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application specification 114--10011 loc b 1 of 11 e 2011 tyco electronics corporation, a te connectivity ltd. company all rights reserved te connectivity, te connectivity (logo), and te (logo) are trademarks. *trademark. other logos, product and/or company names may be trademarks of their respective owners. tooling assistance center 1 -- 800 -- 722 -- 1111 product information 1--800--522--6752 this controlled document is subject to change. for latest revision and regional customer service, visit our website at www.te.com audio/microphone connectors 18 mar 11 rev c all numerical values are in metric units [with u.s. customary units in brackets]. dimensions are in millimeters [and inches]. unless otherwise specified, dimensions have a tolerance of + 0.13 [+ .005] and angles have a tolerance of + 2 _ . figures and illustrations are for i dentification only and are not drawn to scale. 1. introduction this specification covers the requirements for the application of audio/microphone connectors. the connectors are designed to accept a wire size range of 18 through 28 awg and are available in 4, 5, or 6 position. the receptacle connector is panel mounted. application may be done by machine for reel--mounted contacts and by hand for replacement loose piece contacts. ?when corresponding with te personnel, use the terminology provided on this specification to help facilitate your inquiry for information. basic terms and features of components are provided in figure 1. figure 1 socket contact pin contact 6--position receptacle housing (typ) mounting fins locking tab entry slot antirotation key locking collar polarizing groove front (ref) engagement groove plug insert alignment groove locking latch numbered contact cavities strain relief collets polarizing rib (on mating face) latch slot detent plug body flexible cable guard locking tab note i
114- 10011 rev c 2 of 11 2. reference material 2.1. revision summary this paragraph is reserved for a revision summary of the most recent additions and changes made to this specification which include the following: s updated document to corporate requirements. 2.2. customer assistance reference part number 207313 and product code 4989 are representative numbers of audio/microphone connectors. use of these numbers will identify the product line and expedite your inquiries through a service network established to help you obtain product and tooling information. such information can be obtained through a local te representative or, after purchase, by calling the tooling assistance center or product information numbers at the bottom of page 1. 2.3. drawings customer drawings for product part numbers are available from the service network. the information contained in customer drawings takes priority if there is a conflict with this specification or with any other technical documentation supplied by te. 2.4. specifications product specification 108--10032 is available to provide test and performance results. 2.5. instructional material the following list includes available instruction sheets (408--series) that provide assembly procedures for product, operation, maintenance and repair of tooling, as well as setup and operation procedures of applicators; and customer manuals (409--series) that provides setup, operation, and maintenance of machines. document number document t itle 408--3295 preparing reel of contacts for application tooling 408--4392 hand crimping tool 90715--1 408--7347 insertion tools 91002--1 and --2 408--7424 checking terminal crimp height or gaging die closure 408--7819 audio instrument connectors 408--7859 extraction tool 91136--1 408--7901 hand crimping tool 90363--1 408--8040 heavy duty miniature quick--change applicators (side--feed type) 408--9816 handling of reeled products 409--5128 basic amp--o--lectric* model ?k? terminating machines, and accessories 409--5842 amp--o--lectric model ?g? terminating machine 354500--[ ] 409--5855 amp--o--matic* side feed stripper--crimper model ii machine no. 854040--3 and --4 409--5866 ampomator* cls iv lead--making machine 217500--[ ] 3. requirements 3.1. storage a. reeled contacts when using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically. b. shelf life the contacts and housings should remain in the shipping containers until ready for use to prevent deformation to the contacts and/or damage to the housings. the products should be used on a first in, first out basis to avoid storage contamination that could adversely affect signal transmissions. c. chemical exposure do not store contacts or housings near any chemicals listed below, as they may cause stress corrosion cracking in the components.
