89 Catalog 82004 Dimensions are shown for Dimensions are in inches and Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666 Revised 3-11 reference purposes only. millimeters unless otherwise Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686 Specifications subject specified. Latin/S. Am.: +54 (0) 11-4733-2200 Netherlands: +31 (0) 73-6246-999 www.te.com to change. USA: +1 (800) 522-6752 Germany: +49 (0) 6251-133-1999 China: +86 (0) 400-820-6015 FASTON Terminals (Insulated and Uninsulated) Ultra-Fast Fully Insulated FASTON Receptacles and Tabs Ultra-Fast Fully Insulated FASTON Receptacles and Tabs Product Facts ■ One-piece Fully Insulated Premier Line FASTON Receptacle crimp helps prevent shock and short hazards ■ Designed for correct lead-in of tab ■ Designed for full mating with a variety of tab styles including those with shoulders ■ Funnel wire entry ■ Wire Stop ■ Visual inspection of crimp and wire brush ■ Assemblies are color-coded by wire size ■ Assemblies contain wire size and tab size designation ■ Mating tab thickness marked on terminal and visible through housing (.110, .187 and .205 Series) ■ Application tooling available to meet production requirements ■ Tin plated copper alloy terminals ■ UL rated at + 105°C ■ Terminates 26-10 AWG solid, fused and stranded wire (Flags terminate stranded wire only) Performance Capabilities ■ Meets UL-310 specification for quick connect terminals; UL listed under File No. E-66717 ■ Meets CSA C22.2, No. 153 specification for quick connect terminals; CSA Certified under File No. LR 7189 ■ 600-volt application capability (1,000 volts for signs and fixtures) The Ultra-Fast Fully Insulated FASTON Receptacle and Tab offers the advantage of a completely protected terminal and a wire crimp with comparable electromechanical performance to open barrel “F” crimp FASTON Terminals. The “User-Friendly” design combines easy mating with rounded corners. The .187 and .250 series receptacles incorporate a two-stage roll configuration and a canti- lever mounted dimple which provides easy insertion and multiple independent points of contact for reduced tab interface resistance. Ultra-Fast Fully Insulated FASTON Receptacles, Flag Receptacles and Tabs preclude the need for costly electrical safety interlocks or special protective shields to help prevent shock hazards. In addition, electrical short circuits from exposed leads are eliminated, even in equipment requiring close contact spacing. The Ultra-Fast FASTON Receptacle, Flag Receptacle and Tab are preinsulated assemblies featuring a housing molded from type 6/6 nylon material with a +130°C UL temperature rating. The Ultra-Fast FASTON Receptacle housing completely encloses a tin plated copper alloy Premier FASTON receptacle which has been stress-relieved for increased durability and resistance to abuse. The FASTON receptacle is recessed sufficiently within the housing to allow its use in 600-volt applications. The receptacle portion of the terminal is designed for positive mating with a variety of tabs, including those with shoulders. The housing has a slotted membrane which is displaced by two tab shoulders allowing proper engagement of tab and receptacle while maintaining the fully insulated characteristic. Positive entry and lead-in of the tab is provided by the inner housing wall and the lead-in on the terminal rolls. This permits positive engagement, even in blind mating locations. The Ultra-Fast FASTON Tab housing completely encloses a tin plated copper alloy FASTON tab. The FASTON tab is recessed sufficiently within the housing to allow its use in 600-volt applications. The housing is designed to completely encapsulate the tab and receptacle when the two are mated. Quality control is easily maintained. The nylon housing is translucent, allowing visual inspection of the termination. In addition, a crimp code on the platform hand tool is indented into the housing during the crimping operation which identifies that the proper crimp dies were used. Depending on production requirements, TE provides a complete selection of terminating equipment from hand tools to automatic lead makers. R R
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Ultra-Fast Fully Insulated FASTON Receptacles and Tabs · Catalog 82004 Dimensions are shown for Dimensions are in inches and Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666 Ultra-Fast
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89Catalog 82004 Dimensions are shown for Dimensions are in inches and Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666Revised 3-11 reference purposes only. millimeters unless otherwise Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686
for quick connect terminals;UL listed under File No. E-66717
■ Meets CSA C22.2, No. 153specification for quickconnect terminals; CSA Certified under File No. LR 7189
■ 600-volt applicationcapability (1,000 volts forsigns and fixtures)
The Ultra-Fast Fully InsulatedFASTON Receptacle and Tab offers the advantage of a completely protectedterminal and a wire crimpwith comparableelectromechanicalperformance to open barrel“F” crimp FASTON Terminals.The “User-Friendly” designcombines easy mating withrounded corners. The .187and .250 series receptaclesincorporate a two-stage rollconfiguration and a canti-lever mounted dimple whichprovides easy insertion andmultiple independent pointsof contact for reduced tabinterface resistance.
