Catalog 82221
Magnet Wire Terminals and Termination Systems
Standard MAG-MATE Terminals
Product Facts
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Revised 10-02
Terminates all magnet wire
film insulations
Eliminates need for pre-
stripping conductors
Eliminates need to post
insulate termination
Excess magnet wire is
automatically trimmed
during the termination
process
Simultaneously terminates
two magnet wires of the
same size in one terminal
(for splicing or bi-filing)
Various lead wire
attachment options
available
Available in strip form for
semi-automatic or fully
automatic insertions
Available in loose piece
form for hand tool insertions
Varnish resist tab terminals
are available for special
applications
High speed, fully automated
integrated systems provide
uniform terminations
reliability at the lowest
possible applied cost
Clean metal-to-metal
interface produces stable,
gas-tight electrical
terminations free of oxides
and other contaminants
Recognized under the
Component Recognition
Program of Underwriters
Laboratories Inc.,
File No. E13288
R
Standard MAG-MATE
Terminals
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Tyco Electronics offers a full
selection of AMP Standard
MAG-MATE Insulation
Displacement Crimp (IDC)
terminals for magnet wire
terminations.
MAG-MATE terminals are
available in poke-in, poke-in
tab, splice, crimp wire
barrel, solder post, quick
connect tab, pin and
receptacle styles.
Standard MAG-MATE
terminates magnet wire
ranging from 34-12 AWG
[0.16 -2.05 mm].
Each IDC slot terminates up
to four consecutive magnet
wire ranges.
Two magnet wires with the
same diameter can be
terminated in one terminal
down to 23 AWG [0.57 mm].
According to Tyco Electronics
specifications MAG-MATE
cavities are either
integrated into coil bodies
or especially designed
cavity housings. The
magnet wires are precisely
positioned in the “U”shaped
designed termination slots.
The MAG-MATE Inserter
cuts the terminals from the
strip and places the
terminals over the magnet
wire into the plastic cavities.
During this operation the
small stripping devices
penetrate the film insulation
from the magnet wire.
Residual spring energy in
the terminal causes the side
walls of each IDC slot to
function as opposing
cantilever beams.
This constant pressure
results in an intimate metal-
to-metal interface, providing
a reliable, long-term
connection.
The wiping action between
the wire and terminals
removes oxides or other
contaminants present on
both the conductor and the
terminal slot side walls,
producing a clean, stable,
gas-tight electrical
termination.
The AMP MAG-MATE
Inserter may be used as a
semi-automatic bench
machine or integrated in
production lines for fully-
automatic applications.
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Applications
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Motor windings and
connections
Coil connections
Transformer windings and
connections
Bobbin connections
Lighting ballasts
Power supplies
1
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Standard MAG-MATE Terminals
(Continued)
Typical Plastic Cavities
Manufacture only according
to Tyco Electronics
Specification.
Revised 10-02
Technical Documents
Application Specifications
describe requirements for using
the product in its intended
application and or crimping
information. They are intended
for the Packaging and Design
Engineer and the Machine
Setup Person.
114-2050—Poke-In Tab
MAG-MATE
Terminals
114-2069—Standard
MAG-MATE .187
[4.75] Box Height
Terminals
114-2046—Standard
MAG-MATE .300
[7.62] Box Height
Terminals
114-2066—Standard
MAG-MATE .500
[12.7] Box Height
Terminals
114-2067—Standard
MAG-MATE .300
[7.62] Box Height
Latch-In Terminals
Narrow Body
114-2094—Standard
MAG-MATE .300
[7.62] Box Height
Latch-In Terminals
Wide Body
Cavity Size 1,
.187 [4.75] Box Height MAG-MATE
(Reference Application
Spec. 114-2069)
Cavity Size 2,
.300 [7.62] Box Height MAG-MATE
(Reference Application
Spec. 114-2046)
Cavity Size 3,
.300 [7.62] Box Height
Latch-In MAG-MATE, Wide Body
(Reference Application
Spec. 114-2094)
.355
[ 9.08 ] Min.
.215
[ 5.46 ] Min.
.235
[ 5.97 ] Min.
Cavity Size 4,
.500 [12.70] Box Height
MAG-MATE
(Reference Application
Spec. 114-2066)
Cavity Size 5,
.300 [7.62] Box Height
Latch-In MAG-MATE, Narrow
Body
(Reference Application
Spec. 114-2067)
Cavity Size 6,
.300 [7.62] Box Height
MAG-MATE
(Reference Application
Spec. 114-2046)
Note:
MAG-MATE typical
plastic cavities are not for
design; Tyco Electronics
will supply required
dimensions of cavity for
each customer application.