114- 10011 rev c 3 of 11 alkalies ammonia citrates phosphates citrates sulfur compounds amines carbonates nitrites sulfur nitrites tartrates d. ultraviolet light prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housings. 3.2. special characteristics these audio/microphone connectors include a panel mounted receptacle connector and a free--hanging plug connector. the receptacle connector consists of a receptacle housing and the specified number of socket contacts. the housing features a locking collar, two locking tab entry slots, an antirotation key, and four mounting fins. the plug connector consist of a plug insert, a plug body, and the specified number of pin contacts. the insert features two cable strain relief collets, a locking latch, an alignment groove, and an engagement groove. the body features two locking tabs, a latch slot, a detent, and a flexible cable guard. each receptacle has a polarizing groove and each plug insert has a polarizing rib to ensure proper mating. contact cavities are numbered on the back of each connector to provide circuit identification. see figure 1. 3.3. panel mounting requirements audio/microphone connectors are designed for a combination of free--hanging and rear panel mount application. for dimensions and layout design, refer to figure 2. figure 2 17.78 [.700] 1.02 [.040] 3.18 [.125] panel thickness 1.47--1.78 [.058--.070] 3.4. wire selection and preparation a. type the wire size range for audio/microphone connectors is 18 through 28 awg and may be solid or stranded. contacts which accept a wire size range of 18--20 awg are special large conductor contacts which only fit into customer--supplied audio/microphone connectors. b. preparation prior to stripping the discrete wires, remove 20.65 mm [.813 in.] of the cable jacket. note i note i
114- 10011 rev c 4 of 11 the discrete wires must be stripped to the dimension provided in figure 3. do not nick, scrape, or cut the wire conductor during the stripping operation. strip length wire insulation discrete wire insulation wire size , strip wire barrel insulation barrel i n s u l a t i o n diameter w i r e s i z e , awg s t r i p length crimp height crimp width crimp height crimp width 1 8 3.18--3.94 d [.125--.155] 0.97--1.07 2.03--2.54 18 3.56--4.32 [ [.140--.170] 0 . 9 7 1 . 0 7 [.038--.042] 1.52--1.75 2.74--3 2 . 0 3 2 . 5 4 [.080--.100] 2 0 3.18--3.94 d [.125--.155] 0.81--0.91 1 . 5 2 1 . 7 5 [.060--.069] adjustable ( b l s h l d 2 . 7 4 3 [.108--.118] 20 3.56--4.32 [ [.140--.170] 0 . 8 1 0 . 9 1 [.032--.036] (barrel should grip insulation w i t h o u t c u t t i n g 22 0.64--0.74 [.025--.029] w i t h ou t c u t t i ng into it) 0.91--1.37 [.036--.054] 24 3.58--4.34 u [.141--.171] 0.521--0.660 [.0205--.0260] 1.27--1.52 [.050--.060] 1.45--1.7 [.057--.067] [ 0 3 6 0 5 ] 2 6 2 8 [ ] 0.51--0.61 [ 0 5 0 0 6 0 ] [ 0 5 0 6 ] 26--28 0 . 5 1 0 . 6 1 [.020--.024] d automatic machine crimp dimensions, [ hand tool crimp dimensions, u both machine and hand tool crimp dimensions figure 3 3.5. crimped contact requirements locate the contact to be crimped in the appropriate tooling according to the instructions packaged with that tooling. detailed instructions covering the placement of contacts in the tooling and the use of such tooling is packaged with each tool. terminate the contact according to the directions shipped with the appropriate tooling. see section 5, tooling. wire insulation shall not be cut or broken during the crimping operation, nor shall the insulation be crimped into the contact wire barrel. reasonable care should be taken by tooling operators to provide undamaged wire terminations. a typical receptacle contact as it should appear after crimping is shown in figure 4. these requirements apply equally to the pin contact. a. crimp height the crimp applied to the wire portion of the contact is the most compressed area and is most critical in ensuring optimum electrical and mechanical performance of the crimped contact. the crimp height must be within the dimensions provided in figure 3. caution ! caution !
114- 10011 rev c 5 of 11 b. crimp length for optimum crimp effectiveness, the crimp must be within the area shown in figure 4. effective crimp length shall be defined as that portion of the wire barrel, excluding bellmouth(s), fully formed by the crimping tool. instructions for adjusting, repairing, and inspecting tools are packaged with the tools. see figure 10. c. bellmouths front and rear bellmouths shall be evident and conform to the dimensions given in figure 4. d. cutoff tab the cutoff tab shall be cut to the dimensions shown in figure 4. e. burrs the cutoff burr shall not exceed the dimensions shown in figure 4. f. wire barrel flash the wire barrel flash shall not exceed the dimensions shown in figure 4 in section x--x. g. wire location after crimping, the wire conductor and insulation must be visible in the transition area between the wire and insulation barrels. h. conductor location the conductor may extend beyond the wire barrel to the maximum shown in figure 4. i. wire barrel seam the wire barrel seam must be closed with no evidence of loose wire strands visible in the seam. figure 4 0.13 [.005] max. burr cutoff tab 0.25 [.010] max 0.25 [.010] max. wire barrel flash view a section x- x wire barrel crimp height cutoff tab must be visible -- see view a x x no damage or distortion to the contact or the locking lance conductor extension 0.51 [.020] max wire insulation and conductors must both bevisibleinthisarea rear bellmouth 0.18--0.30 [.007--.012] wire barrel flash front bellmouth 0.20 [.008] max effective crimp length wire barrel seam wire barrel crimp width
114- 10011 rev c 6 of 11 j. twist and roll there shall be no twist, roll, deformation or other damage to the mating portion of the crimped contact that will prevent proper mating. see figure 5. figure 5 front of contact (pin or socket) 0 _ wire barrel k. straightness the force applied during crimping may cause some bending between the crimped wire barrel and the mating portion of the contact. such deformation is acceptable within the following limits. 1. up and down the crimped contact, including cutoff tab and burr, shall not be bent above or below the datum line more than the amount shown in figure 6. figure 6 note: angles are drawn for clarification only and are not to scale. datum line 0.25 [.010] max 0.25 [.010] max 2. side to side the side--to--side bending of the contact may not exceed the limits provided in figure 7. periodic inspections must be made to ensure crimped contact formation is consistent as shown. note i
114- 10011 rev c 7 of 11 figure 7 0.25 [.010] max 0.25 [.010] max 3.6. housings housings are available in 4, 5, or 6 circuit positions for your production requirements. figure 8 shows the housing configurations. the housings are made from black thermoplastic. figure 8 4--position 5--position 6--position numbered cavities mounting fins antirotation key locking tab entry slot
114- 10011 rev c 8 of 11 3.7. assembly procedures instruction sheet 408--7819 provides specific assembly procedures. figure 9 shows how the product fits together. insertion tool 91002--[ ] may be used to help insert terminated wires and contacts into the housings if needed. refer to instruction sheet 408--7347. figure 9 panel locking tab detent cable discrete wires alignment groove entire length of collets must grip cable jacket polarizing rib contacts inserted into back of plug insert plug insert mounting fins after mating, turn clockwise to tighten locking tab slot 3.8. repair/replacement if a damaged contact is apparent before the contacts are inserted into the housing, cut the wire in back of the contact and reterminate the wire end. if contacts or housing are damaged after insertion, the wire must be cut directly in back of the housing and reterminated with new contacts and housing. see section 5, tooling. contacts are not repairable once a termination has been made. any defective contact should be removed and replaced with a new one. damaged contacts can be removed from the housing by using extraction tool 91136--1. refer to instruction sheet 408--7859 for extraction procedures. 4. qualification audio/microphone connectors are not required to be agency approved. caution !