Ultra-Fast Fully InsulatedFASTON Receptacles, Flag Receptacles and Tabspreclude the need for costlyelectrical safety interlocks orspecial protective shields tohelp prevent shock hazards.In addition, electrical shortcircuits from exposed leadsare eliminated, even inequipment requiring closecontact spacing.
The Ultra-Fast FASTONReceptacle, Flag Receptacle
and Tab are preinsulatedassemblies featuring ahousing molded from type 6/6 nylon material with a +130°C ULtemperature rating.
The Ultra-Fast FASTONReceptacle housingcompletely encloses a tinplated copper alloy PremierFASTON receptacle whichhas been stress-relieved forincreased durability andresistance to abuse. TheFASTON receptacle isrecessed sufficiently withinthe housing to allow its usein 600-volt applications. Thereceptacle portion of theterminal is designed forpositive mating with a varietyof tabs, including those withshoulders. The housing hasa slotted membrane which is displaced by two tabshoulders allowing properengagement of tab andreceptacle while maintainingthe fully insulatedcharacteristic.
Positive entry and lead-in ofthe tab is provided by theinner housing wall and thelead-in on the terminal rolls.
This permits positiveengagement, even in blindmating locations.
The Ultra-Fast FASTON Tab housing completelyencloses a tin plated copperalloy FASTON tab. TheFASTON tab is recessedsufficiently within thehousing to allow its use in600-volt applications. Thehousing is designed tocompletely encapsulate thetab and receptacle when thetwo are mated.
Quality control is easilymaintained. The nylonhousing is translucent,allowing visual inspection ofthe termination. In addition, a crimp code on the platformhand tool is indented into thehousing during the crimpingoperation which identifiesthat the proper crimp dieswere used.
Depending on productionrequirements, TE provides a complete selection ofterminating equipment fromhand tools to automatic lead makers.
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90Catalog 82004 Dimensions are shown for Dimensions are in inches and Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666Revised 3-11 reference purposes only. millimeters unless otherwise Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686
Ultra-Fast Fully Insulated FASTON Receptacles and Tabs (Continued)
FASTON Terminals (Insulated and Uninsulated)
Ultra
-Fas
t Ful
ly In
sula
ted
FAST
ON R
ecep
tacl
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abs
Test SpecificationsThe following information and accompanying graphs aretaken from TE Product Qualification Testing of Ultra-FastFASTON product. Tests were conducted on representativeproduction samples, and all values shown are averages ofgroup results. The values shown are typical results andmay vary due to differences in processing, application andmethods of testing.
The heat generated by the current passing through a termination is a primary limit to the load-carryingcapabilities of the application. A low termination resistancewill produce a lower temperature rise as current is applied.In order to evaluate this characteristic, UL has establishedcurrent ratings for each wire size and set a maximumtemperature rise to assure safe operation. For example, 16AWG stranded wire has a UL 310 maximum temperaturerise of 30°C above ambient temperature at the rated currentof 10 amps. In the testing of the Ultra-Fast FASTON productapplied to 16 AWG wire, the temperature rise was found tobe below 10°C at the rated current. In fact, the temperaturerise did not exceed 30°C until the current was above 20amps, more than twice the rated current.
