1-553759-1 - Tyco Electronics

Application Specification

114--6010

LOC B

1of 6

E2009 Tyco Electronics Corporation, Harrisburg, PA

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*Trademark. Other products, logos, and company names used are the property of their respective owners.

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

Tel- Splice Connectors 16 SEP 09 Rev E

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 Tel--Splice Connectors used to splice insulated

communication wire in telephone, security, temperature control, and audio systems. These connectors are

available in domestic, international, and flame retardant with 2--wire or 3--wire connection in sealed (with

sealant) for moisture resistant applications or unsealed (without sealant). Two--wire connectors are available in

butt--and--through, half--tap, and clearing (clear and cap). These connectors are designed to terminate wires by

using the insulation displacement technique. Function of each connector is described in Figure 1.

The connectors are marked with the applicable wire size range and are color--coded for identification. Each

connector consists of two pre--assembled housings: the upper (also referred to as contact retainer or blade)

housing and the lower (also referred to as wire entry) housing. Attached to the upper housing is a U--shaped

contact or two blades. The lower housing contains 2 or 3 wire holes or a wire hole and a wire slot. Each hole or

slot accepts only one wire. The contact has 4 or 6 wire contact slots—2 for each wire. The lower housing

contains a wire stuffer which forces the wires into the contact slots when the housings are pressed together for

termination. The lower housing provides strain relief for the wire after termination. The connectors are available

in loose--piece, cartridge, and ultrasonically welded stick form for terminating with manual hand--held tools.

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.

Figure 1

Half--Tap

3-Wire Connector

Clearing (Clear and Cap)

Upper (Blade)

Housing

Blades

Upper (Contact

Retainer) Housing

Contact

Butt--and--Through

Wire Hole

2-Wire Connectors

Wire Slot

Joins Two Tap Wire Ends Joins Uncut Through Wire

withTapWireEnd

Keeps Two Tap Wire Ends

Together But Not Electrically

Connected

Joins Three Tap Wire Ends

Wire Size

Range Marking

Lower (Wire

Entry) Housing

Wire Hole

Lower (Wire

Entry) Housing

2. REFERENCE MATERIAL

2.1. Revision Summary

SUpdated document to corporate requirements

SChanged information in Paragraphs 2.5 and 2.6

NOTE

114- 6010Tel- Splice Connectors

Rev E2 of 6 Tyco Electronics Corporation

2.2. Customer Assistance

Reference Product Part Number 552678 and Product Code 1216 are representative of Tel--Splice 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 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 Specifications (108--series) provide product performance and test information. Documents available

which pertain to this product are:

108--6021 Domestic and International Connectors

108--6042 Flame Retardant Connector

108--6075 Clearing Splice Connector

2.5. Instructional Material

Instruction Sheets (408--series) provide assembly instructions and tooling information. Documents available

which pertain to this product are:

A. Product

408--3109 2-- and 3--Wire Tel--Splice Connectors (Loose--Piece)

408--3175 2--Wire Clearing Splice Connectors (Loose--Piece and Cartridge)

408--7955 Tel--Splice Connectors (Loose--Piece and Cartridge)

B. Tooling

408--3183 Economy Hand Tool 231839--1

408--6506 Cartridge Terminating Tool 230722--1

408--8588 Tel--Splice Connector Applicators 1490017--1 and 1490018--1

2.6. Data Sheet

Material Safety Data Sheets provides characteristics and safety data on the sealant (inside housing of sealed

connectors). Contact Polymeric Systems, Inc. for MSDS part number 985722--1 on this sealant.

3. REQUIREMENTS

3.1. Safety

Do not stack product shipping containers so high that the containers buckle or deform.

3.2. Limitations

The connectors are designed to operate in a temperature range of --40_to 90_C[--40_to 194_F] for domestic

and international connectors and --40_to 100_C[--40_to 212_F] for flame retardant connectors.

Sealed connectors must not be terminated in temperatures below --12_C[10_F].

3.3. Material

The housing is made of polypropylene, UL 94 HB for domestic and international connectors, polyester molding

compound for clearing connectors, and polycarbonate, UL 94 V--O for flame retardant connectors. The contact

and blade are made of phosphor bronze plated with tin or brass plated with tin.

3.4. Storage

A. Ultraviolet Light

Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the connector

material.

114- 6010

Tel- Splice Connectors

Rev E 3 of 6Tyco Electronics Corporation

B. Shelf Life

The connectors should remain in the shipping containers until ready for use to prevent deformation. The

connectors should be used on a first in, first out basis to avoid storage contamination that could adversely

affect performance.

C. Chemical Exposure

Do not store connectors near any chemical listed below as they may cause stress corrosion cracking in

the contacts.

Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds

Amines Carbonates Nitrites Sulfur Nitrites Tartrates

3.5. Color Code

The housing of the connectors is a certain color to indicate the available designations. The color code is stated

in Figure 2.

CONNECTOR HOUSING COLOR

DESIGNATION WITH SEALANT WITHOUT SEALANT FLAME RETARDANT

WITHOUT SEALANT

2--Wire Butt--and--Through Translucent (White) Yellow Clear

2--Wire Half--Tap Translucent Blue Translucent Blue with Yellow Dot Clear

2--Wire Clearing (Clear and Cap) Green Green with Yellow Dot N/A

3--Wire Translucent (White) Yellow Clear

Figure 2

3.6. Wire Selection and Preparation

These connectors will accept any combination of solid copper wire sizes 26 through 19 AWG with an insulation

diameter range of 0.51 through 2.0 mm [.020 through .080 in.]. Wire insulation must be filled, foam skin, or air

core plastic for domestic and international connectors and paper pulp or air core plastic for flame retardant

connectors.

