Application Specification
Pre-Insulated Diamond Grip (PIDG*)
Terminals, Splices, and End Caps
114-2157
09 SEP 08
Rev E
NOTE
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 PIDG terminals, splices, and end caps in various
operating environments. Each consists of a precision–formed metal wire barrel and a copper sleeve encased in
insulating material made of nylon, polyvinyl chloride (PVC) or polyvinyl fluoride (PVF
2
). The insulation is color
coded (solid primary color or a primary color with a color stripe) to correspond with a specific wire size or wire
size range. The terminals, splices, and end caps accept a combination of solid and stranded wire. The wire
barrel contains serrations that provide maximum contact and tensile strength after crimping the terminal, splice,
or end cap onto the wire. The terminals are available with a variety of tongue lengths and configurations; and
the terminals, splices, and end caps are available with various wire barrel lengths and diameters to
accommodate different wire sizes, wire types, and combination of wire sizes.
The terminals, splices, and end caps are available in loose piece form to be terminated with manual and
pneumatically–powered hand held tools and tape mounted to be terminated with bench mount semi–automatic
machines.
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.
Terminal
In-Line Ring Tongue
Wire Barrel
Copper
Sleeve
Tongue
Multiple Stud Hole
Spring Spade Tongue
Insulation
Flanged Spade Tongue
Right Angle Ring Tongue
Offset Ring Tongue
Hook Tongue
In-Line Rectangular Tongue
Right-Angle Rectangular Tongue
Knife Connect/Disconnect
Figure 1 (Cont’d)
E
2008 Tyco Electronics Corporation, Harrisburg, PA
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
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LOC B
*Trademark. Other products, logos, and company names used are the property of their respective owners.
PIDG Terminals, Splices, and End Caps
114-2157
Butt Splice
Opaque Insulation
Transparent Insulation Window
End Cap
Wire Barrel
Insulation
Window
Copper
Sleeve
Figure 1 (End)
2. REFERENCE MATERIAL
2.1. Revision Summary
Revisions to this application specification include:
S
S
S
S
Updated document to corporate requirements
Added NOTE to Paragraph 3.5, I
Added specifications to Paragraph 2.6
Removed Applicator 818057–2 and Machine 818380–1
2.2. Customer Assistance
Reference Product Base Part Number 51864 and Product Code 3022 are representative of PIDG terminals,
splices, and end caps. 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, call PRODUCT INFORMATION at the number at the bottom of page 1.
2.4. Specifications
Product Specification 108–11023 provides test and performance results for insulated terminals and splices for
Class 1 E Nuclear applications.
2.5. 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 operation procedures. Documents
available which pertain to this product are:
408–1261
408–1559
408–1610
408–1632
408–2095
408–2423
408–2498
408–2822
408–2823
408–3295
408–4099
408–4105
Hand Crimping Tools 59239–4 and 59287–2
Hand Crimping Tools 46121, 47386, and 47387
“T”–Head Crimping Tools 59250 and 59275
Terminal and Splice Crimping Dies 69344, 47806–2, 47807–1, 47808–5, and 47808–6
Hand Crimping Tool 69710–1
Crimping Die Assemblies for Tape–Mounted PIDG Terminals and Splices
Crimping Head Cross Reference for Pneumatic Tools
Crimping Die Assemblies 59826–1, 59827–1, and 59828–1
TETRA–CRIMP* Hand Crimping Tool 59824–1
Preparing (Reel–Wrap) Reel of Contacts for Applicator Tooling
Pneumatic TETRA–CRIMP Adapter 679305–1
Straight Action Crimper 217200–[ ]
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PIDG Terminals, Splices, and End Caps
114-2157
408–7424
408–8044
408–8053
408–8082
408–9252
408–9586
408–9640
408–9816
409–1993
409–5842
409–5862
409–5878
Checking Terminal Crimp Height or Gaging Die Closure
Miniature Quick–Change Applicator for Tape–Mounted Closed Barrel Terminals
Miniature Quick–Change Applicators
Miniature Quick–Change Applicators (Side–Feed Type) with Air Feed
PRO–CRIMPER* III Hand Crimping Tool 58433–3
