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Application Specification Series 250 Positive Lock MK I Receptacle Connectors
NOTE
114-- 2153
10 DEC 09 Rev A
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All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2_. Figures and illustrations are for identification only and are not drawn to scale.
1. INTRODUCTION
This specification covers the requirements for the application of Series 250 Positive Lock MK I Receptacle Connectors. These receptacle contacts are designed to accept a wire size range of 20 to 10 AWG. One-- and two position housings are available for your production requirements. The contacts are designed to be mated with tabs containing holes for proper locking. These receptacle contacts are terminated by automatic or semi--automatic machines. When corresponding with Tyco Electronics Personnel, use the terminology provided on this specification to help facilitate your inquiry for information. Basic terms and features of components are provided in Figure 1. Release Latch Single Circuit Housing (Typ) Release Latch Insulation Barrel
Secondary Lock Series 250 Positive Lock Contact Multiple Circuit Housing (Typ) One Position Flag Housing Release Latch Mating End of Housing Retention Nib
Figure 1
Retention Nib
Receptacle Contact Insertion End
Wire Barrel
Series 250 Positive Lock Flag Contact
2. REFERENCE MATERIAL 2.1. Revision Summary
S Updated document to corporate requirements S New logo and format
TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111 E2009 Tyco Electronics Corporation, Harrisburg, PA PRODUCT INFORMATION 1-- 800-- 522-- 6752 All International Rights Reserved TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com
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Series 250 Positive Lock MK I Receptacle Connectors 2.2. Customer Assistance
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Reference Part Number 154717 and Product Code 1113 are representative of Series 250 Positive Lock MK I Receptacle Connectors. These numbers are used in the network of customer service to access tooling and product application information. This service is provided by your local Tyco Electronics Representative or, after purchase, by calling the Tooling Assistance Center or the Product Information number at the bottom of page 1.
2.3. Drawings
Customer Drawings for specific products are available from the responsible Tyco Electronics Engineering Department via the service network. The information contained in the Customer Drawing takes priority if there is a conflict with this specification or any other technical documentation supplied by Tyco Electronics.
2.4. Specifications
Product Specification 108--3017 provides product performance requirements and test information.
2.5. Instructional Material
The following list includes available instruction sheets (408--series) that provide assembly procedures for product, operation, maintenance and repair of tooling, and customer manuals (409--series) that provide setup, operation, and maintenance of machines. Document Number 408--3295 408--7424 408--8040 408--8053 408--9816 409--5128 409--5842 Document Title Preparing Reel of Contacts for Application Tooling Checking Terminal Crimp Height or Gaging Die Closure Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type) Conversion Guide for Miniature Quick--Change Applicators Handling of Reeled Products Basic AMP--O--LECTRIC* Model "K" Terminating Machines, and Accessories AMP--O--LECTRIC Model "G" Terminating Machine 354500--1
3. REQUIREMENTS 3.1. Storage A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housing material.
B. Reel Storage
When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically.
C. Shelf Life
The contacts and housings should remain in the shipping containers until ready for use to prevent deformation to those components. The components should be used on a first in, first out basis to avoid storage contamination that could adversely affect signal transmissions.
D. Chemical Exposure
Do not store contacts near any chemicals listed below as they may cause stress corrosion cracking in the contacts. Alkalies Amines NOTE Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfides Nitrites Sulfur Compounds Tartrates
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Where the above environmental conditions exist, phosphor--bronze contacts are recommended instead of brass if available.
3.2. Special Characteristics
Positive Lock Receptacles are designed with reduced mating forces and a flexible locking dimple. This unique locking feature acknowledges proper mating with an audible mechanical "snap" of the dimple into the hole in the mating tab. The locking feature enhances safety and reliability of the mated circuit for isolated and hard to reach areas.
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Series 250 Positive Lock MK I Receptacle Connectors 3.3. Wire and Receptacle Selection A. Receptacle Selection
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The basic criteria for choosing a receptacle is the width and the thickness of the mating tab. Series 250 Positive Lock MK I will mate with 6.35 x 0.81 mm [.250 x .032 in.] tabs.
B. Wire Selection
Series 250 Positive Lock MK I Contacts will accept wires with insulation diameters, strip lengths, and crimp heights and widths as listed in Figure 2. CAUTION DO NOT nick, cut, or scrape the wire conductor during the stripping operation.
