INTRODUCTION TO TOOLING SOLUTIONS

TE Connectivity. The Leader in Crimp Quality.

Anyone can make a tool to crimp terminals onto a wire. But not everyone can manufacture a tool to crimp
the terminals properly. Crimp termination of wires isn’t easy. At least, doing it right isn’t easy. We know.
We started it. TE Connectivity developed the technology of hand crimping over 70 years ago.

Why is this experience important to you? As the pioneer in crimping technology our highly trained
engineers have studied how the forces of crimping can affect how a tool works, whether it meets
specifications, and even whether it reaches its expected service life. As a result we have led the way, with
tool frames and die sets that maintain their geometry and produce consistent crimps time after time after
time. There are differences that aren’t readily apparent: the materials, the manufacturing processes, the
designs to diverse requirements for different applications.
These are all part of what we’ve known and practiced for years.
Insulation
Support
The Secret to a Successful Crimp
Matching the Terminal to the Tooling - Among
the many factors that are critical in producing a
quality crimp, matching the terminal to the
tooling is crucial. Unlike inferior tooling options,
TE offers engineered solutions that are designed
to match the exact crimp geometry of the Wire Barrel
terminal to be applied on the wire. To ensure a
proper crimp you need to follow these important
steps:

Contact End

1. Wire Selection – AWG and wire insulation

thickness varies from wire to wire. Just
because two wires are listed at the same AWG,
it doesn’t mean their insulation thickness is the
same. If you don’t take into account both
factors the copper or aluminum strands may
not fit in the wire barrel correctly, or the
terminal’s insulation support may be to large
or small for the wire strand.

Insulation
AWG
Thickness

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APPLICATION TOOLING /// DISTRIBUTION CHANNEL TOOLING SOLUTIONS PAGE 5

 INTRODUCTION TO TOOLING SOLUTIONS

The Secret to a Successful Crimp

2. Wire Prep – In order to properly place a wire in a terminal, the wire insulation must first be stripped to
the proper length based on the terminal specifications. If the insulation is cut too short or too long, the
wire will not be seated properly into the wire barrel, causing terminal separations or shorting.

Insulation
Present

Conductor
Present

Front Strands Flush

with Reference Line

Stripping
Length

3. Crimp Specifications – To ensure a proper crimp for a TE connector or terminal you should be using a TE
Connectivity tooling solution that is specifically engineered to the proper Crimp Height, Width and Crimp
Geometry of the selected terminal or contact.

Crimp
Geometry
CH1 CH2

CH2: Insulation crimp height

CH1: Conductor crimp height

Crimp
CB1 CB2
Height

CB2m: Insulation crimp width

CB1m: Conductor crimp width

Crimp
Width

4. Selecting the Right Tool Based on Production Level – Are you in the prototype phase of your project?
Will you soon be ramping up production? Do your tools need to be mobile, or is a bench top unit more
applicable? Are you producing 100’s – 1,000’s of crimps per day?
Once you know the answers to these questions, selecting the right TE Connectivity tool to meet your
needs is simple. (Please refer to page 7 for tooling options.)

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 INTRODUCTION TO TOOLING SOLUTIONS

Choices at Any Production Level

We can offer performance continuity in tools, so customers have the same crimp functionality and quality whether
they are developing, building, or servicing a product. In many cases they can use the same die set in tooling that
spans the range from hand operation through battery, pneumatic, and even electrically powered tools.

LOW VOLUME: Prototype, Repair LOW VOLUME: Small Production Quantities

Manual Hand Tools Manual Hand Tools

INTERMEDIATE: Small to Mid-Level Volumes

Power Hand Tools and Benchtop Tooling — Battery, Hydraulic, Pneumatic Electric

INTERMEDIATE: Semi-Automatic Volumes

Applicators & Spare Tooling Bench Terminators AMPLIVAR Product Termination
— Magnet Wire

INTERMEDIATE: Semi-Automatic Volumes INTERMEDIATE: Fully-Automatic Volumes

Heat Shrink Tubing Equipment Single Crimp
Wire Processor

APPLICATION TOOLING /// DISTRIBUTION CHANNEL TOOLING SOLUTIONS PAGE 7

 INTRODUCTION TO TOOLING SOLUTIONS

Dangers of Improperly Crimped Terminals

From wasted time & scrap all the way up to product recalls and possible litigation, the cost of poor crimp
quality can be expensive. If customers are not using the proper crimp tooling, ie. incorrectly matching the
terminal to the crimp tooling, the end results can be dramatic.
Severity of an Improper Crimp

Possible
Catastrophic
Failures

Poor Poor Increased Rework of Product

Good
Heat Mechanical Electrical Scrap Product Recalls
Crimp
Crimp Crimp
Litigation

