Application Specification
Open Barrel Pigtail and Through Splices
NOTE
114-2088
25 OCT 11 Rev D
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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 open barrel pigtail and through splices. These
splices are available in end feed and side feed. The splices will accept wire sizes and combinations within the
range of 400 to a combined total of 30,000 circular mill area (CMA). The splices feature serrations that help to
hold the wire in place after crimping. All are available in strip form to be crimped using precision crimping dies
and various power assist units.
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.
End Feed Splice
Serrations
Serrations
Side Feed Splice
Carrier Strip
Cutoff Tab
Figure 1
2. REFERENCE MATERIAL
2.1. Revision Summary
Revisions to this application specification include:
•
Changed “thru” to “through”
•
Changed company name and logo
2.2. Customer Assistance
Reference Product Base Part Number 61299 and Product Code 1041 are representative of open barrel pigtail
and through splices. 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 Representative or, after purchase, by calling PRODUCT INFORMATION at the number
at the bottom of page 1.
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. If there is a conflict
between the information contained in the Customer Drawings and this specification or with any other technical
documentation supplied, the information contained in the Customer Drawings takes priority.
©2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
All Rights Reserved
TE logo is a trademark.
*Trademark. Other products, logos, and 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
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2.4. Instructional Material
Instruction Sheets (408-series) provide product assembly instructions or tooling setup and operation procedures
and Customer Manuals (409-series) provide machine setup and operating procedures. Documents that pertain
to this product are:
408-4357
408-7424
408-8012
408-8014
408-8024
408-8039
408-8040
408-8053
408-8059
408-9816
409-5128
409-5842
409-5852
409-5878
AMP-O-LECTRIC* Model “G" Terminating Machine 356462-[ ]
Checking Terminal Crimp Height or Gaging Die Closure
Standard-Type Side-Feed Applicators
Standard-Type End-Feed Applicators
Miniature Quick-Change Applicators (End-Feed Type)
Heavy Duty Miniature Quick-Change Applicators (End-Feed Type)
Heavy Duty Miniature Quick-Change Applicators (Side-Feed Type)
Miniature Quick-Change Applicators
General Preventative Maintenance for Applicators
Handling of Reeled Products
AMP-O-LECTRIC Model “K" Terminating Machines 1-471273-3 and 565435-5
AMP-O-LECTRIC Model “G" Terminating Machine 354500-1
AMPOMATOR* CLS III-G Lead-Making Machines 122500-[ ]
AMPOMATOR CLS IV+ Lead-Making Machines 356500-[ ]
2.1. Storage
A. Shelf Life
Reeled splices should remain in the shipping containers to prevent deformation and limit exposure to
environmental elements until ready for use. Splices should be used on a first in, first out basis to avoid long
term storage contamination that could adversely affect crimp performance.
B. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the splice.
C. Reeled Splices
Care must be taken to prevent twisting, bending, or other distortion that would prevent smooth feeding of the
reeled splices through automatic machine feed mechanisms. Store coil wound reels horizontally and
traverse wound reels vertically. Review reel tag data to determine if breaks in the strip are present within the
reel.
D. Chemical Exposure
Do not store splices near any chemical listed below as they may cause stress corrosion cracking in the
splices.
NOTE
Where the above environmental conditions exist, phosphor-bronze splices are recommended instead of brass.
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2.2. Wire Size and Preparation
Open barrel splices accept bare solid and/or stranded copper wire of various sizes and combinations. Strip
length shall be within 1.14 and 2.16 [.045 and .085] longer than the splice or as needed to ensure that all
conductors are inserted completely through the splice without any insulation extending into the crimped area.
See Figure 2.
CAUTION
Reasonable care must be taken not to nick, scrape, or cut any strands during the stripping operation.
!
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NOTE
Do not twist multiple wires together prior to crimping.
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Stranded Wire
Solid Wire
Strip Length (Refer
to Paragraph 2.2)
Conductors
Strip Length (Refer
to Paragraph 2.2)
Insulation
Figure 2
2.3. Crimped Splice Requirements
Crimp features that must apply to pigtail and through splices after termination are illustrated in Figure 3.
A. Crimp Height and Width
Optimum electrical and mechanical performance is achieved by reducing the cross-sectional area of the
wires and splice by a pre-determined percentage. Crimp width is fixed by the application tooling. Crimp
height must be set and maintained as determined from the crimp height formula provided on the splice
Customer Drawing. See Figure 3.
