APPLICATION SPECIFICATION
CTX50 UN-SEALED RECEPTACLE CRIMP TERMINAL
1.0 SCOPE
This specification details the crimping information and common practices of general crimps for the Molex
CTX50 Un-Sealed Receptacle Terminal. Please refer to sales drawing SD-560023-001 for additional part
information. The information in this document is for reference and benchmark purposes only. Customers
are required to complete their own validation testing if tooling and/or wire is different than what is shown in
this specification.
All measurements are in millimeters and Newtons unless specified otherwise.
Terminals shown in this document are generic representations. They are not intended to be an image of
any terminal listed in the scope.
2.0 PRODUCT DESCRIPTION
DEFINITION OF TERMS:
1
4
ROLLING
BEND UP
3
TWISTING
2
BEND DOWN
CONDUCTOR CRIMP
INSULATION CRIMP
6
(none)
FRONT BELL MOUTH
5
REAR
BELL MOUTH
Figure 1
REVISION:
ECR/ECN INFORMATION:
EC No:
DATE:
SHEET No.
C3
102782
02/03/2016
CTX50 UN-SEALED RECEPTACLE
APPLICATION SPECIFICATION
CREATED / REVISED BY:
CHECKED BY:
1
of
16
APPROVED BY:
DOCUMENT NUMBER:
AS-560023-001
J.Burgio
T.Smith
B.Moser
TEMPLATE FILENAME: AS-34735-002.docm Rev.B
APPLICATION SPECIFICATION
DEFINITIONS OF TERMS (CONT.):
9
CONDUCTOR
STRIP LENGTH
L
K
K
CONDUCTOR BRUSH
L
CUT-OFF TAB
END OF INSULATION
POSITION
Figure 2
CONDUCTOR CRIMP
WIDTH (CCW)
11
INSULATION CRIMP
WIDTH (ICW)
13
CONDUCTOR CRIMP
HEIGHT (CCH)
10
INSULATION CRIMP
HEIGHT (ICH)
12
SECTION K-K
Figure 3
SECTION L-L
STRAIGHTNESS
1
2
3
4
The crimping process may result in some bending between the conductor crimp and the terminal box. This
bending must not exceed the limits shown in Table 4.
REVISION:
ECR/ECN INFORMATION:
EC No:
DATE:
SHEET No.
C3
102782
02/03/2016
CTX50 UN-SEALED RECEPTACLE
APPLICATION SPECIFICATION
CREATED / REVISED BY:
CHECKED BY:
2
of
16
APPROVED BY:
DOCUMENT NUMBER:
AS-560023-001
J.Burgio
T.Smith
B.Moser
TEMPLATE FILENAME: AS-34735-002.docm Rev.B
APPLICATION SPECIFICATION
BELLMOUTH (FLARE)
5 6
The flare that is formed on the edge of the conductor crimp acts as a funnel for the wire strands.
This funnel reduces the possibility that a sharp edge on the conductor crimp will cut or nick the wire
strands. A rear bellmouth is required on the conductor crimp. CAUTION: Excessively large/small
bellmouth may affect mechanical / electrical performance. See Table 3 for bellmouth specifications.
5
6
Figure 7
CUT-OFF TAB
7
This is the material that protrudes outside the insulation crimp after the terminal is separated from the
carrier strip. A cut-off tab that is too long may expose a terminal outside the housing; it may fail electrical
spacing requirements. See Table 3 for cut-off tab length specifications.
7a
7b
Figure 5
CONDUCTOR BRUSH
8
The conductor brush is made up of the wire strands that extend past the conductor crimp into the transition
area towards the terminal box. This helps ensure that mechanical compression occurs over the full length of
the conductor crimp. The conductor brush should not extend past the transition area into the terminal box or
above the conductor crimp/transition wall height (whichever is tallest). CAUTION: Excessive conductor
brush extended above the transition/crimp area can cause terminal retention issues inside plastic cavity.
8a
8b
Figure 6
REVISION:
ECR/ECN INFORMATION:
EC No:
DATE:
SHEET No.
C3
102782
02/03/2016
CTX50 UN-SEALED RECEPTACLE
APPLICATION SPECIFICATION
CREATED / REVISED BY:
CHECKED BY:
3
of
16
APPROVED BY:
DOCUMENT NUMBER:
AS-560023-001
J.Burgio
T.Smith
B.Moser
TEMPLATE FILENAME: AS-34735-002.docm Rev.B
APPLICATION SPECIFICATION
CONDUCTOR STRIP LENGTH
9
The strip length is determined by measuring the exposed conductor strands after the insulation is removed.