Plastic cavities, designed
to Tyco Electronics
specifications, may be
molded as part of the coil
bobbin or attached to a
lamination stack in the area
of the magnet wire coil.
Each cavity is a rectangular
box with two narrow slots
on opposing walls and a
plastic post or anvil
extending upward from the
bottom surface.
During or after the winding
process, the magnet wire is
placed across the plastic
cavities and into the slots,
either manually or by coil
winding equipment.
Unraveling is prevented by
a slight friction fit, suitable
bend or by wrapping the
magnet wire around a tie-off
post.
During insertion, two
insulation displacing
terminal slots strip the film
insulation from the magnet
wire producing a stable
electrical termination.
The plastic anvil supports
the magnet wire, helping to
prevent it from being
dragged down when the
terminal is inserted.
Terminal retention is
secured in the plastic
cavities by either locking
barbs or locking latches in
addition to locking barbs for
quick disconnect FASTON
tab terminals.
Excess magnet wire is
trimmed flush with the
outside of the plastic cavity
by a shear blade traveling
with the terminal insertion
ram.
The sheared wire end can
be tucked inside the plastic
cavity, if necessary, by
cutting the wire off before
the terminal is fully seated
allowing the terminal to drag
the severed end of the wire
into the pocket inside the
cavity.
Tyco Electronics will
provide design and mold
engineering resources to
manufacture any
specifically designed
MAG-MATE cavity
housing.
www.tycoelectronics.com
2
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
Catalog 82221
Magnet Wire Terminals and Termination Systems
Standard MAG-MATE Terminals
(Continued)
Standard MAG-MATE
Interconnection System
How the System Operates
Revised 10-02
➀
➀
Wire Cutter
This part cuts off the
excess magnet wire and
the wire support at the
front of the cavity.
Standard MAG-MATE
Terminals
➅
Locking Barbs
Terminal retention is
secured in the cavity by
four locking barbs.
➁
Insertion Finger
The insertion finger is part
of the MAG-MATE
Inserter. It pushes the
terminal that was sheared
from the carrier strip
through the inserter “tube”
into the positioned cavity.
➂
Contact
Various wire attachments
in three different sizes,
.187, .300, .500 cavity
height (see tables).
➆
Plastic Cavity
Production must be in
accordance with
Tyco Electronics
Application Specifications.
Consulting
Tyco Electronics is
required for design in.
➁
➇
Cavity Slot for Wire
The width has to be in
accordance with the wire
size (see Application
Specification).
➂
➃
IDC Slot
In different sizes for
magnet wire diameters
from 34-12 AWG
[0.16-2.05 mm]. Strain
relief slots available
for high vibration
applications.
➄
Stripping Shoulders
During the insertion
process, these shoulders
strip the film insulation
from the magnet wire in
four areas.
➈
Magnet Wire
The magnet wire is
positioned in the “U” slot.
➉
Wire Support Block
The block supports the
magnet wire during the
cutting process. The
magnet wire is cut flush
to the cavity front side.
11
➃
➄
➅
Anvil
The anvil supports the
wire during the insertion
process.
➆
➈
➇
Termination Sequence
A
= Prepare
B
= Insert
C
= Finish
➁
➀
➂
➉
11
➀
Post Trim Blade
➁
Insertion Finger
➂
Poke-In Contact
➃
MAG-MATE Cavity
➄
Magnet Wire
➅
Support Anvil
A
B
C
➃
➄
➅
3
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Standard MAG-MATE Terminals
(Continued)
Test Results
Standard and Slim Line
MAG-MATE
products have
been submitted to the following
tests without significant millivolt
increase:
Current Cycling
—
480 cycles with each cycle
consisting of 15 minutes “ON”
followed by 15 minutes “OFF”
Thermal Shock
—
25 cycles with each cycle
consisting of 30 minutes at
125°C followed by 30 minutes
at -65°C
Humidity
—
Temperature Cycling
10 cycles between 25°C and
65°C at 95% RH
Heat Age
—
33 days at 118°C
Mini MAG-MATE
products
have been submitted to the
following tests in addition to
those listed without significant
millivolt increase:
Vibration
—
10-55-01- Hz traversed in 1
minute at .06 inches total
excursion; 2 hours in each of 3
mutually perpendicular
directions.
Industrial Gas with Chlorine
—
1000 exposure to 200 ppb each
of sulphur dioxide, nitrogen
dioxide, hydrogen sulphide and
50 ppb chlorine.
Revised 10-02
Resistance vs Thermal Shock (Copper Wire)
Resistance vs Current Cycles (Copper Wire)
Test Current produces 100°C Magnet Wire Operating Temperature
∆T
(C)
Current Rating Curves
The diagram shows the
temperature rise of the
contact, depending on the
magnet wire size being
applied.