B. Crimp Length
For optimum crimp length effectiveness, the crimp must be within the area shown in Figure 3.
Effective crimp length shall be defined as that portion of the splice, excluding bellmouths, fully formed by the
crimping tool. The crimp length must meet the dimensions provided in Figure 3.
C. Bellmouths
Bellmouths contribute to crimp effectiveness and reduce the risk of nicked and/or broken conductor strands
due to sharp material edges at the ends of the splice. Front and rear bellmouths shall conform to the
dimensions given in Figure 3.
D. Cutoff Tab
The cutoff tab shall not exceed the dimension given in Figure 3.
E. Cutoff Burr
The cutoff burr shall not exceed the dimension given in Figure 3.
F. Wire Barrel Flash
Wire barrel flash, which can be caused by incorrect set-up and/or worn and broken crimp tooling, shall not
exceed the dimension given in Figure 3.
G. Conductor Extension
Conductors must extend completely through the splice, but to the maximum dimension given in Figure 3.
H. Seam
The seam must be closed with no evidence of loose wire strands visible in the seam as given in Figure 3.
I. Tensile Strength
Crimp quality shall be judged solely on proper crimp width, crimp height, and conformance to the
requirements given in Figure 3.
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NOTE
When crimped as specified, tensile strength will be approximately 70% of the tensile strength of the smallest wire in the
splice.
i
Pigtail Splice
Front Bellmouth
May Be Visible
0.38+0.38/-0.25 [.015+.015/-.010]
Rear Bellmouth
All Conductors Must Extend
Completely Through Splice
X
X
See View A
Through Splice
0.38+0.38/-0.25 [.015+.015/-.010]
Front Bellmouth
0.38+0.38/-0.25 [.015+.015/-.010]
Rear Bellmouth
Crimp Length 75% (Min) of Splice Length
No Wire Strands in Wire Barrel Seam
All Conductors Must Extend
Completely Through Splice
See View A
View A
0.20 [.008] Max
Burr
Section X-X
0.13 [.005]
Max Flash
Crimp Width
(Ref)
1.14 [.045] Max
Cutoff Tab
Note:
Not to Scale
Figure 3
Crimp Height
(Ref)
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2.4. Repair
If a splice is not crimped correctly or it has been damaged, it cannot be repaired or re-terminated. It must be cut
from the wire and replaced with a new splice.
3. QUALIFICATIONS
Due to numerous wire sizes and combinations, Underwriters Laboratories Inc. (UL) and CSA International will
not grant blanket approval for open barrel splices. Customers must submit their end product to these agencies
for application approval.
4. TOOLING
Tooling for crimping these splices include semi-automatic and automatic machines for power-assisted
application of strip-form splices. Modified designs and additional tooling concepts may be available to meet
other application requirements. See Figure 4.
4.1. Applicator
Applicators are designed for the full wire size range of strip-form, precision formed splices, and are used in high
volume, heavy duty, production requirements. The applicator can be used in a bench or floor model power unit.
4.2. Power Unit
A power unit is an automatic or semi-automatic machine used to assist in the application of a product. A power
unit includes the power source used to supply the force or power to an applicator.
NOTE
AMP-O-LECTRIC Model “K” Terminating Machine 565435-5 has been superseded by Model “G” Terminating Machine
354500-1. For existing applications, the Model “K” will still be supported.
i
AMP-O-LECTRIC Model “K” Terminating
Machines 1-471273-3 or 565435-5
(409-5128)
Heavy Duty Miniature Quick-Change
Applicators (Side-Feed Type)
(408-8040)
AMP-O-LECTRIC Model "G" Terminating
Machines 354500-[ ] (409-5842) or
356462-[ ] (408-4357)
AMPOMATOR CLS IV+ Lead-Making
Machines 356500-[ ] (409-5878)
Heavy Duty Miniature Quick-Change
Applicators (End-Feed Type) (408-8039)
AMPOMATOR CLS III-G Lead-Making
Machines 122500-[ ] (409-5852)
Not Shown: Standard-Type Side-Feed Applicators (408-8012), Standard-Type End-Feed Applicators (408-8014),
Miniature Quick-Change Applicators (End-Feed Type) (408-8024), Miniature Quick-Change Applicators (408-8053)
Figure 4
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