Hand Tool for PV Solar Pin and Socket Crimp Terminals Tool Kit Order No. 63823-6470 TYPE 4C Application Tooling Specification Sheet Hand Crimp Tool Order No. 63823-6400 FEATURES A full cycle ratcheting hand tool ensures complete crimps % Ergonomically designed soft handles % Precisely designed crimping profiles with simple contact positioning % Easy handling due to outstanding force ratio Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool. Many different Tool kits can be used with a single Battery Powered Tool. This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant. % SCOPE Products: PV Solar Pin and Socket Crimp Terminals, 10-14 AWG (6.0-2.5mm²) Terminal Series No. 130196 130197 93302 93303 Terminal Order No. Wire Size and Type Insulation Diameter (ref) Loose Reel only AWG mm² mm In. 130196-0310 130196-0314 10-12 6.00-4.00 7.8 .31 130196-0313 130196-0315 14 2.50 6.7 .26 130197-0325 130197-0346 10-12 6.00-4.00 7.8 .31 130197-0336 130197-0347 14 2.50 6.7 .26 93302-0006 93302-0004 10-12 6.00-4.00 7.8 .31 93302-0005 93302-0003 14 2.50 6.7 .26 93303-0005 93303-0003 10-12 6.00-4.00 7.8 .31 93303-0006 93303-0004 14 2.50 6.7 .26 Customer to cut off terminal from reel: 0.50mm (.020”) maximum Cut-off Tab. Strip Length mm In. 7.00-10.00 .276-.394 7.00-10.00 .276-.394 7.00-10.00 .276-.394 7.00-10.00 .276-.394 7.00-10.00 .276-.394 7.00-10.00 .276-.394 7.00-10.00 .276-.394 7.00-10.00 .276-.394 DEFINITION OF TERMS BEND UP STRIP LENGTH CONDUCTOR BRUSH BELL MOUTH SEAM ROLLING TWISTING WIRE CUT-OFF TAB CONDUCTOR CRIMP BEND DOWN The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope. Doc No: ATS-6382364HM Release Date: 03-04-11 Revision: C Revision Date: 01-03-12 UNCONTROLLED COPY Page 1 of 8 Hand Tool for PV Solar Pin and Socket Crimp Terminals CONDITIONS: Wire Size AWG mm² 10-14 6.00-2.50 10-14 6.00-2.50 Terminal Series No. 130196 and 93302 130197 and 93303 Terminal Series No. Wire Size AWG 10-12 14 10-12 14 130196 and 93302 130197 and 93303 Bell mouth mm In. 0.20-1.50 .008-.059 0.20-1.50 .008-.059 Cut-off Tab Maximum mm In. 0.50 .020 0.50 .020 Bend up Bend down Twist Roll Degree Degree 4 8 4 8 4 8 4 8 mm2 6.00-4.00 2.50 6.00-4.00 2.50 3 3 3 3 3 3 3 3 Conductor Brush mm In. 1.00-3.00 .039-.118 1.00-3.00 .039-.118 Punch Width (Ref) Conductor mm In 3.90 .154 2.90 .114 3.90 .154 2.90 .114 Seam Seam shall not be open and no wire allowed out of the crimping area After crimping, the conductor profile should measure the following. Terminal Series No. 130196 and 93302 130197 and 93303 Wire Size AWG mm2 10 6.00 12 4.00 14 2.50 10 6.00 12 4.00 14 2.50 Conductor Crimp Height mm In. 2.10-2.20 .083-.087 2.00-2.10 .079-.083 1.60-1.70 .063-.067 2.10-2.20 .083-.087 2.00-2.10 .079-.083 1.60-1.70 .063-.067 Pull Force Minimum N Lb. 356.0 80.0 312.0 70.0 223.0 50.0 356.0 80.0 312.0 70.0 223.0 50.0 The above specifications are guidelines to an optimum crimp. Note: A crimp height chart is provided with this manual as Reference Only. Due to the wide range of wires and stranding, actual crimp height measurements may very slightly. An occasional, destructive, pull force test should be preformed to check hand tool crimp. Pull force value must exceed the minimum pull force specifications listed. CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can occur to the tool or die. INSTALLATION To install the Tool Kit into the Power Crimp Head follow the steps below: Anvil and Punch Installation 1. Insert the Anvil into the bottom slots of the nest. Install the M4 x 10 long BHCS and tighten in place. 