Cost of an Improper Crimp

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PAGE 8 APPLICATION TOOLING /// DISTRIBUTION CHANNEL TOOLING SOLUTIONS

 INTRODUCTION TO TOOLING SOLUTIONS

What You Need to Know About TE Hand Tools

Tool Grade
A prime consideration when choosing the appropriate tool for an application. Our hand tools are
categorized into three levels; Service, Commercial and Premium. The higher the grade of the tool, less
operator skill is needed in order to repeatedly meet the specified parameters of the crimp.
Premium (CERTI-CRIMP Tool)
Premium tools include the appropriate crimp die configuration, integral locating, and integral straightening
features that permit terminals or contacts crimped in these tools, to meet all feature requirements in
applicable TEC application (114-) specifications. Most premium tools include an adjustable insulation crimp
height feature and the CERTI-CRIMP ratcheting feature, set at the factory, which ensures the ratchet will
not release until the wire crimp jaws bottom within .001. This guarantees consistent repeatability of the
crimp. Premium hand tools require the least amount of user dexterity.
Commercial (PRO-CRIMPER III Tool)
Commercial die assemblies are designed to meet the wire crimp height requirements per the applicable
TEC application (114-) specifications. Other feature requirements may or may not be met. Commercial
handle assemblies permit the interchange of die assemblies and an adjustable ratcheting feature. Users
are responsible for adjusting the ratchet to obtain the correct crimp height. Commercial tools require a
greater amount of user dexterity than Premium crimp tools.
Service
Service tools are generally single thickness, stamped tools. They are not intended to meet any
specifications and require exceptional user dexterity to obtain acceptable results.
Needed Skills

Service
Hand Tools

Commercial
Hand Tools

Premium
Hand Tools

Price of Hand Tools

Tool Type
Choosing a tool type may be driven by several factors; simply by type preference, or by the application
needs itself, ie. heavy duty crimp, industry specification requirements, etc. The overall wire range is also
a prime consideration when choosing the appropriate tool for an application. Often there will be several
tools referenced to the same product but having different wire ranges.
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 COMMERCIAL: MANUAL HAND TOOLING

Standard Die Envelope (SDE)

FAST FACTS
• Dies meet wire crimp
requirements per
specification
• Over 100 interchangeable
SDE die sets for crimping
over 4,000 different
connectors
• Ability to handle multiple
wire and terminal sizes in
one die set

Standard Die Envelope (SDE)

SDE technology is a new, flexible approach to crimp tooling, that allows use of the same dies on tooling
across a range of application platforms. Dies are interchangeable in tools from portable hand tools —
manual or battery-powered — to pneumatic hand tools and electric bench terminators. It’s a family of tools
that you can take from bench to production or into the field, without the need for dies fitted to each kind of
tool. They’re suited for R & D, networking applications and on-site maintenance work.
Customers can be sure their dies will fit their long-term needs, because they are completely
compatible with all tools in the SDE system. They move with a customer as their needs grow.

If you know the terminal —

this tool will help you find the
die set.
Go to www.tooling.te.com
and look for the magnifying
glass.

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 COMMERCIAL: MANUAL HAND TOOLING

Standard Die Envelope (SDE)

By removing just 2 screws you

can easily swap dies between
your SDE compatible manual,
battery, pneumatic and electric
TE tools.

See pages 24-27

See pages 18-23

See pages 32-35

See pages 60-63

See pages 61-63

APPLICATION TOOLING /// DISTRIBUTION CHANNEL TOOLING SOLUTIONS PAGE 17

 COMMERCIAL: MANUAL HAND TOOLING

Commercial Standard Die Envelope (SDE) Manual Hand Tools

FAST FACTS
• Ratchet control provides
complete crimping cycle
• Emergency ratchet release
• Angled head provides a
comfortable hand and wrist
position
• One tool with over 75
interchangeable die sets
can crimp many different
types of connectors
• Accommodates multiple
terminal sizes in one die set
• Precision construction of
durable high-carbon steel
• Extra strength pivot pins
provide greater durability
• Produced under a quality
management system
certified to ISO 9001.

A Flexible Tooling Approach

Our Commercial Hand Tools provide the versatility of general-purpose service tools along with the
reliability and ease of use of many premium-grade tools. For versatility, all 75 die sets are interchangeable,
including those for open-barrel contacts and terminals. Additionally, many of these die sets have
multiple cavities for crimping a variety of contact or terminal sizes.

PRO-CRIMPER III — Made to Last

For reliability, the tool is constructed of durable high carbon steel with extra strength pivot pins. And,
for user convenience, the PRO-CRIMPER III Hand Tool particularly excels.

