Application Specification
Power Ring Connectors
NOTE
114-- 2087
19 FEB 10 Rev C
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 Power Ring Connectors. The connectors are
designed to be mounted to the chassis of a household appliance.
Each connector consists of a housing, two copper tone terminals, one silver tone terminal, a ground strap
(optional), three screws, and three nuts. The housing features mounting holes and three terminal slots. The
terminals feature a locking lance, a wire barrel, an insulation support barrel, and a tab for a screw and nut.
There are wire barrel designs to cover a wire range of 18 through 10 AWG stranded copper wire. (Refer to the
specific customer drawing for the appropriate wire size range.) The tab end will accept stranded copper
household wire that is within a range of 6 through 10 AWG. This wire can be used unterminated, or it can be
terminated with any precision formed or custom--made terminal with a maximum thickness of 3.175 mm
[.125 in.]. See Figure 1 for optional Ring Tongue Terminal.
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.
Mounting
Hole (Typ)
Terminal
Tab
Cutoff
Tab
Terminal
Slot (Typ)
Terminal
Hold-- downs
(Typ)
Terminal
Stops (Typ)
Locking
Lance
Wire Barrel
Screw
Stabilizer
Ground
Terminal
Slot
Ground
Strap
(Optional)
Nut
Stabilizer
Hole
Insulation
Support
Barrel
Housing
Flange
Ring Tongue Terminal (Optional)
Depending
on the Part Number, Mounting Hole May Not be in Position Shown
Figure 1
2. REFERENCE MATERIALS
2.1. Revision Summary
S
S
S
S
Updated document to corporate requirements and new layout and format
Added new text to Figure 1, and Paragraphs 3.5.3 a, b, and c
Moved dimensions from text in Paragraphs 3.2.C thru 3.2.F to Figure 3
Added new Figures and renumbered
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111
E2010
Tyco Electronics Corporation, Berwyn, PA
PRODUCT INFORMATION 1-- 800-- 522-- 6752
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other product names, logos, or company names might be trademarks of their respective owners.
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LOC B
Power Ring Connectors
2.2. Customer Assistance
114- 2087
Reference Base Product Part Number 520942 and Product Code 1073 are representative of Power Ring
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 the Product Information Center at
the number at the bottom of page 1.
2.3. Drawings
Customer Drawings for specific products 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 Tyco Electronics.
2.4. 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 provide setup, operation, and maintenance procedures of
machines.
Document Number
408--3295
408--7424
408--8040
408--8053
408--8059
408--9816
409--5842
Document Title
Preparing Reel of Contacts for Applicator Tooling
Checking Terminal Crimp Height or Gaging Die Closure
Heavy Duty Miniature Quick--Change Applicator (Side--Feed Type)
Conversion Guide for Miniature Quick Change Applicators
General Preventive Maintenance for Applicators
Handling of Reeled Products
AMP--O--LECTRIC* Model “G” Terminating Machine 354500--[ ]
2.5. Specifications
Product Specification 108--1191 provides product performance and test information. Application Specification
114--2084 provides application requirements for Ring Tongue Terminals that can be used in these connectors.
3. REQUIREMENTS
3.1. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housing
material.
B. Shelf Life
The components should be used on a first in, first out basis to avoid storage contamination that could
adversely affect electrical continuity.
C. Chemical Exposure
Do not store contacts near any chemicals listed below.
Alkalies
Amines
Ammonia
Carbonates
Citrates
Nitrites
Phosphates Citrates
Sulfides Nitrites
Sulfur Compounds
Tartrates
3.2. Wire Selection and Preparation
A. Wire Selection
The crimping barrels are designed to accept 18 through 10 AWG stranded copper wire, and the tab end of
the terminal is designed to receive 6 through 10 AWG stranded copper household wire. Refer to Figure 2
for wire combinations, wire strip lengths, and crimp height values of terminals crimped in the specified
heavy duty applicator.
B. Wire Preparation
The appliance wires and the household wires must be stripped to the dimension shown in Figure 2. Care
must be exercised to prevent cutting or nicking of the conductors.
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Rev
C
Power Ring Connectors
Household Wire
1.27 [.050]
Appliance Wire
114- 2087
19.05
[.750]
Ref
WIRE SIZE
(AWG)
18
16
16
14
14
12
12
10
14 (2 Wires)
14 (2 Wires)
12 (2 Wires)
INSULATION DIAMETER
(MAX)
4.06 [.160]
4.06 [.160]
7.87 [.310]
4.06 [.160]
7.87 [.310]
4.06 [.160]
7.87 [.310]
7.87 [.310]
4.06 [.160] Each
4.32 [.170] Each
4.32 [.170] Each
Locking
Lance
6.35 [.250]
WIRE BARREL CRIMP
HEIGHT +0.05 [.002]
WIDTH (NOMINAL)
2.36 [.093]
2.46 [.097]
2.51 [.099]
2.64 [.104]
2.64 [.104]
2.90 [.114]
2.87 [.113]
3.23 [.127]
3.07 [.121]
3.02 [.119]
3.45 [.136]
3.56 [.140]
3.56 [.140]
4.57 [.180]
3.56 [.140]
4.57 [.180]
3.56 [.140]
4.57 [.180]
4.57 [.180]
3.56 [.140]
4.57 [.180]
4.57 [.180]
Strip one wire to 6.35 mm [.250 in.] and the second wire long enough that the insulation will not enter the insulation support barrel.