The wires must not be stripped. For 2--wire half--tap connectors, the tap wire must be cut to length and the

through wire uncut. For 2--wire, 2--wire clearing, and 3--wire connectors, the wires must be evenly cut to length.

3.7. Wire Placement (Before Termination)

For 2--wire half--tap connectors, tap wires must be bottomed in the housing wire holes. Through wires must be

fully contained in the housing side slot and extend past the housing.

For 2--wire, 2--wire clearing, and 3--wire connectors, wires must be bottomed in the housing wire holes.

3.8. Termination Requirements

A. Wire Location

For 2--wire half--tap connectors, the tap wire must be bottomed in the housing wire hole. The through wire

must be fully contained in the housing side slot and extend past the housing. For 2--wire, 2--wire clearing,

and 3--wire connectors, wires must be bottomed in the housing wire holes. See Figure 3.

B. Crimp Height

The crimp height must be within the dimensions provided in Figure 3.

The developed crimp configurations result from using the specific tooling described in Section 5, TOOLING.

NOTE

114- 6010Tel- Splice Connectors

Rev E4 of 6 Tyco Electronics Corporation

2-Wire Half-Tap Connector 2-Wire Butt- and-Through, 2- Wire Clearing, and

3-Wire Connectors

Wire Bottomed in

Housing Wire Hole

Crimp Height

(Refer to Table)

Crimp Height

(Refer to Table)

TapWireBottomedin

Housing Wire Hole

(See Detail)

Through Wire Fully Contained in Housing

Side Slot and Extends Past Housing

TapWireBottomedin

Housing Wire Hole

(See Detail)

TapWireBottomedin

Housing Wire Hole

(See Detail)

Detail

WIRE SIZE (AWG) CRIMP HEIGHT

26--24 6.17--6.65 [.243--.262]

22--19 6.17--7.01 [.243--.276]

Figure 3

C. Cutoff Tab or Flash (Connectors Removed from Ultrasonically Welded Stick)

The cutoff tab or flash is the remaining portion of the stick that may appear on both sides of the connector

after the connector is removed from the stick. This cutoff tab or flash will not interfere with performance of

the connector.

3.9. Repair

Terminated connectors must NOT be re--used by removing the wires. Defective connectors must be discarded

and replaced.

4. QUALIFICATION

Unsealed flame retardant Tel--Splice Connectors are Listed by Underwriters Laboratories Inc. (UL) in File

E81956. No qualifying support for sealed flame retardant or sealed and unsealed domestic and international

connectors was defined at the time of publication of this document.

5. TOOLING

Tooling part numbers and instructional material packaged with the tooling are shown in Figure 4.

5.1. Terminating Tools

Hand terminating tools for application of loose--piece, cartridge, and ultrasonically welded stick form connectors

are available to cover the full wire size range. The tools are designed to press the housings of the connector

together. This displaces the wire insulation to provide electrical contact points for each wire and, in sealed

connectors, positions the sealant inside the housing.

Industry--standard tools having parallel--action jaws can be used to terminate these connectors; however, as with any

tool used, the terminated connector must be gaged periodically to ensure proper wire insertion depth.

NOTE

114- 6010

Tel- Splice Connectors

Rev E 5 of 6Tyco Electronics Corporation

5.2. Sealed Splice Connector Crimp Height Gage

This gage is required for measuring the crimp height of the terminated connector. It is designed to ensure

proper wire insertion depth. The gage is packaged with the connectors.

Figure 4

Economy Hand Tool

231839--1 (408--3183)

Cartridge Terminating Tool

230722--1 (408--6506)

Sealed Splice Connector

Crimp Height Gage 230495--1

(No Document Available)

Economy Hand Tool

(With Spring--Loaded

Handles) 790162--1

(No Document Available)

Tel--Splice Connector Applicator

1490017--1 (2--Wire Sticks) or

1490018--1 (3--Wire Sticks)

(408--8588)

114- 6010Tel- Splice Connectors

Rev E6 of 6 Tyco Electronics Corporation

6. VISUAL AID

Figure 5 shows a typical application of domestic, international, and flame retardant Tel--Splice Connectors. This

illustration should be used by production personnel to ensure a correctly applied product. Applications which

DO NOT appear correct should be inspected using the information in the preceding pages of this specification

and in the instructional material shipped with the product or tooling.

FIGURE 5. VISUAL AID

TAP WIRES MUST BE BOTTOMED

IN HOUSING WIRE HOLES

THROUGH WIRE MUST BE FULLY

CONTAINED IN HOUSING SIDE

SLOT AND EXTEND PAST HOUSING

2-WIRE BUTT- AND-THROUGH AND CLEARING CONNECTORS

2-WIRE HALF-TAP CONNECTOR

3-WIRE CONNECTOR

HOUSINGS MUST NOT BE

DEFECTIVE IN ANY WAY

TAPWIREMUSTBEBOTTOMED

IN HOUSING WIRE HOLES

TAP WIRES MUST BE BOTTOMED

IN HOUSING WIRE HOLES

WIRES MUST NOT BE

DAMAGED IN ANY WAY

WIRES MUST NOT BE

DAMAGED IN ANY WAY

WIRES MUST NOT BE

DAMAGED IN ANY WAY

HOUSINGS MUST NOT BE

DEFECTIVE IN ANY WAY

HOUSINGS MUST NOT BE

DEFECTIVE IN ANY WAY

FLASH ALLOWED ON CONNECTORS

REMOVED FROM ULTRASONICALLY

WELDED STICK

FLASH ALLOWED ON CONNECTORS REMOVED

FROM ULTRASONICALLY WELDED STICK

FLASH ALLOWED ON CONNECTORS

REMOVED FROM ULTRASONICALLY

WELDED STICK