Pneumatic Crimping Heads 314269–1, 314270–3, and 314537–1
Crimp Quality Monitor Applicators for Side–Feed and End–Feed Applications
Handling of Reeled Products
AMP–TAPETRONIC* Machine 69875
AMP–O–LECTRIC* Model “G” Terminating Machine 354500–1
626 Pneumatic Tooling Assemblies 189721–[ ]
AMPOMATOR* CLS IV+ Lead–Making Machines 356500–[ ]
2.6. Standards and Publications
Military specifications provide industry test and performance requirements. Documents available which pertain
to this product are:
MIL–T 7928/1, “Terminal, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Crimp Style,
Copper, Insulated, Ring Tongue, for Thin Wall Wire, Type II, Class I for 105
_
C Total Conductor
Temperature”
MIL–T 7928/4, “Terminals, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Insulated, Ring
Tongue, Bell–Mounted Type II, Class I for 150
_
C Total Conductor Temperature”
MIL–T 7928/5, “Terminals, Lug and Splices, Conductor, Crimp Style”
MIL–T 7928/6, “Terminals, Lug and Splices, Conductor, Crimp Style, Splice, Electric, (Permanent, Type II,
Class 1) for 150
_
C Total Conductor Temperature”
MS 17182, “Terminal, Lug, Crimp Style, Copper, Insulated (Servo Components), Type II, Class I for 125
_
C
Total Conductor Temperature”
MS 25036, “Terminal, Lug, Crimp Style, Copper, Insulated, Ring Tongue, Bell Mouthed, Type II, Class 1 for
105
_
C Total Conductor Temperature”
MS 25274, “Cap, Electrical (Wire End, Crimp Style, Type II, Class 1) for 105
_
C Total Conductor
Temperature”
3. REQUIREMENTS
3.1. Limitation
These terminals and end caps are suitable for 300 volts maximum, and the splices are suitable for 600 volts
maximum.
The terminals, splices, and end caps having the following insulation can withstand the following temperature
range:
nylon –40 to 105
_
C [–40 to 221
_
F]
PVC –10 to 90
_
C [14 to 194
_
F]
PVF
2
–65 to 150
_
C [–149 to 302
_
F]
3.2. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the insulation.
B. Reel Storage
Tape–mounted reeled product should be stored horizontally to prevent sagging and possible stretching or
distortion of the plastic tape which could adversely affect feeding of the product through the tooling.
C. Shelf Life
The product should remain in the shipping containers until ready for use to prevent inadvertent damage.
The product should be used on a first in, first out basis to avoid storage contamination that could adversely
affect signal transmissions.
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PIDG Terminals, Splices, and End Caps
114-2157
D. Chemical Exposure
Do not store product near chemicals listed below. They could cause stress corrosion cracking of product.
Alkalies
Amines
Ammonia
Carbonates
Citrates
Nitrites
Phosphates Citrates
Sulfur Nitrites
Sulfur Compounds
Tartrates
3.3. Wire Selection and Preparation
Terminals and splices accept solid and/or stranded wire sizes 26 through 10 AWG and end caps accept solid
and/or stranded wire sizes 22 through 10 AWG. The wire size used must be within the range stamped on the
underside of the terminal tongue or on the center of the splice or end cap. Generally, the strip length of the wire
should be equal to the wire barrel length plus 0.76 [.030]. Specific strip lengths are given in Figure 2.
Strip Length
Note:
Not to Scale
(See Table)
Insulation
Conductor
(Stranded Shown)
WIRE
SIZE (AWG)
DIAMETER RANGE
TERMINAL, SPLICE,
OR END CAP
INSULATION COLOR
TERMINAL
WIRE STRIP LENGTH
SPLICE
END CAP
26
26-24
26-22
24
0.66-1.40 [.026-.055]
Multiple
Multiple
Yellow/Black
Yellow
Yellow
6.35-7.14 [.250-.281]
5.16-5.94 [.203-.234]
3.96-4.78 [.156-.188]
4.78-5.56 [.188-.219]
4.37-5.16 [.172-.203]
4.37-5.16 [.172-.203]
H
H
[
24
[
24-20
24 20
0.79-1.40 [ 031 055]
0 79 1 40 [.031-.055]
Yellow/Blue
6.35-7.14 [.188-.281]
White
4.78-5.56 [.188-.219]
4 78 5 56 [ 188 219]
Natural/White
5.56-6.35 [.219-.250]
5 56 6 35 [ 219 250]
Multiple
H
22
0.97-2.79 [.038-.110]
Red/Green
Red
6.35-7.13 [.250-.281]
7.95-8.74 [.313-.344]
5.16-5.94 [.203-.234]
5 16 5 94 [ 203 234]
6.35-7.13 [.250-.281]
6 35 7 13 [ 250 281]
22-16
22 16