2. Insert the Punch into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See Figure 1. Locator Installation and Removal Follow the steps below to install or replace the locator. See Figure 2. To install the locator 1. Position the locator with the hole over the brass pivot shaft and snap it into place. Doc No: ATS-6382364HM Release Date: 03-04-11 Revision: C Revision Date: 01-03-12 UNCONTROLLED COPY Page 2 of 8 Hand Tool for PV Solar Pin and Socket Crimp Terminals POWER CRIMP HEAD LIFT UP ON THE LOCATOR PUNCH M4 X 18mm LONG BHCS M4 X 10mm LONG BHCS PRESS DOWN ON THE BRASS PIVOT SHAFT SWING LOCATOR OPEN Figure 1 ANVIL Figure 2 To remove the locator 1. Open the crimp hand tool. 2. Swing the existing locator open and away from the hand tool. 3. Firmly press down on the brass pivot shaft with your thumb, while pulling the locator up. Slip the locator off the top of the brass pivot shaft. OPERATION Open the tool by squeezing the handles together, at the end of the closing stroke, the ratchet mechanism will release the handles, and the hand tool will spring open. Crimping Terminals 1. Select the desired terminal listed in the preceding charts. 2. Turn the Locator Lock Latch down to unlock. See Figure 3. LATCH LOCKED LATCH UNLOCKED Figure 3 TERMINAL SWING OPEN PUSH HERE TO OPEN WIRE STOP LOCATOR LATCH IN OPEN POSITION LOCATOR Doc No: ATS-6382364HM Release Date: 03-04-11 Revision: C Revision Date: 01-03-12 Figure 4 TERMINAL IN PLACE UNCONTROLLED COPY Page 3 of 8 Hand Tool for PV Solar Pin and Socket Crimp Terminals 3. Swing the terminal locator away from the crimp tool shown in Figure 4. Some terminals with large conductor grips may interfere with the crimp tooling when swinging the locator into position. The terminal must then be loaded into the locator in the closed/crimp position. See Figure 5. 4. Press down on the wire stop on the locator as shown in Figure1. Insert the proper terminal into the proper nest opening. Make sure when choosing the nest opening, it will correspond with the 10, 12 or 14 profile on the hand tool. 5. Return the locator to its original position. TERMINAL HANDLE OPEN WIRE AGAINST WIRE STOP WIRE IN TERMINAL JAWS PARTIALLY CLOSED Figure 5 LOCATOR CLOSED Figure 6 PUSH HERE TO OPEN WIRE STOP 6. Turn the Locator Lock Latch up to lock. Make sure that the terminal is visually centered over the punch. 7. Insert the proper wire over the terminal. 8. Gently touch the wire stop with the end of the wire. See Figure 6 and 7. 9. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed. Release handles to open the jaws. 10. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on the wire. 11. Visually inspect the crimped terminal for proper crimp location. CONDUCTOR PUNCH WIRES AGAINST LOCATOR STOP LOCATOR WIRE TERMINAL Figure 7 CONDUCTOR ANVIL Note: The tamper proof ratchet action will not release the tool until it has been fully closed. For the Battery Power Tool: 1. Cycle the Battery Power Tool to crimp the terminal to the wire. 2. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on the wire. 3. Visually inspect the crimped terminal for proper crimp location. Doc No: ATS-6382364HM Release Date: 03-04-11 Revision: C Revision Date: 01-03-12 UNCONTROLLED COPY Page 4 of 8 Hand Tool for PV Solar Pin and Socket Crimp Terminals Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: LUBRICATION 1. Remove dust, moisture and other POINTS contaminants with a clean brush, or soft, lint(BOTH SIDES) LIGHT OIL free cloth. (EVERY MONTH 2. Do not use any abrasive materials that could OR Figure 8B damage the tool. 5,000 CRIMPS) 3. Make certain all pins; pivot points and bearing surfaces in the tool head are Figure8A protected with a thin coat of high quality machine oil. Do not oil excessively. This tool was engineered for durability, but like any fine piece of equipment, it needs cleaning and lubrication for a maximum service life of trouble-free crimping. The use of light oil, such as 30 weight automotive oil, every 5,000 crimps or monthly, will significantly enhance the tool life and ensure a stable calibration. See Figure 8A or 8B for lubrication points. 