114- 10011 rev c 9 of 11 5. tooling figure 10 provides tool part numbers and instructional material related to wire size. te tool engineers have designed machines for a variety of application requirements. for assistance in setting up prototype and production line equipment, contact te tool engineering through your local te representative or call the tooling assistance center number at the bottom of page 1. s hand crimping tool hand crimping tools that accommodate the full wire size range are designed for prototype and low--volume applications such as repair of damaged contacts. s applicator applicators are designed for the full wire size range of strip--fed, precision formed contacts, and provide for high volume, heavy duty, production requirements. the applicators can be used in bench or floor model power units. each applicator is shipped with a metal identification tag attached. do not remove this tag or disregard the information on it. also, a packet of associated paperwork is included in each applicator shipment. this information should be read before using the applicator; then it should be stored in a clean, dry area near the applicator for future reference. some changes may have to be made to the applicators to run in all related power units. contact the tooling assistance center number located at the bottom of page 1 for specific changes. s power units a power unit is an automatic or semi--automatic device used to assist in the application of a product. power unit includes the power source used to supply the force or power to an applicator. the model ?k? amp--o--lectric terminating machine pn 565435--5 has been superseded by the model ?g? terminating machine pn 354500--1 (409--5842) for new applications. for existing applications, the model ?k? is still recommended because of the large number of installed machines. s insertion tools insertion tools are designed for contacts crimped to small fragile wire. they are designed to stabilize the contact during insertion. s extraction tools extraction tools are designed to release the locking lance inside the connector housing without damaging the housing or contacts. insulation diameter wire size, awg applicator (document) power unit (document) hand tool (document) 680402--1 (408--8040) 217500--[ ] (409--5866) 2.03--2.54 1 8 2 0 6 8 0 4 0 2 2 ( 4 0 8 8 0 4 0 ) 565435--5 (409--5128) 90715--1 2 . 0 3 2 . 5 4 [.080--.100] 18--20 680402--2 ( 408--8040 ) 354500--1 (409--5842) 9 0 7 1 5 1 (408--4392) 680402--3 (408--8040) 354500--[ ] (409--5842) ( ) 4 6 6 6 4 4 3 ( 4 0 8 8 0 4 0 ) 565435--5 (409--5128) 0.91--1.37 2 2 2 8 466644--3 ( 408--8040 ) 354500--1 (409--5842) 90363--1 0 . 9 1 1 . 3 7 [.036--.054] 22--28 466644--4 (408--8040) 354500--[ ] (409--5842) 9 0 3 6 3 1 (408--7901) 466966--1 (409--5855) 854040--3 (409--5855) ( ) figure10(cont?d) note i note i note i
114- 10011 rev c 10 of 11 figure 10 (end) hand crimping tool 90715--1 (408--4392) or 90363--1 (408--7901) typical heavy duty mini--applicator (408--8040) amp--o--lectric model ?k? terminating machine 565435--5 (409--5128) amp--o--lectric model ?g? terminating machine 354500--1 (409--5842) insertion tool 91002--1 and --2 (408--7347) extraction tool 91136--1 (408--7859) amp--o--matic stripper--crimper machine 854040--3 (409--5855) ampomator cls iv lead--making machine 217500--[ ] (409--5866)
114- 10011 rev c 11 of 11 6. visual aid figure 11 shows a typical application of an audio/microphone connector. this illustration should be used by production personnel to ensure a correctly applied product. applications which do not appear correct should be inspected using the information in the preceding pages of this specification and in the instructional material shipped with the product or tooling. figure 11. visual aid no conductor wires showing in wire barrel seam wire conductors and insulation both visible in this area conductor ends must be visible mating end must not be damaged bellmouths must be visible make sure receptacle housing is secure on panel plug and receptacle connector must not be damaged pull lightly on wire to make sure contacts are seated make sure both connectors contain same number of positions

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