Datasheet

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Application Specification

Pre- Insulated Diamond Grip (PIDG*)

114--2157

1 of 14

LOC B

E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company

*Trademark

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.

TOO LING ASSISTANCE CENT ER 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

Terminals, Splices, and End Caps

03 MAY 11 Rev G

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 dr awn to scale.

1. INTRODUCTION

This specification covers the requirements for application of PIDG terminals, splices, and end caps in various

operating environments. Each consists of a precision--formed metal wire barrel and a copper sleeve encased in

insulating material made of nylon, polyvinyl chloride (PVC) or polyvinyl fluoride (PVF

). The insulation is color

coded (solid primary color or a primary color with a color stripe) to correspond with a specific wire size or wire

size range. The terminals, splices, and end caps accept a combination of solid and stranded wire. The wire

barrel contains serrations that provide maximum contact and tensile strength after crimping the terminal, splice,

or end cap onto the wire. The terminals are available with a variety of tongue lengths and configurations; and

the terminals, splices, and end caps are available with various wire barrel lengths and diameters to

accommodate different wire sizes, wire types, and combination of wire sizes.

The terminals, splices, and end caps are available in loose piece form to be terminated with manual and

pneumatically--powered hand held tools and tape mounted to be terminated with bench mount semi--automatic

machines.

When corresponding with 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.

Right Angle Ring Tongue

Right--Angle Rectangular Tongue

Multiple Stud Hole

Figure 1 (Cont’d)

In--Line Ring Tongue

In--Line Rectangular Tongue

Offset Ring Tongue

Knife Connect/Disconnect

Hook Tongue

Spring Spade Tongue

Flanged Spade Tongue

Copper

Sleeve

Insulation

Terminal

Tongue

Wire Barrel

NOTE

Summary of content (14 pages)