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 COMMERCIAL: MANUAL HAND TOOLING

Characteristics of a Commercial Crimping Tool

Every Commercial grade hand tool incorporates features for long lasting performance and ease-of-use.
They include ergonomic handle designs and a ratchet control system designed to ensure proper crimping.

Ratchet System for Improved Repeatability

Ratchet control is provided for complete crimp cycling; this helps eliminate partial crimps. Also, an
emergency ratchet release allows the user to open the tool jaws at any time during the crimp cycle.

Applying the Crimp Force

To reduce handle force, the linkage was designed to match the forces required to crimp our largest
insulated terminal. The result is dramatically less handle force than comparable tools. Also, the angled head
and specially designed handles reduce hand stretch and provide comfortable operation.

Ensuring a Proper Crimp

Locators are mounted on pin-and-socket style tools. They help properly locate the contact in the die set,
provide a wire stop, and help minimize contact rotation and bending during crimping.

Extra Strength
Pivot Pins

Angled Head Improved

Permits Easier View Ergonomic
of Crimp Area Handles

Tool Locator

Emergency
Ratchet
Release

Easily Ratchet Control

Interchangeable to Confirm Dies
Dies Bottom out for
Proper Crimping

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APPLICATION TOOLING /// DISTRIBUTION CHANNEL TOOLING SOLUTIONS PAGE 19

 COMMERCIAL: MANUAL HAND TOOLING

Commercial SDE Tooling Options

PRO-CRIMPER III Hand Tool

Part No. 354940-1 (frame only)
The PRO-CRIMPER III hand tool is ideally suited for R&D prototyping,
networking applications, and commercial, industrial, and institutional
maintenance work.
• Enhanced ergonomics, with a thin, comfortable handle profile
• Manufactured with precision stamping that permits close tolerance
controls on critical parts, for better performance and repeatability
• Improved tool geometry for a longer life, stronger tool frame
• Fits industry’s largest selection of crimp die options

SDE SA Hand Tool

Part No. 9-1478240-0 (frame only)
The unique geometry of this tool results in a comfortable, easy-to-use
handle design that is unmatched in the market.
• Large crimp jaw arc, minimizing roll in open barrel applications
• Easy accessibility for space-constrained applications
• User-adjustable ratchet control and emergency ratchet release

ERGOCRIMP Hand Tool

Part No. 539635-1 (frame only)
• Interchangeable dies
• Virtually a straight action jaw closure
• Ratchet mechanism ensures complete crimp cycle
• Easy access ratchet release
• Handle pressure adjustment with locking device
• Ergonomic non-slip handles

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 COMMERCIAL: MANUAL HAND TOOLING

Customized Hand Tool Kits

In addition to providing standard kits, TE Connectivity is also able to
FAST FACTS provide custom kits for volume requirements containing only tools, or a
combination of tools, dies and terminals tailored to your specific
• Portability
requirements.
• Customization
The kit shown is an example designed specifically for the Automotive
• Cost effectiveness Industry. However, we can also provide kits for promotion and product
• OEM personalization support as well as application support and repair.
The flexibility in creation of these individual kits enables the customer to
• Flexibility in the factory as
help both control and ensure quality.
well as in service and repair
garages
• Consist of well-proven hand
tools and dies as well as
accessories matched to
special applications
• A selection of sample
terminals enables the
technician to start work
immediately

PRO-CRIMPER Hand Tool Kits

TE specialty hand tools are available in convenient kits that contain the
tooling, terminations, and spare parts you need for your crimping operations.

PRO-CRIMPER III Hand Tool PIDG and PLASTI-GRIP Terminal Kit

Part No. 55823-1
Includes hand tool (part no. 58433-3), 225 insulated ring and spade terminals
in 12-10, 16-14 and 22-16 AWG [3.0-5.0, 1.3-2.0 and 0.3-1.3 mm2] wire sizes.

BNC Premises Wiring Kit

Part No. 58477-1
Includes hand tool (part no. 58433-1); plugs—5 RG-58, 10 RG-59/62, 5 RG-58
plenum and RG-59/62 plenum sizes; adapters—2 jack-to-jack and 2 T.

PRO-CRIMPER III Hand Tool Repair Kit

Part No. 679221-1
Includes retaining rings, handle return spring, pawl spring, pivot pins, pawl
pin, ratchet pawl, die pins, nut and die set screws.

