Female Disconnect for Thin Wire Applications A P P L I CAT I O N N OT E Applications: Customers that use TEFLONu and other thin insulation wires Customer Concern: A manufacturer of wire harness assemblies was experiencing crimp failures when using wire with reduced insulation thickness. When the reduced wire insulation thickness was inserted into the crimp zone, the insulated section went past the wire funnel and through the crimp zone resulting in poor terminations and improper electrical connections. Panduit Solution: Female Disconnect for Thin Wire Applications Panduit engineered a new solution to restrict the thin insulation thickness from entering the crimp zone of the barrel. The solution does not require new tooling for installation and is available for both loose piece and reel fed applications. Female Disconnect for Thin Wire Applications (on the left) Standard Female Disconnect (on the right) Application Considerations: This product is not recommended with wire that uses standard insulation thicknesses. Fig.1. Cross Section View of Standard Female Disconnect with Thin Insulated Wire Inserted in Crimp Barrel Fig. 2. Cross Section View of Insulation Restriction Female Disconnect with Thin Insulated Wire Prohibited from Entering Crimp Barrel u TEFLON is a registered trademark of E.I. du Pont de Nemours and Company. w w w. p a n d u it.c o m Female Disconnect for Thin Wire Applications Loose Piece Housing Wire and Receptacle Sizes are Identified on Housing C A Wire Stop Terminal Max. Wire Insul. Dia. B Part Number DPF18-205FIBR-C DPF18-206FIBR-C DPF18-250FIBR-C Tab Size In. (mm) Wire Range AWG (mm2) 0.205/0.187 x .032 (5.2/4.8 x 0.8) 0.205/0.187 x 0.020 (5.2/4.8 x 0.5) 0.250 x 0.032 (6.3 x 0.8) 22 – 18 (0.5 – 1.0) 22 – 18 (0.5 – 1.0) 22 – 18 (0.5 – 1.0) Reel-Fed Color Red Red Red Section View of Crimped Disconnect Wire Crimp Area Insulation Strain Relief Crimp Area Funnel Wire Entry Max. Wire Insul. Dia. In. (mm) 0.106 (2.69) 0.106 (2.69) 0.106 (2.69) A Carrier Strip A ±0.03 (0.8) B ±0.01 (0.3) 0.78 (19.8) 0.78 (19.8) 0.84 (21.3) C ±0.01 (0.3) 0.31 (7.9) 0.31 (7.9) 0.35 (8.9) 0.22 (5.6) 0.22 (5.6) 0.22 (5.6) Crimp Tools CT-1525 Wire Stop (Configuration May Vary) Housing Dimensions In. (mm) C Terminal Max. Wire Insul. Dia. B Section View of Crimped Disconnect Funnel Wire Entry Part Number DPF18205FIBR-3K DPF18206FIBR-3K DPF18250FIBR-3K Tab Size In. (mm) Wire Range AWG (mm2) 0.205/0.187 x .032 (5.2/4.8 x 0.8) 0.205/0.187 x 0.020 (5.2/4.8 x 0.5) 0.250 x 0.032 (6.3 x 0.8) 22 – 18 (0.5 – 1.0) 22 – 18 (0.5 – 1.0) 22 – 18 (0.5 – 1.0) Color Red Red Red Notes: 1.Used For: a. 600 V maximum voltage rating b. 221°F (105°C) maximum temperature rating c. Stranded copper wire only d. 6 – 12 lbs. initial insertion/withdrawal force 2.RoHS compliant Wire Crimp Area Insulation Strain Relief Crimp Area Max. Wire Insul. Dia. In. (mm) 0.106 (2.69) 0.106 (2.69) 0.106 (2.69) Tool Chart – Recommended Presses: CP-871 (UC200) Dimensions In. (mm) A ±0.03 (0.8) B ±0.01 (0.3) 0.84 (21.3) 0.84 (21.3) 0.84 (21.3) 0.31 (7.9) 0.31 (7.9) 0.35 (8.9) C ±0.01 (0.3) 0.22 (5.6) 0.22 (5.6) 0.22 (5.6) CA-800/CA9 Applicator Die Inserts CD-800-10 CD9-10A 3.Material: a. Stamping – CDA 260 brass, tin-plated b. Housing premium grade nylon for superior strain relief insulation crimping 4.Dimensions in brackets are in mm or mm2 5.Package qty: -C = 100 pcs., 3K = 3000 pcs./reel WORLDWIDE SUBSIDIARIES AND SALES OFFICES PANDUIT CANADA Markham, Ontario [email protected] Phone: 800.777.3300 PANDUIT EUROPE LTD. London, UK [email protected] Phone: 44.20.8601.7200 PANDUIT SINGAPORE PTE. LTD. Republic of Singapore [email protected] Phone: 65.6305.7575 PANDUIT JAPAN Tokyo, Japan [email protected] Phone: 81.3.6863.6000 PANDUIT LATIN AMERICA Guadalajara, Mexico [email protected] Phone: 52.33.3777.6000 PANDUIT AUSTRALIA PTY. LTD. Victoria, Australia [email protected] Phone: 61.3.9794.9020 For a copy of Panduit product warranties, log on to www.panduit.com/warranty For more information Visit us at www.panduit.com Contact Customer Service by email: [email protected] or by phone: 800.777.3300 ©2015 Panduit Corp. ALL RIGHTS RESERVED. TMAN14--WW-ENG replaces WW-TMAN08 10/2015