Maintaining a safe temperature rise during cyclicapplications of excessive current is the toughest challengefor the crimp-thru-plastic concept. The ability of theUltra-Fast FASTON product line to meet this goal sets itapart from other preinsulated terminations. TE’s experiencein crimp development results in a termination that exhibitsstable heating characteristics which are well within thesafety requirements of the industry.
The forces caused by the rolls of FASTON style terminalsdetermine the contact interface integrity of a matedreceptacle and tab. These forces must be high enough toprevent oxidation and corrosion from forming inside thecontact area. As these forces are raised to increase theelectrical performance, the engagement and separationforces for mating the contacts are significantly increased.For this reason, the Premier Low Insertion Force FASTONconcept of receptacle design has been carried over to theUltra-Fast FASTON products. This feature providesconsistent engagement and separation forces whilemaintaining a high standard of electrical reliability.
The crimp tensile strength of a wire-to-terminal connectionis important in guarding against such hazards as wireflexing, vibration and wire strain. However, maximum tensilestrength does not insure maximum electrical performance.An acceptable compromise between tensile strength andelectrical performance must always be reached, usingrecommended crimp heights.
1 UL does not have requirements for wire gauges below 22 AWG.Note: Minimum requirements are per TE specifications.
To test a product, it must be subjected to 500 on and offcycles at twice the rated current for the particular wire size.The temperature rise is measured on the 24th cycle and the 500th cycle. The maximum temperature rise is limited to 85°C above ambient temperature with a maximum of15°C increase on any sample between the 24th and 500thcycles. Our testing of 16 AWG wire application indicated a25.5°C maximum temperature rise up to 500 cycles, with amaximum increase of 0.8°C from the 24th to the 500thcycle for one sample in the test group.Current vs. Temperature Rise (16 AWG)
Current Cycling vs. Temperature Rise (16 AWG)
Engagement/Separation
Crimp Tensile
91Catalog 82004 Dimensions are shown for Dimensions are in inches and Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666Revised 3-11 reference purposes only. millimeters unless otherwise Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686
for quick connect terminals;UL listed under File No. E-66717
■ Meets CSA C22.2, No.153specification for quickconnect terminals; CSA certified under File No. LR 7189
■ 600-volt applicationcapability (1,000 volts forsigns and fixtures)
Ultra-Fast Plus fullyinsulated FASTONreceptacles and tabs offerall the advantages of thestandard Ultra-Fast productplus an insulation crimp.
Ultra-Fast Plus fullyinsulated FASTONreceptacles and tabspreclude the need for costlyelectrical safety interlocksor special protective shieldsto help prevent shockhazards. In addition,electrical short circuits from exposed leads areeliminated, even inequipment requiring closecontact spacing.
Ultra-Fast Plus FASTONreceptacles and tabs arepreinsulated assembliesfeaturing a co-moldedhousing produced from twodifferent nylon materials.The receptacle/ tab andwire barrel portions of the
housing are molded fromtype 6/6 nylon material witha +130°C UL temperaturerating. The insulation barrelis molded from a premiumgrade nylon selected toretain the insulation crimpshape. This premium nylon exhibits minimalspringback, thus providingactual insulation crimptensile strength as well asstrain relief for applicationswhere extreme wiredressing and/or vibrationare present.
The Ultra-Fast Plus FASTONreceptacle housingcompletely encloses a tinplated copper alloy premierFASTON receptacle whichhas been stress relieved forincreased durability andresistance to operatorabuse. The FASTONreceptacle is recessedsufficiently within thehousing to allow its use in600-volt applications. Thereceptacle portion of theterminal is designed forpositive mating with avariety of tabs, includingthose with shoulders. Thehousing has a slottedmembrane which isdisplaced by two tabshoulders allowing proper
■ Tested by TUV File No.E9071003 as suitable for endproduct certification to thefollowing standards:
EN 60 950/09.87
DIN IEC 380/VDE 0806/08.81
DIN IEC 601-1 Part 1/VDE 0750T1/05.82
DIN VDE 0700 T1/02.81
engagement of tab andreceptacle whilemaintaining the fullyinsulated characteristics.
