Application Specification
Economy Power II
Contacts and Connectors
NOTE
114-- 13265
26 OCT 09 Rev A
i
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters. Unless
otherwise specified, dimensions have a tolerance of +0.13 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 Economy Power II Contacts and Connectors.
These connectors are available in 2 through 12 positions and the contacts will accept stranded or solid wire in
a 22--16 AWG wire size range. Contact Product Information at the bottom of this page for information on
housing sizes 13 thru 24. The Economy Power II Connectors will mate with the same headers as standard
Economy Power Connectors. The contacts may be ordered with or without internal tongues. The contacts with
internal tongues have a higher mating force and current rating and are typically used with smaller housing
sizes. Those without tongues have a lower mating force and current rating and are typically used with larger
housing sizes.
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.
Wire Barrel
Insulation Barrel
Economy Power II Housing
Economy Power II Contact
Figure 1
2. REFERENCE MATERIAL
2.1. Revision Summary
S
Initial release of application specification
2.2. Customer Assistance
Reference Part Numbers 1744125--[ ], 1744144--[ ], and Product Code K885 are representative numbers of
Economy Power II Contacts and Connectors. 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 Product Information 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 other technical
documentation supplied by Tyco Electronics.
TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111
E2009
Tyco Electronics Corporation, Harrisburg, PA
PRODUCT INFORMATION 1-- 800-- 522-- 6752
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
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2.4. Specifications
Design Objective 108--2297 provides expected product performance and test information.
114- 13265
2.5. Instructional Material
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 provides setup, operation, and maintenance of machines.
Document Number
408--3295
408--7424
408--8040
408--8053
408--9816
408--10116
409--5128
409--5842
409--5852
409--5878
409--10027
409--10029
409--10047
409--10078
Document Title
Preparing Reel of Contacts for Application Tooling
Checking Terminal Crimp Height or Gaging Die Closure
Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type)
Conversion Guide for Miniature Quick--Change Applicators
Handling of Reeled Products
Extracting EP--II Contacts from Housing 1744125--[ ]
Basic AMP--O--LECTRIC* Model “K” Terminating Machines
AMP--O--LECTRIC Model “G” Terminating Machine 354500--[ ]
AMPOMATOR* CLS Model III--G Lead--Making Machine 122500--[ ]
AMPOMATOR CLS IV Lead--Making Machine
Stripping Module 1490502--[ ], 1490500--[ ], and 1725910--[ ]
Stripping Module 1490503--[ ] and 1490501--[ ]
3K Terminating Machines 1725950--[ ] and 5K Terminating Machines 1725900--[ ]
DT--3000 and DT--5000 Machines with SLE Crimp Quality Monitors
3. REQUIREMENTS
3.1. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housing
material.
B. Reel Storage
When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically.
C. Shelf Life
The contacts and housings should remain in the shipping containers until ready for use to prevent
deformation to those components. The components 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
Ammonia
Carbonates
Citrates
Nitrites
Phosphates Citrates
Sulfides Nitrites
Sulfur Compounds
Tartrates
3.2. Material
The contacts are made from phosphor bronze, pre--tinned over copper; and the housings are made from white
UL 94V--0 Rated Nylon.
3.3. Wire Selection and Preparation
Economy Power II Contacts will accept stranded copper wire sizes and insulation diameters as listed in
Figure 2. The crimp heights and insulation barrel crimp widths are also provided.
NOTE
The applied crimp dimension (within the functional range of the product) is dependent on the termination tooling being
used. Refer to the documentation (applicator logs and instruction sheets) supplied with the termination tooling for the
applied crimp height. See Section 5, TOOLING.
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CAUTION
DO NOT nick, cut, or scrape the wire conductor during the stripping operation.
114- 13265
!
