Application Specification
High Current Edge Connector
Contacts and Housings
NOTE
114-- 9005
17 Mar 11 Rev D
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 the application of High Current Edge Connector Contacts and
Housings. Housings are available in 3, 4, 6, 8, 9, 10, and 12 contact positions with contact centerline spacing
of 7.92 mm [.312 in.]. The housings are designed with or without mounting ears and have the capability of
mating with double--sided printed circuit (pc) boards.
These housings are available two styles for wire--to--board and board--to--board applications. Wire--to--board
housings accept heavy duty crimp, snap--in contacts which can accommodate a wire size range of 16--10 AWG
with an insulation diameter of 2.29--5.34 mm [.090--.210 in.]. Contacts are supplied in strip form for automatic
machine termination and in loose piece form for hand tool application. Board--to--board housings are supplied
pre--loaded with solder tine contacts. Housings are placed on pc boards manually.
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.
Contact
Cutoff
Tab
Wire
Barrel
Wire- to- Board Housing
With Mounting Ears
Mounting
Ear(s)
Insulation
Barrel
Locking
Lance
Keying Plug
Track
Card Slot
Contact
Cavity
Board- to- Board Housing
Card Slot
Wire- to- Board Housing
Without Mounting Ears
Mounting
Ear(s)
Standoff(s)
Pre-- Loaded
Solder Tine Contacts
Figure 1
E2011
Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1--800--722--1111
All Rights Reserved
PRODUCT INFORMATION 1--800--522--6752
TE logo is a trademark.
*Trademark. Other product names, logos, or company names might be trademarks of their respective owners.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.te.com
Card Slot
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2. REFERENCE MATERIAL
2.1. Revision Summary
This paragraph is reserved for a revision summary covering 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 530521 and Product Code 5259 are representative numbers of High Current Edge
Connector Contacts and Housings. 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 the Product Information number at the bottom of page 1.
2.3. Drawings
Customer Drawings for each product part number 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 technical
documentation supplied by TE.
2.4. Manuals
Manual 402--40 is available from the service network. This manual provides information on various flux types
and characteristics along with the commercial designation and flux removal procedures. A checklist is included
in the manual for information on soldering problems.
2.5. Specifications
Product Specification 108--9045 provides product performance requirements and test information.
2.6. Instructional Material
The following list includes available instruction sheets (408--series) that provide assembly procedures for
product, and operation, maintenance, and repair of tooling; and customer manuals (409--series) that provides
setup, operation, and maintenance of machines.
408--2095
Hand Crimping Tool 69710--1
408--6516
Keying Plugs 530533--1 and 531369--1
408--7782
Extraction Tool 91116--1
408--7783
Crimping Die Assemblies 90332--1 and 90332--2
408--7802
Crimping Die Assembly 90333--1
408--8040
Miniature Quick Change Applicators 466438--1 and 466439--2
408--9123
High Current Edge Connector Contacts and Housings
409--5842
AMP--O--LECTRIC* Model “G” Terminating Machine 354500--1
3. REQUIREMENTS
3.1. Material
High Current Edge Contacts are made of high conductivity copper alloy with bright tin--over--nickel plating.
Housings are glass--filled, high--temperature thermoplastic.
3.2. Storage
A.
Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in housings.
B.
Reeled Contacts
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 the contacts and damage to the housings. They should be used on a first in, first out basis
to avoid storage contamination that could adversely affect signal transmissions.
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3.3. Wire- to- Board Connectors
A. Wire Selection and Preparation
1. Selection
Contacts are available for solid and stranded copper wire sizes specified in Figure 2.
2. Strip Length
Insulation must be stripped as indicated in Figure 2.
CAUTION
Do not nick, scrape, or cut the wire conductor during the stripping operation.
!
B. Crimp Requirements
1. Cutoff Tab and Burr
The cutoff tab is the remaining portion of the carrier strip after the contact is cut from the strip. The cutoff
tab and the burr resulting from the cutoff tab shearing must not exceed the dimension shown in Figure 2.
2. Locking Lance
The locking lance retains the contact in the housing and must not be deformed or bent beyond the
dimensions shown in Figure 2.
