61312-2 Datasheet, PDF (45/76 Pages) Tyco Electronics – Machine Applied Terminations, Open Barrel Terminals

Machine Applied Terminations, Open Barrel Terminals
(Rings, Spades, Pins, Receptacles, Splices, Tabs)
AMPLIVAR Splices (Continued)
General Application Guidelines
To assist you in obtaining the optimum AMPLIVAR splice
termination, the following guidelines are recommended:
Suggested Splice Selection Procedure
Use the following guide to help you to determine the proper
splice for your application:
1. All magnet wires must be
placed in the bottom of
the wire barrel before
crimping. If lead wire is to
be crimped in the same
termination, it should be
placed on top of the
magnet wires.
2. Wire barrels are
designed to accept a
maximum of three
insulated magnet wires
plus stranded lead wires.
3. The ratio of magnet wire
diameters crimped in any
wire barrel should not
exceed 2:1. This ratio is
approximately a range
from the largest to the
smallest magnet wire of
six sizes.
4. The sum of the circular
mil area (CMA) of the
magnet wires and any
lead wires should not
exceed the capacity of
the splice.
5. The sum of the diameters
of the individual magnet
wires plus twice the
terminal stock thickness
must be equal to or less
than the crimp width.
6. Magnet wire of 26 AWG
[0.40 mm] or smaller
should be used with
7-serration splices having
“shallow serrations,” and
magnet wire of 28 AWG
[0.32 mm] or smaller
should be used with
9-serration splices having
“shallow serrations” (part
numbers identified with
asterisk [*] are in the
tabular data on the
following technical
pages).
7. Magnet wire of 20 AWG
[0.81 mm] or larger
having an insulation
thickness heavier than
“single film coated,”
should not be used with
splices having “shallow
serrations” (those part
numbers marked with an
asterisk [*] in the tabular
data on the following
technical pages).
8. When aluminum magnet
wire is used, splices and
terminals must be tin
plated.
9. Consult Tyco Electronics
for splice and terminal
selection and
recommendations for
all non-standard
applications.
Technical Documents
Application Specifications describe requirements for using the
product in its intended application and or crimping information.
They are intended for the Packaging and Design Engineer and the
Machine Setup Person.
114-2002
114-2003
114-2005
AMPLIVAR
7-Serration
Pigtail Splices
AMPLIVAR
9-Serration
Pigtail Splices
AMPLIVAR
Subminiature
Thru Splices
114-2006
114-2009
114-2016
AMPLIVAR
Subminiature
Pigtail Splices
AMPLIVAR
5-Serration
Thru Splices
AMPLIVAR
Miniature
Pigtail Splices
1. Use 9-serration splices,
tin plated when
terminating aluminum
magnet wire or
combinations with
aluminum magnet wire.
2. Use 9-serration splices
for hermetic and severe
environment applications.
3. Use splices identified
with an asterisk [*] when
terminating 7-serration
26 AWG [0.40 mm]
or smaller wires and
9-serration 28 AWG [0.32
mm] or smaller wires.
4. Calculate the total CMA
of the magnet wires plus
any lead wires to be
terminated. Always use
the coated magnet wire
for CMA.
5. Calculate the total
magnet wire diameters.
6. Select a splice for trial
calculations. It should
have the proper CMA
range. Plating finish
should be considered at
this time.
7. Calculate the sum of the
magnet wire diameters
plus two splice stock
thicknesses. If this total is
less than the crimp width
of the splice selected, it
may be used. If the total
is greater than the crimp
width, a splice with a
greater crimp width must
be selected. Consult
Tyco Electronics for
special wide tooling
recommendations.
Example:
I Selection of a Pigtail Splice to terminate the following wires:
One 28 AWG [0.32 mm] copper magnet wire.
One 22 AWG [0.64 mm] aluminum magnet wire.
One 18 AWG [0.8–0.9 mm²] 19-strand copper lead wire.
I Calculate the total CMA (Procedure 4):
28 AWG [0.32 mm] coated magnet wire
22 AWG [0.64 mm] coated magnet wire
18 AWG [0.8–0.9 mm²] stranded lead wire
= 185 CMA
= 708 CMA
= 1608 CMA
Total
= 2501 CMA
I Calculate the sum of the magnet wire diameters (Procedure 5):
28 AWG [0.32 mm] coated magnet wire
22 AWG [0.64 mm] coated magnet wire
= .0136 [0.35]
= .0266 [0.68]
Total
= .0402 [1.03]
I Select a terminal for trial calculations. Splice No. 62305-2,
page 46 (Procedure 6):
CMA range
Stock thickness
Crimp width
= 600–3000
= .016 [0.41]
= .110 [2.79]
9-serration, tin plated for aluminum magnet wire (Procedure 1).
Splice identified with asterisk [*] for 28 AWG [0.32 mm]
(Procedure 3).
I Calculate the sum of the magnet wire diameters plus two splice
stock thicknesses (Procedure 7):
.0402 + (.016 x 2) = .0722
[1.02 + (0.41 x 2) = 1.84
.0722 [1.84] is less than the splice crimp width of .110 [2.79];
therefore, Part No. 62305-2 may be used.
Catalog 82227
Revised 8-04
www.tycoelectronics.com
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject
to change.
USA: 1-800-522-6752
Canada: 1-905-470-4425
Mexico: 01-800-733-8926
C. America: 52-55-5-729-0425
45
South America: 55-11-3611-1514
Hong Kong: 852-2735-1628
Japan: 81-44-844-8013
UK: 44-141-810-8967