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TERMINAL WIRE SIZE RANGE mm2 [AWG] WIRE APPLIED mm2 [AWG] 0.5 [20] 0.6 [19] 0.7 [18] 1.5 [16] 0.7 [18] 1.5 [16] 2 [14] 2.5 [13.5] 3 [12] 4 [11] 3 [12] 5 [10] INSULATION DIAMETER STRIP LENGTH INSULATION CRIMP WIDTH (Ref) WIRE BARREL CRIMP HEIGHT +0.05 [.002] 1.45 [.057] 1.50 [.059] 1.60 [.063] 1.65 [.065] 1.50 [.059] 1.65 [.065] 1.88 [.074] 2.03 [.080] 2.13 [.084] 2.36 [.093] 2.01 [.079] 2.39 [.094] WIDTH (Ref)
0.5--1.5 [20--16] 0 5 1 5 [20 16]
2.29--3.30 [.090--.130] 2 29 3 30 [ 090 130]
3.30 [.130] 3 30 [ 130]
2.29 [.090] 2 29 [ 090]
0 0.7--2.0 [18--14] 0[ 8 ]
2.41--3.94 [.095--.155] 2 41 3 94 [ 095 155] 3.43--4.95 [.135--.195] 3 56 3 [ 0 3.56--4.32 [.140--.170] 0] 3.43--5.08 [.135--.200] 3 43 5 08 [ 135 200]
5.46 6.22 5.46--6.22 [.215--.245]
3.94 [.155] 3 94 [ 155] 5.33 [.210] 5 59 [ 0] 5.59 [.220] 5.59 [.220] 5 59 [ 220]
2.79 [ 0] 9 [.110]
2.5--4.0 [13.5--11] 5 0[ 35 ] 3.0--5.0 [12--10] 3 0 5 0 [12 10]
3 30 [ 30] 3.30 [.130] 4.57 [.180] 4 57 [ 180]
NOTE
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Figure 2 Each crimp dimension represents the functional range of a wire/contact combination. There are tool designs available to meet various application requirements. The developed crimp configuration is unique for each tool design and is acceptable provided the crimp height is within the functional range. For crimp dimensions of a specific tool, refer to the applicator log packaged with power tools.
3.4. Crimped Contact Requirements
Locate the contact to be crimped in the appropriate tooling according to the instructions packaged with that tooling. Detailed instructions covering the placement of contacts in the tooling and the use of such tooling is packaged with each tool. Terminate the contact according to the directions shipped with the appropriate tooling. See Section 5, TOOLING. CAUTION 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.
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NOTE
Periodic inspections must be made to ensure crimped contact formation is consistent as shown.
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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 2.
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Series 250 Positive Lock MK I Receptacle Connectors B. Crimp Length
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For optimum crimp effectiveness, the crimp must be within the area shown and must meet the crimp dimensions provided in Figure 2. Effective crimp length shall be defined as that portion of the wire barrel, excluding bellmouth(s), fully formed by the crimping tool. Instructions for adjusting, repairing, and inspecting tools are packaged with the tools. See Figure 12.
C. Bellmouths
Front and rear bellmouths shall be evident and conform to the dimensions given in Figure 3. Wire and Insulation Must Both Be Visible In This Area No Insulation Crimped In Insulation Barrel Seam
Flush to 0.76 [.030] Max
No Wire Strands Showing In This Area Rear Bellmouth 0.38-- 0.64 [.015-- .025]
Front Bellmouth 0.38 [.015] Max X
Crimp Length 0.13 [.005] Max. Burr View A
X
See View A
Wire Barrel Crimp Width
Wire Barrel Crimp Height
0.13 [.005] Max. Wire Barrel Flash
0.00 - 0.38 [.000 - .015] Cutoff Tab
Figure 3
Section X- X
D. Cutoff Tab
The cutoff tab shall be cut to the dimensions shown in Figure 3.
E. Burrs
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 in Section X--X.
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Series 250 Positive Lock MK I Receptacle Connectors G. Wire Location
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After crimping, the wire conductor and insulation must be visible in the transition area between the wire and insulation barrels.
H. Conductor Location
The conductor may extend beyond the wire barrel to the maximum shown in Figure 3.
I. Wire Barrel Seam
The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam.
J. Twist and Roll
There shall be no twist, roll, deformation, or other damage to the mating portion of the crimped contact that will prevent proper mating. See Figure 4. 15_ (Max)
Wire Barrel Front of Receptacle Contact
Figure 4
K. Straightness
The force applied during crimping may cause some bending between the crimped wire barrel and the mating portion of the contact. Such deformation is acceptable within the following limits. 1. Up and Down The crimped contact, including cutoff tab and burr, shall not be bent above or below the datum line more than the amount shown in Figure 5.
