408- 2353
Die Assemblies for COPALUM Terminals and Splices and HF- 30 Pin and Socket Contacts
5 of 12Rev B Tyco Electronics Corporation
3. Activate power unit so that moving die advances
and holds terminal in place. Do NOT deform
terminal wire barrel.
4. Insert stripped wire all the way into terminal wire
barrel. End of wire must be flush with or extend
beyond end of wire barrel as shown in Figure 3,
Detail A. See Figure 3, (Detail D and E), for HF--30
Contacts.
5. Activate power unit to complete crimp.
6. Refer to Figure 5A and Section 4, CRIMP
INSPECTION.
3.3. Crimping Procedure (COPALUM Butt Splice)
1. Position butt splice in stationary die so that end
of splice is flush with sides of dies and view port in
splice is facing stationary die. See Figure 3,
Detail B.
2. Activate power unit so that moving die advances
and holds splice in place. Do NOT deform splice
wire barrel.
3. Insert stripped wire into splice wire barrel until
end of wire butts against wire stop as shown in
Figure 3, Detail B.
For aluminum--to--aluminum applications, butt
splices will accept the same wire size at either
end. For aluminum--to--copper applications,
however, the size of the copper wire must be
“stepped down” to the next smaller wire size to
compensate for differences in the physical
properties of copper and aluminum. Determine
correct splice wire loading by referring to CMA
range listed in Figure 2. If “stepping down” to a
smaller wire size is not desirable, i.e., if
aluminum--to--copper applications are to be made
using the same size wire at each end of the butt
splice, Tyco Electronics recommends that the
perforated sleeve be removed from inside that
particular end of splice that is to be crimped on
copper wire. When two or more wires are used in
either end of butt splice, combined
cross--sectional area must be within the CMA
range listed for the splice in Figure 2.
4. Activate power unit to complete crimp.
5. To crimp other half of butt splice, remove and
rotate splice 180_ end--over--end. If splice cannot
be rotated, rotate crimping head. Reposition
uncrimped half in stationary die as described in
Step 1. Insert wire and then crimp the splice.
6. Refer to Figure 5A and Section 4, CRIMP
INSPECTION.
3.4. Crimping Procedure (COPALUM Parallel Splices)
1. Center parallel splice in stationary die as shown
in Figure 3, Detail C.
2. Activate power unit so that moving die advances
and holds splice in place. Do NOT deform the
splice.
3. Insert stripped wires all the way into splice.
Ends of wires must be flush with or extend beyond
ends of splice.
4. Activate power unit to complete the crimp.
If terminal or splice sticks in die after crimping,
apply rocking action to remove from die.
5. Refer to Figure 5A and Section 4, CRIMP
INSPECTION.
3.5. Crimping Procedure (HF- 30 Pin and Socket
Contacts)
1. Ensure the terminal dash number , crimp die
assembly, and wire size agree with table in
Figure 2B prior to crimping
.
2. Visually inspect contacts for presence of insert.
SeeFigure4.
Ver ify perforated insert is present prior
to
crimping
contact assembly. Crimp will not
function properly without insert.
3. Center pin or socket contact wire barrel in
stationary die as shown in Figure 3, Detail D & E.
4. Activate power unit so that moving die advances
and holds contact in place. Do NOT deform the
contact wire barrel.
5. Insert properly stripped wires all the way into
contact. Insulation should butt up against contact
wire barrel, see criteria identified in Figure 3,
Detail D.
6. Activate power unit to complete the crimp.
If contact sticks in die after crimping, apply
rocking action to remove from die. Use Tyco
Electronics Lubricant (pat number 168433--1) to
prevent sticking of HF--30 contacts in crimping
dies. Apply a thin coat to die surfaces
periodically. Do NOT lubricate excessively.
Remove excess lubricant from surface as
required. Lubricant transferred from the crimp
area onto certain terminations may affect the
electrical characteristics of an application.
7. Refer to Figure 5B and Section 4, CRIMP
INSPECTION.
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