Connector Tooling Guide - LCT Global Inc.

1 Connector Tooling Guide An ISO9001. and AS9100. Registered Company DANIELS . MANUFACTURING. CORPORATION. Preface and Table of Contents Daniels tools have been utilized in military CONTENTS. Important Facts About Crimping .. 1. aircraft and aerospace programs for over Tensile Test Systems .. 2. MPT 500-A Heavy Duty Motorized Pull Tester .. 4. 50 years (DMC founded in 1949). HPT-200 Hand Held Wire Crimp Pull Tester .. 5. Standard Adjustable Crimp Tool.. 6. M22520/1-01 (AF8). By continuously planning and adding Miniature Adjustable Crimp Tools .. 8. M22520/2-01 (AFM8). to our product lines, we are now fulfilling the M22520/7-01 (MH860). M22520/39-01 (39-000). demands of other high technology fields such Ultra Precision (MH800). Pneumatic Crimp Tools .. 10. (WA22). as computers, lasers, communications, and (WA22P). (WA27F). many other areas of electronic packaging. Specialty Pneumatic Tools .. 11. First End Package The people behind the DMC name are Second End Package Large Gage Pneumatic Crimp Tools.

2 12. M22520/23-01 (WA23). pleased to present our Connector Assembly Large Gage Contact Application Information.. 13. Technical Application Guide .. 14. Tools and Accessories on the pages that Connector Illustration Contact Color Code (BIN). follow. We believe the application data which Wire Stripping M39029 Contact Quick Location Chart Connector /Assembly Tool Guide By Series .. 16 44. accompanies each section will answer your MIL-STD-1760 Connector Tooling .. 27. Circular Indent Crimp Tools .. 45. specific questions concerning Tooling ; (MH801) (MH802) (MH803) (MH804). M22520/4-01 (GS100-1). M22520/31-01 (GS200-1). however, we encourage you to contact us by Coaxial Contact Tool Selection Guide .. 46. Open Frame Crimp Tools .. 48. telephone or fax for the personal services of M22520/5-01 (HX4). M22520/10-01 (HX3). our knowledgeable staff of application Pneumatic Open Frame Tool .. 50. Open Frame Operation, Dies, and EHCY Series Electric Tool.

3 51. experts. Pneumatic/Hydraulic Portable Crimp Tool Systems .. 52. DMC Crimp Dies For A Full Range NOTICE of Capabilities .. 53. ANY PRICES WE QUOTE VERBALLY OR ANY Typical Die Configurations and Applications PRICES APPEARING IN OUR PRINTED PRICE LISTS connectors Tool Selection Guide .. 54 65. ARE SUBJECT TO CHANGE WITHOUT PRIOR NOTICE. Hydrac Hydraulic Crimping Tools .. 66 69. IF YOU NEED FIRM PRICES FOR FUTURE Contact Retention Test Tools .. 70. DELIVERIES YOU SHOULD REQUEST A WRITTEN Installing and Removal Tools .. 71 73. QUOTATION FROM OUR SALES OFFICE. MIL-I-81969. WE ARE NOT LIABLE FOR CONSEQUENTIAL OR Commercial Standard Hand Crimp Tools .. 74. GMT232. SPECIAL DAMAGES OF ANY NATURE OR KIND, RESULT- DCT4. ING FROM THE USE OF ANY OF OUR PRODUCTS. GMT. Hand-Held Pneumatic Wire Stripping Tool .. 75. (WSP 1630). DANIELS MANUFACTURING CORP. EMI/RFI Band Application System .. 76. 526 THORPE RD. ORLANDO, FL 32824 Connector Service Maintenance/Support Kits.

4 80. PHONE 407/855-6161 FAX 407-855-6884. E-MAIL: Limited Warranty .. 81. FOR WARRANTY & LIMITATION OF LIABILITY INFORMATION SEE PAGE 81. REV. 9 COPYRIGHT 2005 DANIELS MANUFACTURING CORPORATION.. DANIELS. Important Facts MANUFACTURING. CORPORATION. About Crimping CRIMPING: THEN AND NOW small as AWG 32. drop at a designated current. The first multi-pin connectors were Both documents were combined The mechanical strength of a terminated by soldering the conductor in 1971 into MIL-C-22520D. All crimped joint and hence its pull-out to non-removable contacts. However, previous military standards for crimp force (tensile strength), varies with the high temperature applications and tools were then cancelled including deformation applied. Therefore, by the need for simple and reliable field the MS3191. properly shaping the deformation a service led to the introduction of MIL-C-22520 (changed in 1996 high pull-out force can be achieved, connectors with removable contacts.)

5 To MIL-DTL-22520) has since replaced the crimp die of the tool deter- These were crimped onto the con- many other crimp tool documents mines the crimp configuration and ductor rather than being soldered. including: MS3198, MS22910, deformation. The first standard crimp tool MS17776, MS28731, MS90388, The dies in the tool determine the developed to crimp these new con- MS14037, MS27437, MS27828, completed crimp configuration which tacts was introduced in the early MS27832, MS55619, MS27426 and is generally an element of contact sixties. MS3191-1, a military drawing, others. This list includes specifications and/or Connector design. Some of the defined this tool and its accessories. for indent crimp tools, terminal lug design considerations are: a) The type The MS3191-1 utilized a four indent crimp tools, pneumatic tools, coaxial of contact, its size, shape, material crimp pattern together with a positive cable crimp tools and Connector and function, b) The type and size of stop locator which controlled the travel service kits.