Multiple
H
Natural/Red
20
18
16
1.17-2.79 [.046-.110]
1.42-2.79 [.056-.110]
1.60-3.30 [.063-.130]
Red/Red
Red/White
Blue/Blue
Natural/Blue
5.16-5.94 [.203-.234]
5 16 5 94 [ 203 234]
Blue
6.35-7.13 [.250-.281]
6 35 7 13 [ 250 281]
7.95-8.74 [.313-.344]
7.93-8.71 [.312-.343]
6.35-7.13 [.250-.281]
6.35-7.13 [.250-.281]
6.35-7.13 [.250-.281]
6.35-7.13 [.250-.281]
16-14
16 14
Multiple
H
H
D
16-14
D
14
Multiple
Yellow/Black
Blue/Green
Natural/Yellow
1.98-3.30 [.078-.130]
12-10
12 10
Multiple
H
7.93-8.71 [.312-.343]
7 93 8 71 [ 312 343]
Yellow
8.71-9.53 [.343-.375]
8 71 9 53 [ 343 375]
8.74-9.53 [.344-.375]
12
10
2.41-5.08 [.095-.200]
3.02-5.08 [.119-.200]
Yellow/Yellow
Yellow/Brown
9.53-10.31 [.375-.406]
9.53-10.31 [.375-.406]
H
Contact PRODUCT INFORMATION at the number on page 1 for acceptable insulation diameter ranges
[
Large sleeve terminal designed for Class I E Nuclear applications
D
For use with heavy–duty terminals having an insulation thickness of 1.02–1.27 [.040–.050]
Figure 2
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PIDG Terminals, Splices, and End Caps
114-2157
NOTE
The wire conductor(s) must not be nicked, scraped, or cut during the stripping operation.
i
3.4. Wire Placement
The stripped wire must be inserted into the wire barrel until the wire insulation is against the wire barrel but not
inside it. The wire insulation must be inside the metal sleeve. A gap between the wire insulation and wire barrel
is allowed, but not to exceed the dimension given in Figure 3.
Transparent Insulation Window Butt Splice Shown
1.59 [.062]
Splice
Insulation
Maximum Gap
Wire Insulation May Butt Against,
Wire Barrel
But Not Enter, Wire Barrel
Metal Sleeve
Wire Insulation Must Be
Inside Metal Sleeve
Figure 3
3.5. Crimp Requirements
A. Crimp Height
The spring–back of the terminal, splice, or end cap insulation prevents an accurate direct measurement of
crimp height. However, crimping a slug of solder (60% tin and 40% lead) with a diameter slightly larger
than the conductor outside diameter can verify proper termination. The crimp height of the resulting solder
slug can be checked with a standard micrometer or comparator. The measurement must be made over
the most compressed area of the solder slug. See Figure 4.
NOTE
i
NOTE
Some tooling with multiple crimping chambers form an embossed dot code in the terminal, splice, or end cap
insulation that indicates which crimping chamber was used. This dot code can be used as a visual inspection to ensure
that the correct wire size and crimping chamber were used.
The resilience of the splice insulation prevents accurate direct measurement of crimp height. Crimp height can be
obtained by measuring a crimped solder slug (60% tin and 40% lead) with a diameter comparable to the wire size.
The slug must be measured over the most compressed area of the slug with a standard micrometer or crimp height
comparator (refer to 408-7424 for specific instructions). The solder slug diameter and crimp height must be within the
dimensions provided in Figure 4.
i
B. Wire Barrel Crimp Profile and Location
The wire barrel crimp produced by the tooling (dies, heads, hand tools, pneumatic tools, or machines)
must be either a confined crescent crimp which appears as a depressed oval shape or a flat rectangular
crimp over the center of the wire barrel. The crimp must be evenly formed. Refer to Figures 4, 5, and 11.
Crescent crimp tooling produces the crescent crimp, and TETRA–CRIMP tooling produces the flat
rectangular crimp. For a tooling–to–crimp profile cross–reference, refer to Figure 10.
C. Dot Code
The dot code on the insulation must be well formed and correspond with the wire size or color code
marking on the crimping chamber of the tooling used. See Figures 4 and 5.
D. Bellmouths
There shall be no rear bellmouth. The front bellmouth shall be evident on the top and bottom of the wire
barrel as shown in Figure 5. Also see Figure 11.
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Tyco Electronics Corporation
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