Positive entry and lead-in ofthe tab is provided by theinner housing wall and thelead-in on the terminal rolls. This permits positiveengagement, even in blindmating locations.
The Ultra-Fast Plus FASTONtab housing completelyencloses a tin platedcopper alloy FASTON tab.The FASTON tab isrecessed sufficiently withinthe housing to allow its usein 600-volt applications. The housing is designed tocompletely encapsulate thetab and receptacle whenthe two are mated.
Quality control is easilymaintained. The nylonhousing is translucent,allowing visual inspection ofthe termination.
Depending on production requirements,TE provides a completeselection of terminatingequipment from hand toolsto automatic lead makers.
Insulation Crimp Cross Section
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94Catalog 82004 Dimensions are shown for Dimensions are in inches and Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666Revised 3-11 reference purposes only. millimeters unless otherwise Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686
Hand Tools — Insertion250 Series—314916-1250 Series Flag—314919-1
Hand Tools — Extraction250 Series—314917-1
Ultra-Pod fully insulatedFASTON receptacles offerthe newest in one-stepautomatic application ofinsulated quick connects.The unique integral plasticcarrier designed specificallyfor this product allowsinsulated F-Crimpterminations to be producedquickly and easily. Appliedcost savings are attainablewith either bench or high-speed automatictermination equipment and the elimination of anysecondary insulationoperations. Both thecrimping of the terminal andthe terminal insulating occurin a single stroke of thepress and applicator — the crimping on the down-stroke and the insulating onthe up-stroke.
The receptacles containedwithin the Ultra-PodFASTON receptacleassemblies are tested andcustomer qualified and can be used in existingapplications whereinsulation has beenaccomplished by othermeans. The low insertionforce design provides easiertab insertion, reducesoperator fatigue andimproves the productivityand reliability of the endassembly operation.
The insulating housing isproduced by a uniquemolding process whichprovides an integral carrierand eliminates the crimplocation problems related tosecondary carriers. Thishousing, produced from130°C rated 6/6 nylon,
covers the FASTONreceptacle sufficiently toprovide for use in 600-voltapplications. Mostimportantly, this insulatingsystem helps eliminate theworkplace hazards andlabor costs of chemicallyexpanded or heat shrinktubing.
Depending on productionrequirements, TE provides a complete selection ofterminating equipment frombench press to automaticlead maker.
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96Catalog 82004 Dimensions are shown for Dimensions are in inches and Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666Revised 3-11 reference purposes only. millimeters unless otherwise Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686
1 Flammability rating of plastic material.2 150°C rated nylon.3 UL recognized.4 No UL or CSA approvals.5 VDE certified to IEC 60695-2-11 Glow Wire temps. 650°C, 750°C, & 850°C.
97Catalog 82004 Dimensions are shown for Dimensions are in inches and Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666Revised 3-11 reference purposes only. millimeters unless otherwise Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686
(2) 20 or 2.66 5.08 9.40 14.86 17.27 0.81V-0 Natural
Brass 521633-1(2) 18Tin Plated Brass 521633-2
1 Flammability rating of plastic material.2 UL pending for double wire terminations.3 No UL or CSA approvals.4 No CSA approvals.5 VDE certified to IEC 60695-2-11 Glow Wire temps. 650°C, 750°C, & 850°C.