6 Wires to be accommodated, c) The of the indenters (crimp depth). The establishment of MIL-DTL- type of Tooling into which the configu- The MS3191-1 design was a 22520 was a milestone on the road ration must be built. compromise between simplicity of to crimp tool standardization. Its operation and crimp performance development has eliminated the waste since the crimp depth for any given and confusion which accompanied contact was not adjustable to accom- the overlapping applications of many modate the differing diameters of the different standard crimp tools called EIGHT INDENT. conductors to which it would be out by a deluge of unrelated military crimped. It was, however, suitable for drawings. the crimp connectors of that era. MIL-DTL-22520 established a An improved tool design featuring single specification which set forth performance requirements for all crimp FOUR INDENT. independently adjustable crimp depths was soon introduced as MS3191-4.

7 Tools to be used on military standard The MS3191-4 had an internal adjust- electrical connectors . ment, totally independent of the loca- THE CRIMPING CONCEPT TWO INDENT. tor, which permitted the selection of Crimping is a method of firmly seven separate crimp depths, allowing attaching a terminal or contact end to optimal crimping of conductors rang- an electrical conductor by pressure ing from AWG 12 to 26 regardless of forming or reshaping a metal barrel the wire barrel size of the contact. HEXAGONAL CRIMP. together with the conductor. The MS3191-4 also introduced the forming of a satisfactory crimp use of the double tipped indenter to depends on the correct combination produce an eight indent crimp pattern of conductor, crimp barrel and tool. which has consistently achieved CIRCULAR CRIMP. When applied with a properly superior tensile pull off values. matched tool, a union would be MS3191-4 introduced the concept established which has both good of a turret head containing three loca- electrical and mechanical charac- tors which could be used without B CRIMP.

8 Teristics. The tool will provide these separating any of them from the basic requirements consistently and reliably crimp tool. with repeatability assured by quality In 1969 two military specifications cycle controlled Tooling . There are for crimp tools were developed to several common configurations of NEST & INDENT CRIMP. replace the existing military drawings. crimped joint; several examples are They were MIL-T-22520C (Navy) and shown below. MIL-T-83724 (USAF) which defined a The electrical resistance of a standard size crimp tool similar to the properly designed and controlled CAPTIVE CRIMP. MS3191-4, but with an expanded crimped joint should be equal to, or eight step crimp depth range. These less than, the resistance of an equal specifications also defined a miniature section of wire. Specifications state crimp tool to crimp conductors as INSULATION DISPLACEMENT. the requirements in terms of millivolt COPYRIGHT 2005 DANIELS MANUFACTURING CORPORATION Tensile Test Systems For Wire Terminations and Similar Applications portable design of these test machines make any of them a superior choice for on-site or laboratory use in an infinite variety of applications.

9 The operation THE DEPENDABLE of the equipment is simple yet versatile, and DMC will customize A LPHA EST -T the gripping jaws or other components to make test sample installation and MODEL HPT-200 HAND-HELD. SYSTEM removal an easy task. PULL TESTER. Models are available with output Now available from DMC is a line display readings in Pounds, Newtons, of Electronic Tensile Test Systems and/or Kilograms to conform with the Also consult DMC for Model which may be used in conjunction requirements of the users system. HPT-200 hand-held pull tester which with SPC Programs or other Quality Units are available for either 115 or blends the accuracy and rugged Control disciplines in both OEM and 230 volt power input. design of the Alphatron pull testers maintenance applications. The elec- It's only natural that the company into a portable battery powered unit. tronic digital readout displays are a which supplies the best wire termina- fast and reliable source of test data, tion tools and equipment would add and in some models the data may the very best Digital Tensile Testers to be output to a printer or other RS232 further meet the demand for fewer compatible devices.

10 Sources and improved support The rugged construction and the through a wider range of user needs..5% Accuracy (1/2 of 1%). Portable Designs Easy to Operate SPC Compatible Many Grips Available Custom Applications Are No Problem Featured is Model MPT-200A. Other models Now Available .. are listed on ALPHA-TEST DATA LINK. Page 3, 4. and 5. SOFTWARE. To serve the data collection needs of your test lab or in-process operations. Part No. 15-7010. PAGE 2 COPYRIGHT 2005 DANIELS MANUFACTURING CORPORATION.. DANIELS. Tensile Test Systems MANUFACTURING. CORPORATION. Technical Information MOTORIZED PULL TESTERS GENERAL SPECIFICATIONS. MPT-500A MPT-200A PT-100A PT-100 HPT-200. Capacity 500 lbf 200 lbf kg 150 lbf kg 100 lbf kg 200 lbf kg kg 889 N 667 N 445 N 889 N. Accuracy (1/2 of 1%) (1/2 of 1%) (1/2 of 1%) (1/2 of 1%) (1/2 of 1%). Resolution lbf lbf lbf lbf lbf Display Type Digital Display Digital Display Digital Display Digital Display Digital Display w/Peak w/Peak w/Peak w/Peak w/Peak Hold Reading Hold Reading Hold Reading Hold Reading Hold Reading Display LED w/.