3. Terminating
Select the contact to be crimped for the wire size being used. Crimp the contact according to the
instructions packaged with the appropriate tooling.
4. Wire Conductor Location
After crimping, the end of the wire conductor must be flush with or extend 1.27 mm [.050 in.] from the
front end of the contact wire barrel. Both the insulation and the conductor must be visible between the
wire barrel and the insulation barrel. Care must be taken not to allow the wire insulation to be crimped in
the wire barrel. See Figure 2.
5. Wire Barrel Seam
The seam must be completely closed and there must be no evidence of loose wire strands or wire
strands visible in the seam.
CAUTION
When crimping contacts with large wire sizes, extra caution should be taken to ensure that all wire strands are in the
wire barrel
!
6. Wire Barrel Flash
Wire barrel flash is the formation that may appear on both sides of the wire barrel as the result of the
crimping process. It must not exceed the dimension provided in Figure 2.
7. Crimp Height and Width
The effective crimp length applied to the wire barrel is the most compressed area and is most critical in
ensuring optimum electrical and mechanical performance of the crimped contact. The crimp height and
width of the wire and insulation barrels must be within the dimensions provided in Figure 2.
8. Bellmouths
Bellmouths should be visible at the front and rear of the contact after crimping. The rear bellmouth and
front bellmouth lengths must not exceed the dimensions shown in Figure 2.
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Effective Crimp Length
Strip
Length
Insulation
Note:
Not to Scale
A
Wire Conductor
Location
Both Wire and Insulation
Must Be Visible in
Transition Area
Rear Bellmouth
0.38 [.015] (Min)
Burr
1.39 [.005]
(Max)
Wire Barrel
Seam
Front Bellmouth
0.25 [.010] (Max)
Wire
Barrel
Insulation
Barrel
Locking Lance
1.27-- 1.52 [.050-- .060]
Wire Barrel
Crimp Height
(See Table)
Wire Barrel
Crimp Width
(See Table)
A
Crimped High Current
Edge Contact
Wire Barrel Flash
1.39 [.005] (Max)
Section A- A
WIRE
SIZE
(AWG)
18
16
14
12
10
4.06 5.33
4.06--5.33
[.160--.210]
7.11 7.62
7.11--7.62
[.280--.300]
2.29--3.68
[ 090
[.090--.145]
5]
6.10--6.60
[ 0 60]
[.240--.260]
INSUL
DIA
STRIP
LENGTH
WIRE BARREL CRIMP
HEIGHT
1.78--1.88
[.070--.074]
1.91--2.06
[.075--.081]
1.83--2.36
[.072--.093]
1.78--3.38
[.070--.133]
2.44--3.15
[.096--.124]
Figure 2
WIDTH
Cutoff Tab
0.25 [.010] (Max)
CONTACT
INSULATION BARREL CRIMP (Ref)
HEIGHT
Adjustable
WIDTH
0.20--2.84
[.008--.112]
[ 008
]
3.86 4.01
3.86--4.01
[.152--.158]
4.50--4.65
[
[.177--.183]
83]
3.05 4.06]
3.05--4.06]
[.120--.160]
5.38 5.54
5.38--5.54
[.212--.218]
6.27 6.43
6.27--6.43
[.247--.253]
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9. Alignment
The wire end of the contact, including the cutoff tab and burr, must not be bent above or below the
datum line more than the amount shown in Figure 3. The mating end of the contact must not exceed the
requirements of Figure 3. The side--to--side bending of the contact must not exceed the limits specified.
Up and Down Alignment
0.51 [.020]
(Max)
Datum
Line
1.02 [.040]
(Max)
Datum
Line
1.52 [.060]
(Max)
Side- to- Side Alignment
Datum
Line
7.19-- 7.29
[.283-- .287]
Figure 3
10. Twist and Roll
There shall be no twist or roll in the crimped portion in relation to the mating end that will impair usage of
the contact. See Figure 4.
Twist and Roll
Crimped
Portion
Datum
Line
Avoid Twist and Roll
Figure 4
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