4. Store the tool in a clean and dry area when not in use. Miscrimps or Jams for Crimp Hand Tools Only (See Figure 11) Should this tool ever become stuck or jammed in a partially closed position, Do Not force the handles open or closed. The tool will open easily by rotating the small slotted screw marked with an arrow. See Figure 11. Warranty This tool kit is for electrical terminal crimping purposes only. This tool kit is made of the best quality materials. All vital components are long life tested. All tools are warranted to be free of manufacturing defects for a period of 30 days. Should such a defect occur, we will repair or exchange the tool kit free of charge. This repair or exchange will not be applicable to altered, misused, or damaged tools. CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling. CAUTIONS 1. Manually powered hand tools are intended for low volume or field repair. This tool is NOT intended for production use. Repetitive use of this tool should be avoided. 2. Insulated rubber handles are not protection against electrical shock. 3. Wear eye protection at all times. 4. Use only the Molex terminals specified for crimping with this tool. CAUTION: Repetitive use of this tool should be avoided. Doc No: ATS-6382364HM Release Date: 03-04-11 Revision: C Revision Date: 01-03-12 UNCONTROLLED COPY Page 5 of 8 Hand Tool for PV Solar Pin and Socket Crimp Terminals Certification Molex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for customers to re-certify hand tools. % This tool is qualified to pull force only. To re-certify, crimp a terminal to a wire, which has been stripped 12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than 25mm (1.00”) per minute. See the Molex web site for the Quality Crimp Handbook for more information on pull testing. % When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and replaced. % This tool is very difficult to disassemble and reassemble. Customer repair is not recommended. The chart below shows all applications for this Tool Kit. Tool Kit Order No. Tool Tool Power Head Adapter Figure No. Order no. Description Order No. Description 63810-1000 Hand Crimp Frame (Long) N/A N/A 9 63823-6470 63816-0200 Battery Power Tool (110 V) 63816-0300 Power Crimp Head 10 63816-0250 Battery Power Tool (220 V) 63816-0300 Power Crimp Head 10 Applications for the Tool Kit Hand Crimp Tool Battery Powered Tool POWER CRIMP HEAD TOOLING KIT TOOLING KIT BATTERY POWERED TOOL LOCKING PINS HAND CRIMP FRAME LONG AND SHORT Figure 9 Figure 10 WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper instruction and without first reading and understanding the instructions in the proper Manual or Specification Sheet. See Chart above for the correct Manual or Specification Sheet. WARNING: NEVER install tooling or service this tool while it is connected to any power source. Make sure the power is disconnected. CAUTION: To prevent injury, keep fingers away from the crimping area when operating this tool. CAUTION: Wear safety glasses when operating or servicing this tool. Doc No: ATS-6382364HM Release Date: 03-04-11 Revision: C Revision Date: 01-03-12 UNCONTROLLED COPY Page 6 of 8 Hand Tool for PV Solar Pin and Socket Crimp Terminals HAND TOOL PARTS LIST Item Number 1 2 3 Order Number 63810-1000 63823-6470 63823-6475 Description Hand Crimp Frame (Long) Tool Kit with Locator Locator (only) Quantity 1 1 REF M4 X 8mm LONG BHCS 1 1 RATCHET RELEASE SCREW 2 WITH TOOL KIT 3 LOCATOR ONLY M4 X 10mm LONG BHCS M4 X 18mm LONG BHCS Figure 11 2 Doc No: ATS-6382364HM Release Date: 03-04-11 Revision: C Revision Date: 01-03-12 UNCONTROLLED COPY Page 7 of 8 Hand Tool for PV Solar Pin and Socket Crimp Terminals POWER HEAD PARTS LIST Item 1 2 Order No 63816-0300 63823-6470 Engineering No. 63816-0300 63823-6470 Description Power Crimp Head Tool Kit Quantity 1 1 2 1 1 M4 by 8mm Long BHCS M4 by 18mm Long BHCS M4 by 10mm Long BHCS Figure 12 2 http://www.molex.com Doc No: ATS-6382364HM Release Date: 03-04-11 Revision: C Revision Date: 01-03-12 UNCONTROLLED COPY Page 8 of 8