applicable terminal cavity at the wire end (back) of housing with the locking feature facing the locking feature slot of the terminal cavity. The terminal must be inserted into the terminal cavity until there is an audible "snap." The terminal must engage the housing. Refer to Figure 6. Generation I Terminal Locking Lance Terminal Locking Lance Engaging Housing Housing Locking Lance Locking Feature Slot of Terminal Cavity Generation II Terminal Locking Lance Slot Terminal Locking Lance Slot Engaging Housing Housing Locking Feature Slot of Terminal Cavity Generation III Terminal Terminal Locking Lance Engaging Housing Locking Feature Slot of Terminal Cavity Housing Locking Lance Locking Feature Slot of Terminal Cavity Terminal Locking Lance Engaging Housing Figure 6 Rev G Tyco Electronics Corporation 7 of 10 Standard Timer Connectors 3.5. Repair and Replacement 114-49003 Terminals are not repairable once a termination has been made. Any damaged or defective terminals must be removed and replaced. Terminals can be removed from the housing using available tooling. CAUTION Damaged product should not be used. If a damaged terminal is evident before it is inserted into the housing, the wire can be cut in back of the terminal and the wire end can be re-terminated. If a terminal or housing is damaged after ! insertion, the wire must be cut directly in back of the housing and re-terminated. 4. QUALIFICATIONS Standard Timer Connectors are Listed by Underwriters Laboratories Inc. (UL) in File E28476 and Certified by CSA International in File LR 7189. 5. TOOLING Tooling part numbers and instructional material packaged with the tooling are shown in Figure 7. NOTE Machines have been designed for a variety of application requirements. For assistance in setting up prototype and production line equipment, contact your local Representative or call the TOOLING ASSISTANCE CENTER at the i number at the bottom of page 1. 5.1. Applicator The applicators are designed to crimp strip-fed terminals onto pre-stripped wire. These applicators accept interchangeable crimping dies and must be installed onto a power unit. 5.2. Power Unit These semi-automatic machines provide the force required to drive the applicator for crimping tape-mounted terminals. These machines are designed to be bench mounted and provide for medium-volume applications. 5.3. Extraction Tool The extraction tool is designed to remove a terminal from the housing by releasing the locking lance from the housing without damaging the housing or over-stressing the terminal. 8 of 10 Tyco Electronics Corporation Rev G Standard Timer Connectors 114-49003 Extraction Tool 454983-1 (408-9332) (For Generation I Terminal) Extraction Tool 844751-1 (408-9514) (For Generation II Terminal) AMP-O-LECTRIC Model K" Extraction Tool 1976096-1 (408-10142) (For Generation III Terminal) Terminating Machine 471273-[ ] (409-5128) AMP-O-LECTRIC Model G" Terminating Machine 354500-1 and -2 (409-5842) Heavy Duty Miniature Quick-Change Applicators (Side-Feed Type) (Refer to Table) (408-8040) AMPOMATOR CLS III-G Lead-Making Machine 122500-2 and -3 (409-5852) AMPOMATOR CLS IV+ Lead-Making Machine 356500-1 and -2 (409-5878) ADUZI Lead-Making Machine 662700-[ ] (409-5884) WIRE INSULATION DIAMETER APPLICATOR POWER UNIT SIZE (AWG) PART NUMBER 122500-2, -3, 356500-1, -2, or 662700-[ ] 471273-[ ] 354500-1 or -2 122500-2, -3, 356500-1, -2, or 662700-[ ] 471273-[ ] 471273-[ ] 122500-2, -3, 356500-1, -2, or 662700-[ ] 471273-[ ] 354500-1 or -2 DESCRIPTION 680416-1 22-18 22 18 1.90-3.30 1 90-3 30 [.075-.130] 680416-2 680416-3 Lead-Making Model K" Model G" 20-14 2.16-3.18 [.085-.125] [ 085 125] 466498-1 Lead-Making 466498-2 (2) 18 or (2) 16 (2) 3.18 [.125] Max 466603-2 Model K" Model K" 3.18 [.125] or 18 14 18-14 (2) 2 79 [ 110] Max 2.79 [.110] 567349-4 Lead-Making 567349-5 3.18 [.125] Max 567349-9 Model K" Model G" Figure 7 Rev G Tyco Electronics Corporation 9 of 10 Standard Timer Connectors 114-49003 6. VISUAL AID Figure 8 shows a typical application of Standard Timer Connectors. This illustration should be used by production personnel to ensure a correctly applied product. Applications which DO NOT appear correct should be inspected using the information in the preceding pages of this specification and in the instructional material shipped with the product or tooling. CRIMPED TERMINAL INSULATION SUPPORT BARREL SEAM SHALL BE CLOSED WITH NO WIRE INSULATION SHOWING WIRE MUST NOT BE NICKED, CUT OR SCRAPED , THERE MUST BE NO WIRE STRANDS SHOWING IN WIRE BARREL SEAM FRONT AND REAR BELLMOUTHS MUST BE EVIDENT WIRE INSULATION MUST NOT ENTER WIRE BARREL WIRE CONDUCTOR AND INSULATION MUST BE VISIBLE IN TRANSITION AREA END OF WIRE MUST BE FLUSH THERE MUST BE NO DAMAGE TO MATING AREA TO OR EXTEND SLIGHTLY BEYOND WIRE BARREL ALL TERMINALS MUST BE TERMINALS INSTALLED IN HOUSING SECURELY LOCKED INTO HOUSING THERE MUST BE NO DAMAGE TO HOUSING THERE MUST BE NO DAMAGE TO HOUSING LATCHES MUST NOT BE BROKEN OR DAMAGED LATCHES MUST NOT BE BROKEN OR DAMAGED FIGURE 8. VISUAL AID 10 of 10 Tyco Electronics Corporation Rev G |
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