Figure 2
3.3. Crimp Requirements
A. Locking Lance
The end of the locking lance should be the dimension shown below the terminal tab plane as indicated in
Figure 3. Inspection of several un--crimped contacts will provide the required visual appearance before and
after crimping of a terminal.
B. Carrier Cutoff Tab and Burr Allowance
Neither cutoff tab shall extend beyond the side of the terminal and the maximum allowable burr on the
cutoff is provided in Figure 3.
C. Crimp Configuration and Location
The crimp applied to the wire portion of the terminal is the most compressed area, and is the most critical
to assure optimum performance of the termination. The effective length shall be as defined in Figure 3
(excluding bellmouths) over the length of the wire barrel.
The wire barrel will be crimped in the “F” Crimp configuration where the tips of the wire barrel will turn
inward and encapsulate all wire strands. The insulation support barrel may be crimped in the “F” or “O”
Crimp configuration where the tips of the insulation barrel will encapsulate the insulation and form the
insulation support. See Figure 3.
D. Wire Barrel Seam
The wire barrel shall be completely closed with no portion of the conductor protruding from the seam. The
crimp flash along the sides of the wire barrel that are caused by the crimping pressure and allowable
tolerances in the tool shall not exceed the dimension provided in Figure 3.
E. Conductor Location
The conductor of the wire may be flush to a protrusion of what is shown in Figure 3 from the front of the
wire barrel. Both insulation and conductor should be visible in the transition area between the insulation
and wire barrels. No insulation should be in the wire barrel.
Rev
C
Tyco Electronics Corporation
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Power Ring Connectors
27% of
Crimp Width
(Ref)
114- 2087
A
Wire Barrel Seam
Insulation Support Barrel
Crimp Width
Crimp
Height
Cutoff Tab
A
0.08 [.003]
Max
Front Bellmouth
0.51 [.020] Max
Conductor Protrusion
0-- 1.57 [.000-- .062]
Wire Barrel
Crimp Length 3.8 [.150] Min
Rear Bellmouth
0.51-- 1.02
[.020-- .040]
Crimp Flash
0.13 [.005] Max
Locking Lance
1.27 [.050]
Below Terminal
Plane
Figure 3
SECTION A- A
F. Bellmouths
The bellmouths that are caused by extrusion of the terminal metal during termination shall be as shown for
the rear and the front bellmouths. See Figure 3.
G. Insulation
The insulation should not be visibly damaged, broken, or cut after crimping.
H. Vertical and Horizontal Straightness
Terminals must be straight and aligned within the tolerance shown in Figure 4.
I. Twist or Roll
The twist or roll of the crimped terminal must not exceed the limits specified in Figure 4.
5 (Max)
5 (Max)
ALIGNMENT TO VERTICAL PLANE
6 (Max)
Vertical
Base Plane
2 (Max)
ALIGNMENT TO HORIZONTAL PLANE
Figure 4 (cont’d)
Horizontal
Base Plane
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Rev
C
Power Ring Connectors
114- 2087
10 (Max)
TWIST/ROLL
Figure 4 (End)
Base Line
10 (Max)
3.4. Housing
A. Hole Layout
The mounting plane hole layout for the two offset mounting holes and the single ground strap is provided
in Figure 5.
NOTE
When selecting a location for the connector, the wire bend radius specified by the wire manufacturer must be
considered. Also, to permit attachment of the wire, there should be sufficient slack between the wire end and any
strain relief.
i
B. Attaching Hardware
Any commercially available hardware such as sheetmetal screws, bolts and nut, rivet or other hardware
that is compatible with the mounting plane may be used to secure the housing to the mounting plane.
NOTE:
Typical hole layout. For specific
hole layouts for your production
requirements, contact Tyco Electronics
at the numbers at the bottom of
page 1.
28.58
[1.125]
Min
30.23
[1.190]
18.29 [.720]
19.05
[.750]
3X4.00 [.157]
For No. 10
Metal Screws
Edges of
Mounting
Plane
31.75
[1.250]
Min
Grounding Strap
Mounting Hole
15.11 [.595]
Figure 5
3.5. Attaching Appliance and Household Wire
(Figures 6 and 7)
The household wire can be attached to the terminal tab as bare wire or with a terminal attached. Any precision
formed or custom--made terminal of 3.18 mm [.125 in.] maximum thickness may be used. See Figure 6 for the
Ring Tongue Terminal which may be used. Grounding the appliance through the ground wire (center/neutral
position) with the ground strap is optional. Figure 6 provides a composite of the various termination techniques.
The assembly procedures for all techniques are covered by the following text.
1. Crimp the appliance wire to the tab terminal wire and insulation barrels using the tooling and crimping
instructions packaged with the tooling.
2. Lay the appliance wire on the center of the terminal cavity then, guiding the terminal under the
terminal hold--downs, pull back on the wire until the terminal locking lance passes over the housing
locking rib and locks behind the rib.
Rev
C
Tyco Electronics Corporation
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