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APPLICATION TOOLING /// DISTRIBUTION CHANNEL TOOLING SOLUTIONS PAGE 21

 COMMERCIAL: MANUAL HAND TOOLING

Tooling-to-Terminal Cross Reference

Wire Range Max Hand Tools Tool Type

UNINSULATED TERMINALS
AWG mm2 Insul. Dia. Commercial Commercial
COMMERCIAL TOOLS

PRO-CRIMPER Hand Tools (PC) 22-16 0.3-1.25 — — 58546-1 PC

SOLISTRAND 16-14 1.25-2 — — 58546-1 PC
Terminals and Splices 12-10 3-5 — — 58546-1 PC
8 7 — — — —

SDE-SA Hand Tools (SDE-SA)

Wire Range Max Hand Tools Tool Type
INSULATED TERMINALS
AWG mm2 Insul. Dia. Commercial Commercial

PIDG FASTON 22-18 0.3-0.8 .100 2.54 58433-3 PC

Receptacles 16-14 1.25-2 .170 4.32 58433-3 PC
ERGO-CRIMP Hand Tool (6409oo Series) 12-10 3-5 .250 6.35 — —

PIDG 22-16 0.3-1.25 .125 3.18 58433-3 PC

Terminals and Splices,
PLASTI-GRIP
Terminals 16-14 1.25-2 .150 3.81 58433-3 PC

12-10 3-5 .230 5.84 58433-3 PC

Wire Range Max Hand Tools Tool Type

FULLY-INSULATED TERMINALS
AWG mm2 Insul. Dia. Commercial Commercial

Ultra-Fast FASTON 22-18 0.3-0.8 .230 5.84 58628-1 PC

Tabs and Receptacles 16-14 1.25-2 .260 6.60 58628-1 PC

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PAGE 22 APPLICATION TOOLING /// DISTRIBUTION CHANNEL TOOLING SOLUTIONS

 COMMERCIAL: MANUAL HAND TOOLING

Tooling-to-Terminal Cross Reference

Style Wire Range Max Hand Tools Tool Type

OPEN BARREL TERMINALS
AWG mm2 Insul. Dia. Commercial Commercial

AMPLIMITE 28-24 0.08-0.2 .040 1.02

Size 20 DF Contacts 58448-2 PC
D-Sub. Connectors 24-20 0.2-0.5 .060 1.52
Size 22 DF Contacts 28-22 0.08-0.3 .040 1.02 90800-1 PC
AMPMODU 26-22 0.12-0.3 .061 1.55 58641-1 PC
Mod. IV Contacts
Connectors 24-20 0.2-0.5 .069 1.75 — —
28-24 0.08-0.2 .055 1.40 — —
24-20 0.2-0.6 .062 1.57 58541-1 PC
Type II Contacts
18-16 0.8-1.4 — — 58541-1 PC
14 2 — — 58541-1 PC
30-26 0.05-0.15 .060 1.52 — —
26-24 0.12-0.2 .055 1.40 58495-1 PC
CPC Connectors, 24-20 0.2-0.6 .080 2.03 58495-1 PC
M Series Connectors Type III+ Contacts 24-20 0.2-0.6 .100 2.54 — —
24-20 0.2-0.6 .120 3.05 — —
18-16 0.8-1.25 .100 2.54 58495-1 PC
18-14 0.8-2 .100 2.54 — —
FASTON 22-18 0.3-0.8 .130 3.30 — —
Straight Receptacles 250 Series 18-14 0.8-2 .170 4.32 58524-1 PC
(Premier Line Only) 14-10 2-5 .200 5.08 58525-1 PC
30-22 0.05-0.3 .075 1.91 — —
Commercial Contacts 24-18 0.2-0.8 .100 2.54 90574-1 PC
20-14 0.5-2 .130 3.30 90575-1 PC
24-18 0.2-0.8 .100 2.54 90548-1 PC
Universal & 20-14 0.5-2 .130 3.30 90546-1 PC
MATE-N-LOK
Connectors Universal II Contacts 20-18 0.5-0.8 .200 5.08 90547-1 PC
16-14 1.25-2 .200 5.08 90547-1 PC
Mini-Universal 20-16 0.5-1.25 .126 3.20 90760-1 PC
26-22 0.12-0.3 .069 1.75 90758-1 PC
Mini-Universal II
22-18 0.3-0.8 .094 2.39 90759-1 PC
Contacts
20-16 0.5-1.25 .126 3.20 58707-1 PC
22-20 0.3-0.6 .106 2.70 2217267-1 SDE-SA
Power Triple Lock Power Triple 20-16 0.6-1.25 .130 3.30 2217208-1 SDE-SA
Connectors Lock 18-14 0.9-2.1 .146 3.70 2217266-1 SDE-SA
12 3.3 .167 4.25 2217268-1 SDE-SA

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APPLICATION TOOLING /// DISTRIBUTION CHANNEL TOOLING SOLUTIONS PAGE 23

 CRIMP QUALITY GUIDELINES

Correct
Insulation
Bellmouth must always be present
Present
WIRE CRIMP
Conductor Correct selection of wire,
Present terminal and applicator