Flag Insulation Support
A
D
C B
98Catalog 82004 Dimensions are shown for Dimensions are in inches and Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666Revised 3-11 reference purposes only. millimeters unless otherwise Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686
Here is a pre-insulatedterminal designed forcomplete and uniformreliability in most difficultcircuit environments. EachPIDG Terminal consists of atin plated brass body with aspecially designed coppersleeve and insulation sleevefitted over the terminalbarrel. The design of the tooldies and the construction of the terminal promotesuniform insulation thicknessunder crimping pressure,transmitting this pressureevenly to the center of thecrimp area.
TE compression crimpingproduces crimps for a given size wire and terminalthat are precisely alike in appearance andperformance. This is acalculated result madepossible by designing theterminal and the crimpingtool as precisely matcheddevices. The dies areprecision-engineered fromthe finest hard-metal alloys.Crimping pressure iscontrolled by a ratchetdevice on the hand tool or a corresponding pre-calibration in the crimping
Temperature Rating: 105° CWire E66717 LR7189
Range Recognized Certified22-16 22-16 Stranded
300 V Max.,16-14 16-14 Stranded12-10 12-10 Stranded
105°C Max.1
1 UL and CSA — Nylon.
jaws of TE automatedcrimping machines.
Crimping pressure canneither over-stress norunderstress the terminalbarrel — machined diesfully bottom to the precisecrimp height required.
The resulting termination is free of contamination, is resistant to shock andcritical environments, and its tensile strengthapproaches that of the wire itself.
Product Facts■ Pre-insulated terminal
designed for complete anduniform reliability in themost difficult circuitenvironment
■ Consists of an unplated ortin plated brass body or a tin plated phosphor bronzebody with a speciallydesigned copper sleeve andinsulation sleeve fitted overthe terminal barrel
■ Design of the tool dies andconstruction of the terminalinsures uniform insulationthickness under crimpingpressure, transmitting thispressure evenly to thecenter of the crimp area
The TE Mated Tool/TerminalConcept■ TE compression crimping
produces crimps for a given size wire and terminalthat are precisely alike in appearance andperformance
■ Terminal and the crimpingtool are designed asprecisely matched devices
■ Dies are precision-engineered from the finesthard-metal alloys
■ Crimping pressure iscontrolled by a ratchetdevice on the hand tool or a corresponding pre-calibration in the crimpingjaws of TE automatedcrimping machines
The Crimp■ Crimping pressure does not
overstress nor understressthe terminal barrel —machined dies fully bottomto the precise crimp height
■ Resulting termination isfree of contamination
■ Resistant to most shock andcritical environments
■ Tensile strength approachesthat of the wire itself
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100Catalog 82004 Dimensions are shown for Dimensions are in inches and Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666Revised 3-11 reference purposes only. millimeters unless otherwise Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686
22-18 .230 .800 .140 .016 .020509-1,900 B 5.84 20.32 Red 3.56 Brass 0.41 0.51 640917-1* 640917-2 640916-1[0.26-0.96]
† Not UL or CSA approved or listed. 1 Wire range is limited as noted. 3 Requires tool 90276-2* Available in small packaging quantities. 2 Unplated receptacle body. 4 Requires die 58541-1
MaterialInsulation — NylonReceptacle Body — Brass perASTM B-36 or phosphor bronze perASTM B-139Plating — Tin per MIL-T-10727except where noted.Metallic Sleeve — Copper perASTM B-152Plating — Tin per MIL-T-10727
Note: All part numbers are RoHS compliant.
101Catalog 82004 Dimensions are shown for Dimensions are in inches and Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666Revised 3-11 reference purposes only. millimeters unless otherwise Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686
Tooling for Insulated FASTON Receptacles and Tabs — 26 to 10 AWG Wire RangeTools for Tape Mounted Terminations Tools for Strip Form Terminations
Wire Size Hand Tool Tape Dies for Tape Dies for Tape Dies for AMPOMATOR69875 AMP-TAPETRONIC AMP-O-LECTRIC1 Model “G” AMPOMATOR CLS III G, CLS III G, CLS IVNo Applicator Required Applicator 567200-3 CLS IV Applicator 687658-1 Applicators