Application Specification
PIDG* FASTON* Tabs and
Fully-Insulated Receptacles
114-13076
09 JAN 08
Rev A
NOTE
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 .
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Figures and illustrations are for identification only and are not drawn to scale.
_
1. INTRODUCTION
This specification covers the requirements for the application of PIDG FASTON Tabs and DIAMOND GRIP*
Fully–Insulated Receptacles. The contact insulation made of nylon and is color–coded by wire size range to
eliminate errors during installation. These contacts are designed to accept a wire size range of 22–10 AWG.
Color–coded wire sizes are: 22–18, red; 16–14, blue; and 12–10, yellow.
PIDG FASTON Fully–Insulated Receptacle Contacts are available in series size 6.35 mm [.250 in.]. Application
may be done by hand for loose piece contacts and/or machine for tape– or reel–mounted contacts.
When corresponding with Tyco Electronics 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.
Color-Coded
Insulation
250-Series
Fully-Insulated
PIDG FASTON
Receptacle (Typ)
Insulation
Crimp Area
Color-Coded
Insulation
250-Series
PIDG FASTON
Tab (Typ)
Figure 1
2. REFERENCE MATERIAL
2.1. Revision Summary
S
Updated document to corporate requirements
S
Added new document number to Paragraph 2.4
S
Added new tooling and related NOTE to Figure 11
2.2. Customer Assistance
Reference Base Part Number 696357 and Product Code G742 are representative numbers of PIDG FASTON
Tabs and Fully–Insulated Receptacles. 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 Tyco Electronics Representative or, after purchase, by calling the
Tooling Assistance Center or the Product Information Center number at the bottom of this page.
2.3. Drawings
Customer Drawings for specific products 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 Tyco Electronics. Contact the Product Information Center number at the bottom of
this page if such a conflict is encountered.
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 FASTON Tabs and Fully-Insulated Receptacles
2.4. Instructional Material
114-13076
The following list includes available instruction sheets (408–series) that provide assembly procedures for
product, operation, maintenance and repair of tooling, as well as setup and operation procedures of
applicators; and customer manuals (409–series) that provide setup, operation, and maintenance of machines.
Document Number
408–2822
408–2823
408–3295
408–7424
408–7432
408–7903
408–8044
408–8059
408–8063
408–8082
408–9252
408–9640
408–9816
409–1993
409–5128
409–5842
409–5852
409–5866
409–5878
409–10016
Document Title
Crimping Die Assemblies 59826–1, 59827–1, and 59828–1
TETRA–CRIMP* Hand Crimping Tool 59824–1
Preparing Reel of Contacts for Application Tooling
Checking Terminal Crimp Height or Gaging Die Closure
Force Gage 92–100505
Hand Crimping Tool 90276–2
Miniature Quick–Change Applicators for Tape Mounted Closed Barrel Terminals
General Preventive Maintenance for Applicators
TETRA–CRIMP HD Miniature Quick–Change Applicators (Side–Feed Type)
Miniature Quick–Change Applicators (Side–Feed Type)
PRO–CRIMPER Hand Crimping Tool 58433–3
Crimp Quality Monitor Applicators for Side–Feed and End–Feed Applications
Handling of Reeled Products
AMP–TAPETRONIC* Machine 69875
Basic AMP–O–LECTRIC* Model “K” Terminating Machine 565435–5
AMP–O–LECTRIC Model “G” Terminating Machines 354500–[ ]
AMPOMATOR* CLS III–G Lead Making Machine 122500–[ ]
AMPOMATOR CLS IV Lead–Making Machine 217500–[ ]
AMPOMATOR CLS IV+ Lead–making Machine 356500–[ ]
Entry Level Terminator (ELT) Machine 1338600–[ ]
3. REQUIREMENTS
3.1. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the contacts.
B. Reeled Contacts
When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically.
C. Shelf Life
The contacts should remain in the shipping containers until ready for use to prevent deformation to the
contacts and/or damage to the housings. The contacts should be used on a first in, first out basis to avoid
storage contamination that could adversely affect signal transmissions.
D. Chemical Exposure
Do not store contacts near any chemicals listed below, as they may cause stress corrosion cracking in the
contacts.
Alkalies
Amines
NOTE
Ammonia
Carbonates
available.
Citrates
Nitrites
Phosphates Citrates
Sulfur Nitrites
Sulfur Compounds
Tartrates
Where the above environmental conditions exist, phosphor-bronze contacts are recommended instead of brass if
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CAUTION
An excessively moist or dry environment may adversely affect the hydroscopic material used in the tab and receptacle
insulation.
!
3.2. Materials
The receptacle and tab bodies are made of brass plated with tin, and the insulation is made of nylon. The
insulation is highly resistant to abrasion.