I (A)
Product Specifications
describe technical performance
characteristics and verification
tests. They are intended for the
Design, Test and Quality
Engineer.
108-2012 Standard .187and
.300 MAG-MATE
Terminals
108-2053 Standard .500 Box
MAG-MATE
Terminals
108-1484 Slim Line MAG-MATE
Terminals
108-2016 Mini MAG-MATE
Terminals
Note:
For all applications,
Tyco Electronics recommends that
samples of the magnet wire to be
used be submitted for engineering
evaluation.
33 AWG
30 AWG
27 AWG
26 AWG
24 AWG
22 AWG
19 AWG
16 AWG
4
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
15 AWG
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 82221
Magnet Wire Terminals and Termination Systems
Standard MAG-MATE Terminals
(Continued)
300 Box Poke-In Terminals
Standard MAG-MATE
Terminals
Material
Tin plated brass
.135
[3.43]
.300
[7.62]
.300
[7.62]
.135
[3.43]
.118
[3.00]
.118
[3.00]
.135
[3.43]
.118
[3.00]
Revised 10-02
.300
[7.62]
Typical Cavity Size 2
(See page 2)
A
B
C
Type
Copper Magnet Wire Range
1
AWG
mm
34-33
33-31
31-28
30-27
0.16-0.18
0.18-0.23
0.23-0.32
0.25-0.36
0.36-0.57
0.45-0.64
Lead Wire Range
3
AWG
mm
2
20-18
20-18
20-18
20-18
20-18
—
20-18
20-18
—
0.5-0.9
0.5-0.9
0.5-0.9
0.5-0.9
0.5-0.9
—
0.5-0.9
0.5-0.9
—
0.5-0.9
0.5-0.9
0.5-0.9
0.5-0.9
0.5-0.9
0.5-0.9
—
—
Stock
Thickness
.010
0.25
.010
0.25
.012
0.30
.012
0.30
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.012
0.30
.012
0.30
.012
0.30
.016
0.41
.012
0.30
.012
0.30
.016
0.41
.016
0.41
.016
0.41
.016
0.41
.016
0.41
Strip
63662-1
62431-1
1217234-1
62429-1
63636-1
8
62935-1
63754-1
5
63658-1
1217084-1
5
62420-1
62420-4
6
1217824-1
1
63725-1
5
63591-1
62833-1
63786-1
†
1217011-1
1217368-1
63789-1
1217026-1
63590-1
7
63590-2
63590-3
6
63551-1
7
63551-2
†
63551-3
6
1217192-1
1217191-1
1217190-1
1217189-1
Part Number*
L. P.
—
62527-1
—
62526-1
—
63044-1
—
1217757-1
62524-1
—
—
—
—
62912-1
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Dual L. P.
—
—
—
63855-1
—
62842-1
—
—
62841-1
—
—
—
—
1217736-1
†
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
A
300 Box
Standard IDC
Locking
Poke-In
27-23
25-22
2
22-20
2
0.64-0.81
20
2
19-17
2
30
B
4
300 Box
Standard IDC w/
Strain Relief Slot
Locking
Poke-In
29-28
2
28-26
2
27-23
2
31-28
30-27
C
300 Box
Standard IDC
Non-Locking
Poke-In
0.81
0.91-1.15
0.25
0.29-0.32
0.32-0.40
0.36-0.57
0.23-0.32
0.25-0.36
20-18
20-18
20-18
20-18
20-18
20-18
—
—
27-23
27-26
25.5-24
23.5-22
2
21.5-20
2
0.36-0.57
0.36-0.40
0.43-0.51
0.54-0.64
0.68-0.81
—
—
—
—
—
—
—
—
—
—
Two magnet wires may be terminated in the same terminal slot if diameters are equal.
Single magnet wire only; 22 AWG [0.64 mm] or larger unless otherwise noted.
3
Solid or overcoated stranded lead wire only. Product will also accept Poke-In Tab Terminal shown on page 7.
4
Strain relief slot for high vibration applications.
5
Enhanced anti-overstress behind Poke-In feature for severe applications. Part does not accept lead wires.
6
Finish is tin plated phosphor bronze.
7
Finish is tin over nickel plated brass.
8
Deep Poke-In design for enhanced lead wire retention. Special cavity design required. Contact Tyco Electronics Engineering for details.
* Recognized under the Component Program of Underwriters Laboratories, Inc.
†
These part numbers are available upon special request; contact Tyco Electronics Engineering for details.
1
2
Preferred part numbers are printed in bold.
Chart continued on next page
5
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
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