The strip length determines the conductor brush length when the end-of-insulation position is centered in
the transition area between conductor and insulation crimps. See Table 3 for the length requirement
CAUTION: Care must be taken to ensure that all conductor strands are equal in length (no diagonally cut
strands). No scratched or missing strands are permitted. The insulation cut must be uniform (no diagonally
cut insulation and no extrusions of insulation).
CONDUCTOR CRIMP
This is the metallurgical compression of a terminal around the wire's conductor. This connection creates a
common electrical path with low resistance and high current carrying capabilities.
CONDUCTOR CRIMP HEIGHT/WIDTH
10 11
The conductor crimp height is measured from the top surface of the formed crimp to the bottom most radial
surface. The conductor crimp width is measured across the widest portion of the crimp. Do not include the
extrusion points in these measurements. Measuring crimp height/width is a quick, non-destructive way to
help ensure the correct metallurgical compression of a terminal around the wire's conductor and is an
excellent attribute for process control. The crimp height/width specification is typically set as a balance
between electrical and mechanical performance over the complete range of wire stranding and coatings,
and terminal materials and plating. Although it is possible to optimize a crimp height/width to individual wire
strands and terminal plating, one crimp height/width specification is normally created. See Table 2 for crimp
height/width specifications.
INSULATION CRIMP HEIGHT/WIDTH
12 13
Insulation crimp heights/widths are specified in Table 2. CTX50 Un-Sealed Receptacle Terminals are
designed to accommodate multiple wire sizes. Although within the terminal range, an insulation grip may
not completely surround the wire, an acceptable insulation crimp will still be provided.
The insulation crimp should be visually evaluated to confirm it provides adequate compression on the wire.
It should also be evaluated by sectioning through the center of the crimped insulation grip. The grip should
compress the insulation but not pierce it or otherwise damage the integrity of the insulation. The grip should
not contact the conductors under any circumstance. Mechanically, the insulation grip should withstand
repeated flexing of the wire as shown in Figure 7 without pulling out of the grip. The wire is flexed 5 times
each in two perpendicular planes in the following sequence: b to a, a to b, b to c, c to b, then repeat (see
Figure 7).
Figure 7
Once the optimum setting for an insulation crimp height is determined, it is important to document it. The
operator can then check it as part of the setup procedure.
REVISION:
ECR/ECN INFORMATION:
EC No:
DATE:
SHEET No.
C3
102782
02/03/2016
CTX50 UN-SEALED RECEPTACLE
APPLICATION SPECIFICATION
CREATED / REVISED BY:
CHECKED BY:
4
of
16
APPROVED BY:
DOCUMENT NUMBER:
AS-560023-001
J.Burgio
T.Smith
B.Moser
TEMPLATE FILENAME: AS-34735-002.docm Rev.B
APPLICATION SPECIFICATION
EXTRUSIONS (ANVIL FLASH / BURR)
14
These are the small flares that form on the bottom of the conductor crimp resulting from the clearance
between the punch and anvil tooling. If the anvil is worn or the terminal is over-crimped, excessive extrusion
can result.
An uneven extrusion may also result if the punch and anvil are misaligned, if the feed is misadjusted or if
there is insufficient or excessive terminal drag (see Figure 8 and Table 3).
14
Anvil Flash
Figure 8
INSULATION GRIP STEP
15
The insulation grip step is the designed offset between the conductor grip and the insulation grip which
must be met by the crimp process (see Figure 9 and Table 3).
15
Insulation Grip
Step
J1
J
J2
Figure 9
END-OF-INSULATION POSITION
This is the location of the insulation in relation to the transition area between the conductor and insulation
crimps. Equal amounts of the conductor strands and insulation needs to be visible in the transition area.
The end-of insulation position ensures that the insulation is crimped along the full length of the insulation
crimp and that no insulation gets crimped under the conductor crimp. The end-of-insulation position is set
by the wire stop and strip length for bench applications. For automatic wire processing applications the end-
of-insulation position is set by the in/out press adjustment (see Figure 2).
REVISION:
ECR/ECN INFORMATION:
EC No:
DATE:
SHEET No.
C3
102782
02/03/2016
CTX50 UN-SEALED RECEPTACLE
APPLICATION SPECIFICATION
CREATED / REVISED BY:
CHECKED BY:
5
of
16
APPROVED BY:
DOCUMENT NUMBER:
AS-560023-001
J.Burgio
T.Smith
B.Moser
TEMPLATE FILENAME: AS-34735-002.docm Rev.B
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