Bellmouth Permissible
Want to know more
Crimp barrel is closed, Sufficient gap
about proper crimp
legs support between legs
each other and bottom of crimp
techniques? View our
Crimp Theory
Locking lances and terminal
Fundamentals videos body not deformed All strands are equally distributed
Cut off tabs present and deformed
on our website at
tooling.te.com or find INSULATION CRIMP INSULATION CRIMP
them on our YouTube Correct Insulation Diameter, Applicator and Terminal.
channel.
F-CRIMP

Insulation is pierced and could

damage conductor
Crimp Theory
Fundamentals Video.
https://www.youtube.co
m/watch?v=foFgl8c17so Insulation is securely held
Crimp barrel closed
Insulation legs are not closed

For double wire applications with different size wires

always place wire with smallest outer diameter in the bottom.
OVERLAP CRIMP

Insulation material is pierced

Insulation is securely held

Legs overlap Insulation is not securely held
Legs do not overlap
WRAP OVER
CRIMP

Insulation securely held Insulation is Insulation is

Legs must pass each other not securely held over crimped

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PAGE 82 APPLICATION TOOLING /// DISTRIBUTION CHANNEL TOOLING SOLUTIONS

 CRIMP QUALITY GUIDELINES

Incorrect Test
WIRE CRIMP
Crimp height measurement Crimp heights and tolerances

For crimp height tolerances for any given contact,

please refer to the relevant application specification.

Terminal damaged Examples:

Contact P/N Wire Range Tolerance Application Spec.
MQS 962885 0,20 - 0,50 mm2 ± 0,03 mm 114-18025
962886
JPT 927775 0,50 - 1,00 mm2 ± 0,05 mm 114-18050
JPT 927773 1,50 - 2,50 mm2 ± 0,05 mm 114-18050

Cut off tab too long Digital crimp height micrometer

Crimp barrel distorted
(0.001mm increments) according to
DIN ISO 9001
Part Number 547203-1
WIRE CRIMP
Incorrect applicator adjustment
Asymmetric Unacceptable
Terminal twisted
crimp formation excessive
flash and/or cracks

Terminal feed Anvil and crimper

Cut off tab deformed incorrectly adjusted not aligned or worn

Crimp height too tight Incorrect terminal / wire selection

INSULATION CRIMP

Wire crimp
Wire size too large Wire size too small
without conductor

30
Insulation inside the wire crimp °

°
30
Crimp barrel Legs too close to
does not close bottom of crimp.
Insufficient Insulation must be securely
Conductor Brush protruding into terminal body deformation of strands, held after bend test
showing voids.
Bellmouth on wrong end
Incorrect crimp height adjustment
Crimp height Crimp height
Training & Services
too loose too tight

Please contact our

service hotline
for information.
Insufficient Flash at under side
Terminal bend
deformation, of crimp, due to Tel: 1-800-722-1111
showing voids over crimping

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APPLICATION TOOLING /// DISTRIBUTION CHANNEL TOOLING SOLUTIONS PAGE 83