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Tyco Electronics Corporation
Rev A
PIDG FASTON Tabs and Fully-Insulated Receptacles
114-13076
3.3. Special Characteristics
These pre–insulated DIAMOND GRIP (PIDG) receptacles will accept a tab width of 6.35 mm [.250 in.].
Serrations inside the wire barrel provide maximum contact and tensile strength to stranded wire sizes. See
Figure 2.
Color-Coded
Insulation
Series Designator
Dimension
Tab (Typ)
Wire Stop
Contact Receptacle
Figure 2
3.4. Wire Size and Preparation
A. Type
The total wire range for PIDG FASTON Fully–Insulated Receptacles is 22 through 10 AWG. See Section
4, QUALIFICATIONS, for specific agency certification and listings.
B. Preparation
The wire must be stripped to the dimension provided in Figure 3.
CAUTION
Do not nick, scrape, or cut the wire conductor during the stripping operation.
!
The table in Figure 3 also provides insulation strip lengths as determined by the wire size used. Also listed
are acceptable wire insulation outside diameters for the contacts, and color codes used to easily identify
loose–piece contacts.
Locate the contact to be crimped in the appropriate tooling according to the instructions packaged with
that tooling. Refer to Section 5, TOOLING. Perform the crimping operation.
Stranded Wire
Strip
Length
Conductor
Insulation
SERIES SIZE
WIRE SIZE, AWG
INSULATION DIAMETER
WIRE STRIP LENGTH RANGE
COLOR CODING
22-18
250
16-14
12-10
2.03-3.05 [.080-.120]
2.92-4.32 [.115-.170]
3.81-6.35 [.150-.250]
8.33-7.51 [.328-.296]
8.33-7.51 [.328-.296]
9.15-8.33 [.360-.328]
RED
BLUE
YELLOW
Figure 3
Rev
A
Tyco Electronics Corporation
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PIDG FASTON Tabs and Fully-Insulated Receptacles
114-13076
3.5. Tensile Inspection
Crimped contacts should hold the wire firmly and have a pull–test tensile value meeting that specified in the
chart in Figure 4.
NOTE
Adjust tensile testing machine for head travel of 25.4mm [1 inch] per minute. Directly and gradually apply force for 1
minute.
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CRIMP PULL-OUT TEST
Wire Size
[AWG]
22
Minimum Force
Newtons
35.6
Pounds
8
20
57.8
13
18
89
20
16
133.4
30
14
222.4
50
12
311.4
70
10
355.9
80
Figure 4
3.6. Crimp Requirements
The contacts must be crimped in the appropriate tooling according to the instructions packaged with the
tooling.
CAUTION
Terminal insulation shall NOT be cut or broken during the crimping operation. Reasonable care should be taken by
tooling operators to provide undamaged terminations.
!
A. Straightness
There shall be no twist, roll, deformation, or other damage to the mating portion of the crimped contact
that will prevent proper mating. See Figure 5.
8
°
Max.
8
°
Max.
Datum Line
Figure 5
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A
PIDG FASTON Tabs and Fully-Insulated Receptacles
114-13076
B. Crimp Height Procedure
Because these contacts have insulated wire barrels, crimp height readings cannot be measured.
Therefore, to check for proper crimp height, crimp a piece of solid–core solder as specified in Figure 6.
Solder with a ratio of 60% tin to 40% lead is recommended for the test. Check the height of the crimped
solder against the crimp height dimensions given in the instructional material shipped with the application
tooling. Also, refer to Instruction Sheet 408–7424.
CAUTION
The springback of the insulation prevents an accurate direct measurement of the crimped product. DO NOT apply
crimp height dimensions directly to the contact. This practice will over-crimp the contact, cracking the wire barrel, and
possibly causing damage to the tooling.
!
WIRE SIZE (AWG)
22-18
16-14
12-10
SOLDER DIA, mm [in.]
3.18 [.125 (1/8)]
4.76 [.1875 (3/16)]
6.35 [.250 (1/4)]
Figure 6
3.7. Terminated Contact
Figure 7 shows a typical contact as it should appear after crimping.
Bellmouth Must be
Visible at Both Ends
Wire Barrel
Wire Insulation
Crimp
Crimped
Insulation
Wire Barrel
Crimp
Figure 7
NOTE
Periodic inspections must be made to ensure crimped contact formation is consistent as shown.
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CAUTION
The insulation on pre-insulated contacts shall NOT be cut or broken during the crimping operation. Exercise of
reasonable care by tooling operators should be sufficient to provide undamaged terminations.
!
3.8. Mating Tab Dimensions
Figure 8 shows features and dimensional requirements for tab contacts intended for mating with PIDG
FASTON Fully–Insulated Receptacles.
Rev A
Tyco Electronics Corporation
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