3_ (Max)
Datum Line 3_ (Max) NOTE: Angles are drawn for clarification only and are not to scale.
Figure 5
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Series 250 Positive Lock MK I Receptacle Connectors
2. Side to Side The side--to--side bending of the contact may not exceed the limits provided in Figure 6.
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3_ (Max)
Datum Line
3_ (Max)
NOTE: Angles are drawn for clarification only and are not to scale.
Figure 6
3.5. Tensile Strength
Crimped contacts should hold the wire firmly and have a crimp pull--out test value meeting that specified in the table in Figure 7. NOTE Adjust tensile testing machine for head travel of 25.4 mm [1 in.] per minute. Directly and gradually apply force for 1 minute.
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CRIMP PULL-- OUT TEST Wire Size mm2 [AWG] 0.5 [20] 0.7 [18] 1.5 [16] 2 [14] 3 [12] 5 [10] Minimum Force Newtons 58 89 133 222 311 356 Figure 7 Pounds 13 20 30 50 70 80
3.6. Mating Tab Dimensions
Figure 8 shows features and dimensional requirements for tab terminals intended for mating with Series 250 Positive Lock MK I Receptacle Contacts. NOTE Testing may be done using a gage as described in Residential Controls-- - Quick--Connect Terminals, ANSI/NEMA No. DC2-- - 1982. Test tabs shall have dimensions as shown in Figure 8.
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Series 250 Positive Lock MK I Receptacle Connectors
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Tab Without Shoulders
See (b) B
0.76 [.030] Max (Side Surface Bevel to Top Surface Bevel) 45_ Approx (2 Places) (a) 0.25 [.010] Max Cutoff Flash, No Wider or Thicker Than Lead Edge A (Front to Top Surface Bevel
C
I Hole Dia 0.08 [.003] A Shoulder May Be Eliminated if Not Feasible
D
G Radius
H -A-
1.14 [.045] Min Use if Shoulder Exists
F
E
Use to Locate Hole if No Shoulder Exists
Shoulders Optional
0.13 [.005] R Max Both Sides 0.08 [.003] 10_ +2_ (Typ) Min Clearance Over Length
I DIA
TAB SIZE 6.35 x 0.81 [.250 x .032]
A+ B+ C+ D+ E+ F+ G+ H 0.13 [.005] 0.13 [.005] 0.03 [.001] 0.08 [.003] 0.20 [.008] 0.08 [.003] 0.13 [.005] (MIN) 0.89 [.035] 7.92 [.312] 0.81 [.032] 6.35 [.250] 4.52 [.178] 3.40 [.134] 1.27 [.050]
8.26 1.65--2.03 [.325] [.065--.080]
NOTE(a) Bevel need not be a straight line if within confines as shown, or a radius of G0.13 mm [.005 in.] may be substituted. NOTE(b) Min Clearance is 9.78 mm [.385 in.] w/o Insulator; 10.03 mm [.395 in.] w/Insulators 154719 and 962522; and 12.06 mm [.475 in.] w/Insulators 520961 and 520910. NOTE Dimensional measurements shall not include plating, burrs, or flatness tolerance. Hole must be symmetrical with no burrs.
3.7. Mating and Testing
Figure 8
The forces required to mate and unmate a test mating tab and receptacle shall be as specified in Figure 9. Measure the force using a testing device capable of holding the reading. It must also provide accurate alignment with slow and steady mating and unmating of the test tab and receptacle.
FORCE (NEWTONS [LBS]) FIRST MATING (MAX) INDIVIDUAL FIRST MATING (MAX) FIRST UNMATING (MINIMUM) LOCKED TEST TAB AND RECEPTACLE 80 [18] 27 [6] 98 [22] Figure 9 11 [2.5] 9 [2] UNLOCKED SIXTH UNMATING (MINIMUM) UNLOCKED
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Series 250 Positive Lock MK I Receptacle Connectors 3.8. Housings
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Series 250 Positive Lock MK I Housings are available in one or two positions. These housings perform an insulation function as well as protecting the mating tabs and receptacles. See Figure 10. One- Position Receptacle Housings
Secondary Lock Receptacle Contact Insertion End
Flag Mating End of Housing
Two- Position Receptacle Housings
Retention Nib
Figure 10
3.9. Assembly/Disassembly Procedures A. Assembling Connector
The contacts are retained in the housings by a window in the bottom of the contact that straddles a raised nib in the housing. See Figure 11B and C. To achieve the straddle position, the nib must be displaced by the receptacle when inserted into the housing. See Figure 11D. To achieve this displacement, the housing must flex. It is important that housings remain in the closed plastic shipping bag to retain the proper moisture content until assembled.