 Glossary of Terms
ACTION PIN Contact (connector): Manufactured Closed Entry Contact: Female contact designed Crimping Chamber: Area of a crimping tool in
exclusively by TE Connectivity, having a split pin to prevent entry of a pin or probing device hav- which a contact or terminal is crimped; the
to provide gas tight retention in a printed circuit ing a cross-sectional dimension (diameter) crimping enclosure formed by the mating of the
board plated-thru hole without solder. greater than the mating pin. anvil (nest) and crimper (indenter). When the
dies or jaws are fully closed or bottomed, it is
Anvil (tooling): Most commonly used to identify Component: A wire or cable that is combined
the crimping chamber that is checked with a go
that part of the crimping die — normally station- with other wires or cables to make a multi-
no-go plug gauge to confirm that the crimp pro-
ary — which positions and supports the terminal component cable.
duced by the tooling satisfies the crimp height
during crimping. Sometimes referred to as nest.
Concentric Stranding: A method of stranding specification.
Arc Voltage: Voltage that continues to pass conductor. Specifically, the final conductor is
Crimping Dies: A term used to identify the shap-
through a surge protector during activation of built up in layers so that the inner diameter of a
ing tools that, when moved toward each other,
GDT (approx. 20 volts). succeeding layer is always equal to the outer
produce a certain desirable shape to the barrel
diameter of the underlying layer.
ASTM (American Society for Testing and Materials): of the terminal or contact that has been placed
A nonprofit industry-wide organization that for- Conductivity: The capability of a material to between them. Crimping dies are often referred
mulates test methods and material specifica- carry electrical current, usually expressed as a to as die sets or as die inserts.
tions, and publishes standards, testing methods, percentage of copper conductivity (copper
Crimping Head: Tooling containing jaws and link-
recommended practices, definitions and other being 100%). Specifically, the ratio of the current
age for use in pneumatic or hydraulic powered
materials. flow to the potential difference causing the flow.
units to crimp loose-piece contacts/terminals
The reciprocal of resistance.
AWG (American Wire Gauge): The recognized that may be too large for hand tool applications.
method (in the United States) of specifying Conductor: The metallic strand or strands used
Crimping Tool: A term commonly used to identi-
conductor size. The higher the gauge number, to carry an electric current.
fy a hand held mechanical device that is used to
the smaller the conductor size.
Conductor Resistance: The resistance to flow of the crimp a contact, terminal or splice.
Bare Conductor: A conductor not covered with electrical current along a conductor. Expressed
Cross Crimp: A crimp that deforms the terminal
insulating material. in ohms/1,000 feet (usually referenced to 20°C).
by exerting on the top and bottom of the termi-
Barrel: 1.) Connector Barrel: The section of the Conduit: A tubular raceway for holding wires or nal barrel without confining the sides. Usually
terminal, splice, or contact that accommodates cables. identified by a raised crescent (moon) shaped
the stripped conductor. 2.) Insulation Barrel: The form on the surface of the crimp.
Connector: A device used to physically and
section of the terminal, splice, or contact that
electrically connect two or more conductors. Current: A movement or flow of electrons. Also,
accommodates the conductor insulation. 3.)
Contact: The element in a connector that makes the measure of this flow, expressed in amperes.
Open Barrel: The section of a cap that accom-
modates the conductor. the actual electrical connection. Also the parts Current-carrying Capacity: The maximum cur-
of a connector that actually carry the electrical rent an insulated conductor is capable of carry-
Bellmouth: Flared at the mouth. The rear of a
current, and are touched together or separated ing without exceeding its insulation- and/or jack-
properly crimped wire barrel will have a slight
to control the flow. et temperature limitations under specified ambi-
flare (bellmouth) to relieve the strain on the wire
Contact Crimp: A contact whose rear portion ent conditions.
strands as they leave the area of high compres-
sion and take their natural lay. A bellmouth is a hollow cylinder that accepts the conductor. Current Rating: The maximum continuous elec-
may also be present in front of the wire barrel. A crimping tool is applied to swage or form the trical flow of current recommended for a given
contact metal firmly against the conductor. situation. It is expressed in amperes.
Breakdown Voltage: The voltage at which an
Sometimes referred to as a solderless contact.
insulator or dielectric fails to maintain the Die: See crimping dies.
applied voltage. Contact Engaging and Separating Force: Force
Die Closure: Term used to designate a crimping
required to either engage or separate contacts.
Breakout: A region in a harness assembly where area (crimping chamber) when the dies are fully
Values are generally established for maximum
a wire or a group of wires is detached to form closed or bottomed. Die closure is checked with
and minimum forces.
a separate, terminated branch. Also known as a go/no go plug gauge to confirm that the crimp
transition. Contact Resistance: Measurement of electrical produced by the tooling satisfies the crimp
resistance of mated contacts when assembled in height specification.
Bunch Stranding: A method of twisting individ-
a connector under typical service use. Electrical
ual strands to form a finished stranded conduc- Dielectric: A material that serves as an insulator.
resistance is determined by measuring from the
tor. Specifically, a number of strands twisted The amount of resistance to voltage in a given
rear of the electrical area of one contact to the
together in a common direction and with a uni- insulation.
rear of the contact area of the mating contact
form pitch (or twist) per inch.
(excluding both crimps) while carrying a speci- Dielectric Isolation (IC): Most silicon integrated
Butt Splice (electrical): A splice wherein two fied test current. circuits depend on back biased semiconductor
wires from opposite ends butt against each junctions to provide isolation between compo-
Contact Size: The diameter of the engagement
other, or against a stop, in the center of the nents on the chip. Dielectric isolation involves a
end of a pin contact; also related to the current
splice. number of additional process steps, which result in
carrying capacity of a contact.
silicon dioxide rather than a junction surrounding
Cable: Two or more wires in a twisted or parallel
Continuity: A continuous path for the flow of each component to be isolated. The silicon dioxide,
configuration. Also, a shielded wire.
current in an electrical circuit. a dielectric, provides the necessary isolation.
Cabler: A machine that mechanically assembles
Core: 1.) In cables, a component or assembly of Dielectric Strength: Maximum voltage a dielec-
a group of insulated wires.
components over which additional components, tric can withstand without rupture. Expressed as
Cabling: The act of twisting together two or such as a shield or a sheath, are applied. volts per mil.
more insulated components to form a cable. 2.) Inner wall of dual-wall heat-shrinkable tubing.
Discontinuity: Rated interconnection: broken
Capacitance: The property of an electrical con- Crimp: The final configuration of a terminal bar- connection (open circuit) or loss of a specified
ductor (dielectric in a capacitor) that permits the rel after the necessary compression forces have connection characteristic. Transient phenomena:
storage of energy as a result of electrical dis- been applied to cause a functional union Short-term interruption or unacceptable varia-
placement. The basic unit of capacitance is the between the terminal barrel and the wire. tion in current or voltage.
farad, however, measurement is more commonly
Crimper (tooling): Often used to identify that Drain Wire: In a cable, an un-insulated conductor
in microfarads or picofarads.
part of the crimping die — usually the moving laid over the component, or components, in a
Carrier: A group of strands or ends used to form part — which indents or compresses the terminal foil-shield cable. Used as a ground connection.
a finished braid. barrel. Also called indenter.
Electromagnetic Compatibility (EMC): The abili-
Circular Mil Area (CMA): A unit of area equal Crimp Height: A top to bottom measurement ty of an electronic device to operate in its
to the area of a circle whose diameter is 1 mil of the crimped barrel, using a crimp height com- intended environment without its performance
(0.001 inch). Used chiefly in specifying cross- parator in the prescribed manner. being affected by EMI and without generating
sectional areas of conductors. EMI that will affect other tooling.