PAGE 1
Application Specification 114-- 2157 Pre- Insulated Diamond Grip (PIDG*) Terminals, Splices, and End Caps NOTE i 03 MAY 11 Rev G 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.
PAGE 2
114- 2157 End Cap Butt Splice Opaque Insulation Transparent Insulation Window Wire Barrel Insulation Window Copper Sleeve Figure 1 (End) 2. REFERENCE MATERIAL 2.1. Revision Summary Revisions to this application specification include: S Changed company logo 2.2. Customer Assistance Reference Product Base Part Number 51864 and Product Code 3022 are representative of PIDG terminals, splices, and end caps.
PAGE 3
114- 2157 408--8082 408--9252 408--9586 408--9640 408--9816 409--1993 409--5842 409--5862 409--5878 Miniature Quick--Change Applicators (Side--Feed Type) with Air Feed PRO--CRIMPER* III Hand Crimping Tool 58433--3 Pneumatic Crimping Heads 314269--1, 314270--3, and 314537--1 Crimp Quality Monitor Applicators for Side--Feed and End--Feed Applications Handling of Reeled Products AMP--TAPETRONIC* Machine 69875 AMP--O--LECTRIC* Model “G” Terminating Machine 354500--1 626 Pneumatic Tooling Assemblies 189721--[ ]
PAGE 4
114- 2157 D. Chemical Exposure Do not store product near chemicals listed below. They could cause stress corrosion cracking of product. Alkalies Amines Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Sulfur Compounds Tartrates 3.3. Wire Selection and Preparation Terminals and splices accept solid and/or stranded wire sizes 26 through 10 AWG and end caps accept solid and/or stranded wire sizes 22 through 10 AWG.
PAGE 5
114- 2157 NOTE The wire conductor(s) must not be nicked, scraped, or cut during the stripping operation. i 3.4. Wire Placement The stripped wire must be inserted into the wire barrel until the wire insulation is against the wire barrel but not inside it. The wire insulation must be inside the metal sleeve. A gap between the wire insulation and wire barrel is allowed, but not to exceed the dimension given in Figure 3. Transparent Insulation Window Butt Splice Shown Splice Insulation 1.59 [.
PAGE 6
114- 2157 Crimp Inspection Using Micrometer or Comparator Wire Barrel Crimp Profile and Location Micrometer or Comparator Dot Code (1 Dot Shown) Center of Most Compressed Area (Refer to Table for Crimp Height) Crimp Evenly Formed Over Center of Wire Barrel Crescent Crimp (Depressed Oval Shape) C Flat Rectangular Crimp F Dot Code (1 Dot Shown) Solder Slug C F Produced by Crescent Crimp Tooling Produced by TETRA--CRIMP Tooling SOLDER SLUG WIRE SIZE (AWG) TERMINAL, SPLICE, OR END CAP INSULATION COL
PAGE 7
114- 2157 Note: Terminal Shown — Same Applies to Splice and End Cap Dot Code (1 Dot Shown) is Well Formed and Corresponds With Crimping Chamber of Tooling Used Overstress Marks Not Apparent on Insulation Wire Conductor(s) Visible Within This Area (Except Splice and End Cap, See Detail A and Detail B) No Rear Bellmouth Wire Insulation Inside Metal Sleeve But Not Inside Wire Barrel Front Bellmouth Evident (Top and Bottom of Wire Barrel) No Flash in This Area Detail A — Splice Wire Size Marking Matches
PAGE 8
114- 2157 If the crimp passes the bend test, the insulation crimp must be tested by pulling the wire from the terminal, splice, or end cap. If the wire insulation is only slightly deformed, the crimp is correct. Figure 8, Detail B shows a desired crimp, providing adequate support without damage to either the insulation or the wire conductor(s).
PAGE 9
114- 2157 Cross- Section of Insulation Crimp at Wire End of Terminal, Splice, or End Cap (Illustrations Represent Uppermost Wire Insulation Range of Terminal, Splice, or End Cap (Thinner Wire Insulation May Appear Slightly Different, But Will Perform the Same, Refer to Figure 2) Detail A — Too Loose Detail B — Correct Wire Insulation Detail C — Too Tight Metal Sleeve Terminal, Splice, or End Cap Insulation Figure 8 3.7.
PAGE 10
114- 2157 4. QUALIFICATIONS Most, but not all, PIDG terminals, splices, and end caps are Listed by Underwriters Laboratories Inc. (UL) in File E13288 and Certified by CSA International in File LR7189. NOTE i To determine whether a terminal, splice, or end cap (identified by part number) meets the requirements of an agency, contact PRODUCT INFORMATION at the number at the bottom of page 1. 5.
PAGE 11
4- 2157 Loose Piece Terminal, Splice, or End Cap Hand Tools and Die Assemblies (Refer to Table for Part Numbers) Double Action Hand Tools (DAHT) (408-- 1559) “T”-- Head Hand Tools (T-- HD HT) (408-- 1610) Heavy Head Hand Tools (HHHT) (408-- 1261) TETRA-- CRIMP Hand Crimping Tool (408-- 2823) PRO-- CRIMPER III Hand Crimping Tool (408-- 9252) Terminal and Splice Die Assemblies (408-- 1632) Hand Crimping Tool 69710-- 1 (Accepts All Die Assemblies Listed in Table) (408-- 2095) 626 Pneumatic Tooling Sys
PAGE 12
114- 2157 Tape- Mounted Terminal, Splice, or End Cap Die Assemblies and Applicators Power Units Die Assemblies 69872, 69873, 69874, 69877, and 69897 (408-- 2423) Die Assemblies 59826-- 1, 59827-- 1, and 59828-- 1 (408-- 2822) AMP-- TAPETRONIC Machine 69875(409-- 1993) AMP-- O-- LECTRIC Model “G” Terminating Machine 354500-- 1 (409-- 5842) Miniature Quick-- Change Applicator 567200-- 3 (408-- 8082) Miniature Quick-- Change Applicator 687658-- 1 (408-- 8044 ) AMPOMATOR CLS IV+ Lead-- Making Machine 3565
PAGE 13
114- 2157 6. VISUAL AID Figure 11 shows a typical application of PIDG terminals, splices, and end caps. This illustration should be used by production personnel to ensure a correctly applied terminal, splice, or end cap. 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.
PAGE 14
114- 2157 PROPER CRIMP CRIMP CENTERED ON WIRE BARREL SMALL AMOUNT OF SPACE BETWEEN WIRE CONDUCTOR(S) AND WIRE BARREL Detail A Detail B (Insulation and Metal Sleeve Removed) FRONT BELLMOUTH ON TOP AND BOTTOM OF WIRE BARREL FRONT BELLMOUTH ON TOP OF INSULATION IMPROPER CRIMP CRIMP TOO FAR FRONT ON WIRE BARREL NO SPACE BETWEEN WIRE CONDUCTOR(S) AND WIRE BARREL Detail A Detail B (Insulation and Metal Sleeve Removed) NO BELLMOUTH ON TOP OF WIRE BARREL NO BELLMOUTH ON TOP OF INSULATION CRIMP TOO FAR BAC