408- 2353

Die Assemblies for COPALUM Terminals and Splices and HF- 30 Pin and Socket Contacts

5

of 12

Rev 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.

Verify 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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DANGER

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