PAGE 84 APPLICATION TOOLING /// DISTRIBUTION CHANNEL TOOLING SOLUTIONS

 Glossary of Terms
Electromagnetic Interference (EMI): Unwanted prevents the conductor from being exposed due colors of insulation for each conductor, although
electrical or electromagnetic energy that causes to insulation receding away from the terminal. a single color may be used for all conductors.
undesirable responses, degrading performance Insulation Resistance: The electrical resistance Serrations: Small grooves or indentations within
or complete malfunctions in electronic tooling. between two conductors separated by an insu- a terminal wire barrel. The serrations increase
Electromotive Force (emf): See voltage. lating material. the tensile strength and improve the electrical
EMI: Abbreviation for electro magnetic interference. Interference: Electrical or electromagnetic dis- conductivity of the crimped termination.

Extraction Tool: A tool used for removing con- turbance causing undesirable response in elec- Sleeve: The insulated or metallic covering over
tacts from a connector body. tronic tooling. the barrel of a terminal.

F Crimp: A crimp that brings the center of the Jack: A connecting device into which a plug can Solid Conductor: A conductor composed of one
barrel along an open seam downward into a V. be inserted to make circuit connections. The jack single strand.
may also have contacts which open or close to Splice: A joint connecting conductors with good
Ferrule: A short tube used to make solderless perform switching functions when the plug is
connections to shielded or coaxial cable. Also mechanical strength and conductivity; a terminal
inserted or removed. See also: receptacle. that permanently joins two or more wires.
molded into the plastic inserts of multiple contact
connectors to provide strong, wear-resistant Jacket: 1.) A material covering over a wire or Strand: A single unit of a conductor.
shoulders on which contact retaining springs can cable assembly. 2.) Outer covering of a dual-wall
heat-shrinkable tubing. Strip: To remove insulation from a wire or cable.
bear.
Jackscrew: A screw attached to one half of a two- Surface Resistance: The ratio of the direct cur-
FFC: Flexible flat cable; flat flexible cable; or flexible rent applied to an insulation system to the cur-
flat conductor. A form of multiple conductor cable piece, multiple-contact connector and used to
draw both halves together and to separate them. rent that passes across the surface of the sys-
consisting of parallel flat metal strips imbedded tem.
in a flat flexible insulating material. kV (kilovolt): A unit equal to 1,000 volts.
Surface Resistance: Ratio of the direct current
Flat Braid: A braided shield composed of flatstrands. Mega (M): A prefix meaning one million (106). applied to an insulation system to the current
Flat Cable: A cable with each component in a Multiconductor: More than one component with- that passes across the surface of the system.
single, flat plane. in a single-cable complex. Tab: Used to scribe the flat blade portion of certain
Flat Conductor: A conductor having a rectangu- Nominal: A descriptor applied to a dimension terminals (e.g. FASTON tab, taper tab, solder tab).
lar cross section, as opposed to a round or representing the center of the range of tolerance Tab-lok Crimp: A type of crimp used on FASTON
square cross section. or a value if no tolerance is applied. flag terminals whereby a tab on the wire barrel is
Fretting Corrosion: A form of accelerated oxida- O Crimp: An insulation support crimp for open inserted through a slot in the terminal. The
tion that appears at the interface of contacting barrel terminals and contacts. In its crimped crimping action flattens the tab between two
materials undergoing slight cyclic relative form it resembles an O and conforms to the lances, which in turn are locked over the tab.
motion. All non-nobel metals (tin) are suscepti- shape of the round wire insulation. O crimp is Terminal: An electrically conductive item
ble to some degree of fretting corrosion and will also used to describe the circumferential crimps designed to be attached to a circuit or device
suffer contact resistance increases. used on COAXICON ferrules. for convenience in making electrical connections.
Gauge: A term used to denote the physical size Open Barrel: See barrel. Terminal Area: The portion of a printed circuit –
of a wire. See also AWG. Peripheral Seal: A seal provided around the usually along the edge – used for making the
Ground: A connection, intentional or accidental, periphery of connector inserts to prevent the input-output connections. Sometimes this term
