wire termination specification 1.0 scope: this specification is designed to insure the proper performance of the 7720 and the 40555 series i.d.t. connector systems. 2.0 applicable drawings: products conforming to this specification are noted on the individual sales drawings. 3.0 conductor requirements: 3.1 conductor: 28-24 awg solid tinned copper wire 28-22 awg (7 strand) concentric stranded tinned copper wire 28-24 awg (7 strand) concentric stranded topcoated or fused copper wire 3.2 insulation: discrete wire: ul style 1007 or 1061 with pcv insulation. insulation dia. of (1.52)/.060 max. when terminating wires one position at a time, or (1.27)/.050 dia. max. when mass terminating. molex cable: ul style 2651 (stranded wire must have 7 strands) on (2.54)/.100 centers. molex cable numbers 24241, 7767, 8997, 7234, 7307, 24226, 7560, 8996 see figures 1 and 2 for cable preparation. es-40000-3996 rev. a sheet 3 95/mar/10 ec u5-0926 dcbrd03.sam 6 1 of 77200002 smes-7720-0002 sht no. file document no. 96 /02/08 b lenz r edgley samiec m lisle date: yr / mo / day approved by: checked by: written by: status design control description rev this document contains information that is proprietary to molex inc. and should not be used without written permission update ec u50393 9-9-96 samiec d wire termination specification title revise on pc only 6 5 4 3 2 1 sht english engineering specification
4.0 conductor requirements: see figure 3 4.1 conductor size identification: terminals stamped with the letter "a" accept molex cable no?s. 7234- 26 awg solid tinned copper 24241- 26 awg stranded tinned copper 7307- 28 awg stranded tinned copper 7767- 28 awg stranded topcoat copper terminals stamped with the letter "a" accept wire that meets requirements in section 3.0 28 awg stranded tinned copper 28 awg solid tinned copper 28 awg stranded topcoated copper 26 awg stranded tinned copper 26 awg solid tinned copper terminals stamped with the letter "h" accept molex cable no?s.. 8996- 26 awg stranded topcoated copper 8997- 24 awg stranded topcoated copper 24226- 24 awg stranded tinned copper terminals stamped with the letter "h" accept wire that meets requirements in section 3.0 24 awg solid tinned copper 26 awg stranded topcoated copper 24 awg stranded tinned copper 24 awg stranded topcoated copper terminals stamped with the letter "f" accept molex cable no?s. 7560- 22 awg stranded tinned copper terminals stamped with the letter "f" accept wire that meets requirements in section 3.0 when used in assembly a-7720-w* 22 awg stranded tinned copper english engineering specification es-40000-3996 rev. a sheet 4 95/mar/10 ec u5-0926 dcbrd03.sam smes-7720-0002 sheet file name document no. description rev this document contains information that is proprietary to molex inc. and should not be used without written permission see sheet 1 d
5.0 molex termination tooling: required for terminating 22 awg conductors discrete wire = cam4 / 62300-0100 cable = am 8640 / 011-20-0412 am8640b / 011-20-0771 6.0 termination requirements: 6.1 cable insertion depth: cable should be inserted to depth where the molded wire strain relief?s can return to their normal position, and a gap is maintained between the wire and the bottom of the strain relief window, as shown in figure 4. 6.2 exposed conductor exposed conductors shall not exceed the limits specified in figure 5 after termination figure 5 english engineering specification es-40000-3996 rev. a sheet 4 95/mar/10 ec u5-0926 dcbrd03.sam smes-7720-0002 sheet file name document no. description rev this document contains information that is proprietary to molex inc. and should not be used without written permission see sheet 1 d
6.3 the wire must be displaced in both insulation displacement slots and must protrude through the secondary slot by (.63)/.025 min. as shown in figure 6. figure 6 6.4 horizontal pull out force: the connector must maintain the following min. pull out values when a force is applied at a rate of 1 inch per minute to the cable in a direction perpendicular to the insulation displacement section, as shown in figure 7. (note cable must be slit to form individual conductors after termination but prior to testing). awg pull force 24 awg 8.0 lbs min 26 awg 4.6 lbs min 28 awg 3.9 lbs min figure 7 6.5 vertical pull out force the connector must maintain the following min. pull out values when a force is applied at a rate of 1 inch per minute to the cable in a direction parallel to the insulation displacement section, as shown in figure 8. ( note cable must be slit to form individual conductors after termination but prior to testing. test is performed without strain relief covers.) awg pull force 22 awg to be determined 24 awg 1.5 lbs min. 26 awg 1.5 lbs min. 28 awg 1.5 lbs min. english engineering specification es-40000-3996 rev. a sheet 4 95/mar/10 ec u5-0926 dcbrd03.sam smes-7720-0002 sheet file name document no. description rev this document contains information that is proprietary to molex inc. and should not be used without written permission see sheet 1 d
figure 8 6.6 torsional resistance connector must withstand a maximum twist on a terminated cable of 130 deg. without disturbing the insulation displacement interface in the primary or secondary slots (see figure 9). ( note cable must be slit to form individual conductors after termination but prior to testing). figure 9 6.7 visual inspection: after termination, insulation displacement section of the terminal to be free of tool marks from termination equipment. termination evaluation procedure step 1 strain relief removal - remove shaded portion of the strain relief using a razor blade english engineering specification es-40000-3996 rev. a sheet 4 95/mar/10 ec u5-0926 dcbrd03.sam smes-7720-0002 sheet file name document no. description rev this document contains information that is proprietary to molex inc. and should not be used without written permission see sheet 1 d
step 2 removal of terminal - insert probe into locking tang window and depress the locking tang until it clears housing, then push the terminal out of the housing using a blunt .025 sq. pin step 3 conductor removal - using a small pair of pliers spread the i.d.t. slot and remove conductor by pushing in direction shown. step 4 removing insulation - insulation to be removed without disturbing i.d.t. area step 5 conductor inspection - four deformation points must be clearly visible when using 10x magnification. english engineering specification es-40000-3996 rev. a sheet 4 95/mar/10 ec u5-0926 dcbrd03.sam smes-7720-0002 sheet file name document no. description rev this document contains information that is proprietary to molex inc. and should not be used without written permission see sheet 1 d
english engineering specification es-40000-3996 rev. a sheet 4 95/mar/10 ec u5-0926 dcbrd03.sam smes-7720-0002 sheet file name document no. description rev this document contains information that is proprietary to molex inc. and should not be used without written permission see sheet 1 d
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