B. Unmating Connector
To release the lock, an integrally--designed release latch must be depressed. See Figure 11A. This is accomplished either with a thumb (Figure 11A and B), or a cam surface (Figure 11C), inside the housing. Unless the release latch is depressed either manually or with the optional designated area of the housing, the receptacle cannot be removed without damage force being applied. Tabs for use with Positive Lock MK I Receptacle Connectors must have a hole in the mating area. The proper tab configuration for mating with Positive Lock MK I Receptacle Connectors is shown in Figure 8. The basic tab dimensions are also found in UL Specification 310.
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Series 250 Positive Lock MK I Receptacle Connectors
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"A"
Locking Dimple
Release Latch (Depress to Unlock Tab)
Mating Tab Housing Retention Window "B" Press to Release
Retention Nib
Secondary Lock
"C"
Latch Depressing Cam Surface
Pull to Release
Retention Nib "D"
Retention Nib
Housing Retention Window
Figure 11
3.10. Repair/Replacement
Damaged crimped contacts or housings must be removed, discarded, and replaced with new components. CAUTION 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.
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Tyco Electronics Corporation
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Series 250 Positive Lock MK I Receptacle Connectors 4. QUALIFICATIONS
Series 250 Positive Lock MK I Receptacle Connectors are Component Recognized by Underwriters Laboratories Inc. (UL) in File E66717 and E28476. They are also Certified by CSA International in File LR7189A.
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5. TOOLING
This section provides a selection of tools for various application requirements. They include semi--automatic and automatic machines for power--assisted application of strip form contacts. Modified designs and additional tooling concepts may be available to meet other application requirements. For additional information, contact one of the service group numbers at the bottom of page 1. A listing of tooling recommendations covering the full wire size range is provided in Figure 12. NOTE
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Tyco Electronics Tool Engineers have designed machines for a variety of application requirements. For assistance in setting up prototype and production line equipment, contact Tyco Electronics Tool Engineering through your local Tyco Electronics Representative or call the Tooling Assistance Center number at the bottom of page 1.
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. NOTE
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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 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. NOTE
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The Model "K" AMP--O--LECTRIC Terminating Machine PN 565435--5 has been superseded by the Model "G" Terminating Machine PN 354500--1 (Customer Manual 409--5842) for new applications. For existing applications, the Model "K" is still recommended because of the large number of installed machines.
WIRE SIZE mm2 0.5--1.5 0.7--2.0 2.6--4.0 3.0--5.0 AWG 20--16 18--14 13--11 12--10 INSULATION DIAMETER 2.29--3.30 [.090--.130] 2.41--3.18 [.095--.125] 3.56--4.32 [.140--.170] 3.43--5.08 [.135--.200] APPLICATOR (DOCUMENT) 567181--2 (408--8040) 466542--3 (408--8040) 466883--2 (408--8040) 567417--2 (408--8040) POWER UNIT (DOCUMENT) 354500 1 (409 5842), 354500--1 (409--5842), 565435--5 (409--5128)
Typical Heavy Duty Miniature Applicator (Side--Feed) (408--8040)
AMP--O--LECTRIC Model "K" Terminating Machine 565435--5
AMP--O--LECTRIC Model "G" Terminating Machine 354500--1
Figure 12
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Series 250 Positive Lock MK I Receptacle Connectors 6. VISUAL AID
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Figure 13 shows a typical application of Series 250 Positive Lock MK I 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. RECEPTACLE CONTACT SHALL BE LOCKED IN PLACE. PULL BACK GENTLY ON WIRE TO ENSURE LOCKING ENGAGEMENT
WIRE AND INSULATION BOTH VISIBLE RELEASE LATCH SHALL NOT BE DEFORMED CONTACT NOT DEFORMED
NO INSULATION IN INSULATION BARREL SEAM
NO WIRE IN WIRE BARREL SEAM WIRE MUST BE FLUSH OR PROTRUDE SLIGHTLY
HOUSING NOT DAMAGED OR CRACKED FIGURE 13. VISUAL AID
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