between an electrical circuit and the earth or ingress of fluids or contaminants at the perime- is used synonymously with pad.
some conducting body (e.g. chassis) serving in ter of mated connectors. Terminal Barrel: See barrel.
place of earth. Pigtail: A short conductor or wire extending Trimming: The adjustment of resistor or capaci-
Grounding Conductor: A conductor that pro- from an electrical or electronic device to serve tor values in thick or thin film circuits by pattern
vides a current return path from an electrical as a jumper or ground connection. changes, irreversible thermally induced changes,
device to ground. Pin Contact: Electrical terminal, usually in a con- or removal of portions of material by laser or
Hardness: A general term that correlates with nector. Normally smaller termination than a lug. abrasive techniques. Dynamic trim is unique to
strength, rigidity, and resistance to abrasion or Pretinned: Description of an electrical compo- these technologies, and of great value to circuit
penetration. Measured on Shore or Rockwell nent to which solder has been applied prior to sol- design and manufacture.
scales. dering. Volt (V): The unit of measurement for electro-
Harness: A system providing electrical connec- Primary Insulation: The inner member of a dual motive force (emf). It is equivalent to the force
tion between two or more points. wall wire insulation. The insulation applied required to produce 1 ampere through a resist-
Hertz (Hz): International standard term for directly on the conductor. ance of 1 ohm.
cycles per second. Named after the German Printed Circuit Board (PCB): An insulating board Voltage (E): The term most often used to desig-
physicist Heinrich R. Hertz (e.g., 60 cycles per serving as a base for a printed circuit. When the nate electrical pressure that exists between two
second is equal to 60 hertz or 60 Hz). printing process is completed, the board may points and is capable of producing a flow of cur-
Inductance: One cause of reactance. An electro- include printed components and printed wiring. rent when a closed circuit is connected between
magnetic phenomenon in which the expanding the two points. Voltage is measured in volts, mil-
Rated Voltage: The maximum voltage at which livolts, microvolts and kilovolts. The terms elec-
and collapsing of a magnetic field surrounding an electric component can operate for extended
a conductor or device tends to impede changes tromotive force (emf), potential, potential differ-
periods without undue degradation. ence and voltage drop are often referred to as
in current. The effects of inductance become
greater as frequencies increase. The basic unit Receptacle: Usually the fixed or stationary half voltage.
for inductance is the henry. of a two-piece multiple contact connector. Also Voltage Drop: The voltage developed across a
the connector half usually mounted on a panel component or conductor by the flow of current
Insertion Tool: A tool used to insert removable and containing socket contacts.
contacts into a connector. through the resistance or impedance of that
Removable Contact: A contact that can be component or conductor.
Insulation Barrel: See barrel. mechanically joined to or removed from an Voltage Rating: The voltage that may be con-
Insulation Crimp: The area of a terminal splice or insert. Usually special tools are required to lock tinuously applied to wire.
contact that has been formed around the insula- the contact in place or remove it for repair or
tion of a wire. replacement. W Crimp: A confined type of crimp that makes
two longitudinal indentations which form a W
Insulation Displacement: A terminating tech- Resistance: A measure of the difficulty in moving cross section. Used on SOLISTRAND terminals.
nique whereby an insulated wire is forced into a electrical current through a conductor or insula-
restrictive slot in a terminal, during which time tion when voltage is applied. Measured in ohms. Wall Thickness: The thickness of the applied
the wire insulation is displaced, and the bare insulation or jacket.
Resonance: A frequency at which captive
wire engages the sides of the slot. reactance and inductive reactance Wire: A single conductor covered with insulation.
Insulation Grip: The ability of certain crimped Ribbon Cable: Flat cable with conductors that Wire Barrel: See barrel.
terminals to hold firmly in place both the con- have been individually insulated together. Its Wire Crimp: See crimp.
ductor and a small portion of insulation. This structure is usually characterized by individual

APPLICATION TOOLING /// DISTRIBUTION CHANNEL TOOLING SOLUTIONS PAGE 85