Stranded Wire
Strip Length
Strip Length
Conductor
Insulation
WIRE
SIZE
RANGE
22--18
8
WIRE
SIZE
(AWG)
22
20
18
20
20--16
0 6
18
16
INSULATION
DIAMETER
RANGE
1.7--2.9
1.7--2.9
1.7--2.9
1.7--2.9
1.7--2.9
1.7--2.9
STRIP
LENGTH
2.69--3.30
2.69--3.30
2.69--3.30
2.46--2.84
2.46--2.84
2.46--2.84
Figure 2
WIRE BARREL CRIMP
HEIGHT +0.05
1.00
1.10
1.15
1.12
1.27
1.47
WIDTH
1.78
1.78
1.78
1.78
1.78
1.78
Solid Wire
Conductor
Insulation
INSULATION
BARREL CRIMP
WIDTH
2.60
2.60
2.60
2.60
2.60
2.60
CONTACT
TYPE
Economy
Power II
Receptacle
Contact
C t t
3.4. Crimped Contact Requirements
Locate the contact to be crimped in the appropriate tooling according to the instructions packaged with that
tooling. Detailed instructions covering the placement of contacts in the tooling and the use of such tooling is
packaged with each tool.
Terminate the contact according to the directions shipped with the appropriate tooling. See Section 5,
TOOLING.
CAUTION
Wire insulation shall NOT be cut or broken during the crimping operation, nor shall the insulation be crimped into the
contact wire barrel. Reasonable care should be taken by tooling operators to provide undamaged wire terminations.
!
NOTE
Periodic inspections must be made to ensure crimped contact formation is consistent as shown in Figure 3.
i
A. Crimp Height
The crimp applied to the wire portion of the contact is the most compressed area and is most critical in
ensuring optimum electrical and mechanical performance of the crimped contact. The crimp height must
be within the dimensions provided in Figure 2.
B. Crimp Length
For optimum crimp effectiveness, the crimp must meet the crimp dimensions provided in Figure 2.
Effective crimp length shall be defined as that portion of the wire barrel, excluding bellmouth(s), fully
formed by the crimping tool. Instructions for adjusting, repairing, and inspecting tools are packaged with
the tools.
NOTE
The effective crimp length is given for tooling design only, and should not be used for inspection criteria.
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C. Bellmouths
Rear bellmouths shall be evident and conform to the dimensions given in Figure 3.
114- 13265
D. Cutoff Tab
The cutoff tab shall be cut to the dimensions shown in Figure 3 in View A.
E. Burrs
The cutoff burr shall not exceed the dimensions shown in Figure 3 in View A.
F. Wire Barrel Flash
The wire barrel flash shall not exceed the dimensions shown in Figure 3 in Section X--X.
G. Wire Location
After crimping, the wire conductor and insulation must be visible in the transition area between the wire
and insulation barrels.
Conductor Location
0.1-- 1.2
Wire Barrel Closed at
Seam with No Strands
Protruding or Showing
No Insulation
in Seam
Wire Insulation and
Conductors Must
Both be Visible in
this Area
Rear Bellmouth
0.1-- 0.7
X
X
Section X- X
Wire Barrel
Crimp Width
View “A”
0.13 Max Wire
Barrel Flash
Wire Barrel
Crimp Height
Figure 3
0.5 Max
Cutoff Tab
0.13 Max
Burr
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H. Conductor Location
The conductor may extend beyond the wire barrel to the maximum shown in Figure 3.
114- 13265
I. Wire Barrel Seam
The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam.
J. Twist and Roll
There shall be no twist, roll, deformation, or other damage to the mating portion of the crimped contact
that will prevent proper mating.
K. Straightness
The force applied during crimping may cause some bending between the crimped wire barrel and the
mating portion of the contact. Such deformation is acceptable within the following limits.
1. Up and Down
The crimped contact, including cutoff tab and burr, shall not be bent above or below the datum line
more than the amount shown in Figure 4.
2. Side--to--Side
The side--to--side bending of the contact may not exceed the limits provided in Figure 4.
Side--to--Side
2_ 30’ Max.
Up and Down
Datum Line
3_ Max.
4_ Max.
NOTE:
Angles are drawn for clarification only and are not to scale.
Figure 4
3.5. Housings
Economy Power II Connector Housings are available in 2 through 24 positions. They are available in a white
color nylon and consist of a 94V--0 flame retardant material.
3.6. Contact Insertion
Orient the crimped contact as shown in Figure 5. Insert contact into housing until it bottoms, and audible click
is heard or felt. Pull back lightly on the wire to ensure retention of crimped contact in housing.
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