Lighting Components and Application Guide

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Lighting Components and Application Guide Early Involvement Pays Off in Competitive Advantage With over 8,000 engineers and 17 design centres, plus manufacturing facilities in 25 countries globally, we put a premium on innovation when it comes to helping companies solve tough design problems. Talking to us early on in your design cycle will give you the full benefit of our expertise to help you: " Shorten the design cycle " Reduce costs " Increase reliability " Design for manufacturability In short, we can help you achieve a sustainable competitive advantage. Whether it's showing you the best existing products, offering a value- added solution or designing a new product, our commitment to advanced engineering and world-class manufacturing delivers innovation that can advance any lighting project.

Our Electronic Components division is the world's largest supplier of passive electronic components, including connectors and interconnect systems, relays, switches, circuit protection devices, touchscreens, sensors, and wire and cable. Tyco Electronics Can Help Your Next Lighting Programme To Shine The lighting industry is undergoing rapid changes in the quest for energy efficiency, longer life, and new applications. From stadium displays to residential illumination, innovation in lighting is taking advantage of broad-based technological progress.

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years, Tyco Electronics has worked with leaders in the lighting industry to lower costs, increase reliability, and devise new and novel ways to create and apply lighting products. Today, as the leader in passive electronic components, and with over 500,000 part numbers, we can put our expertise to work on your development programmes. 3 Tyco Electronics 9 ability to serve your present and future requirements is realised through the synergies of a strong R&D programme and our expertise in materials science, product design and process engineering, all supported by our network of knowledgeable application engineers, sales representatives and customer service personnel. GIC Engineering Centres 1. Bangkok 2. Bensheim 3. Greensboro NC 4. Harrisburg PA 5. Kawasaki 6. Kyungsan 7. Menlo Park CA 8. Neunkirchen 9. Shanghai 10. Shenzhen 11. Sydney 12. Turin GIC Manufacturing North America 1. East Providence RI 2. Guaymas MX 3. Hermosillo MX 4. Juarez MX 5. Lancaster PA 6. Lickdale PA 7. Menlo Park CA 8. Portland OR 9. PTP/Reidsville Rd NC EMEA 1. Bideford 2. Collegno 3. Doncaster 4. Grenoble 5. L 8viv 6. Roedermark 7. Swindon 8. Trutnov 9. Waidhofen Asia Pacific 1. Auckland 2. Christchurch 3. Kingsgrove 4. Qingdao 5. Shanghai 6. Shenzhen 1 2 8 7 9 7 6 7 3 3 3 4 3 2 2 2 4 4 4 9 8 10 9 11 12 5 5 5 5 6 8 6 6 1 1 1 Within our development teams, we have the knowledge and the skills which are required to meet the needs of many different applications, ranging from fluorescents and HID lighting to solid state lighting. Our global presence means we operate wherever you do, and we can support you worldwide through a single account management programme, to simplify design and sourcing. Our focus on lighting gives you access to the widest selection of standard and semi-custom products, including: " Connectors and terminal blocks " Wire and cable " Relays " Shrink tubing " Switches from such well-respected brands as AMP, Madison Cable, OEG, Potter & Brumfileld, Raychem and Schrack. Faster Front-End Design With market dynamics forcing ever-shortening design cycles, our ability to quick-turn product concepts will keep your projects on schedule and shorten the time to market. Our capabilities include: " Computer-aided engineering - giving some of the most sophisticated modelling and simulation capabilities in the industry to validate a design before prototyping " Rapid prototyping - from stereolithography for rough 8form and fit 9 evaluation in minutes, to model shops that turn prototypes in days, providing you with product samples quickly and conveniently " CAD model interchange - allowing us to import your CAD files into our system for custom application development. Alternately, we provide our CAD files in a wide range of formats for maximum compatibility, to ease integration of our products into yours. Sharing files is simple, fast and seamless Innovative Engineering for Mechanical, Electrical, and Thermal Performance From extensive research in materials, contact physics and signal transmission - to advanced tools which can model, simulate and validate a design, we understand the requirements of the lighting industry. Every product we design considers the mechanical, electrical and thermal parameters 3 and their interactions. Every design is subject to solid modelling, finite-element analysis (FEA), root-cause failure analysis (RCFA) and failure-mode and effects analysis (FMEA) 3 all supported by extensive design reviews and documentation, so that the design is optimised for its application. As a Six Sigma company with Lean Manufacturing, we are continually improving our processes by reducing variation and eliminating waste. Six Sigma methodologies are part of our culture, which is one that puts design excellence and product quality at the forefront of everything we do. Expertise in Lighting 4 Catalogue No. 1773449-5 tycoelectronics.com/lighting World-Class Test Facilities 5 Our in-house test capabilities include mechanical, electrical and environmental testing, to qualify and validate that our products meet your specifications. Our test labs are approved by Underwriters Laboratories for testing Tyco Electronics 9 passive components, which is your sign that they meet stringent requirements for rigorous and reliable analysis. Routine capabilities include: " Environmental Testing Temperature and humidity Temperature cycling Thermal shock Heat aging " Electrical Contact resistance Dielectric withstanding voltage Temperature rise versus current EMI " Mechanical Vibration Shock Tension/compression Mating cycles Mating/unmating forces Normal force Flex life Crush resistance Your Standards Are Our Standards Our engineering teams have a thorough knowledge of agency standards and regulations. We design and test our products to allow you to satisfy these requirements, through qualification testing, periodic retesting, labelling and marking. We comply with standards from ANSI/AAMI, IEC, UL/CSA, CE, VDE and other international agencies. We comply so you can comply. Fast Access to Information We make it quick and easy for you to find the information you need and to order samples and production parts, as well as to obtain documentation and CAD models. Our Web Site tycoelectronics.com/lighting is your single location for comprehensive product information, including CAD models, product and application specifications, drawings and competitive cross references. Our advanced parametric search engine allows you to find the exact part you need, and all the documentation that goes with it. E-commerce gives you access to ordering, order tracking, distributor inventories, samples and much more. Visit Our Lighting Portal for All Things Lighting To make things easy, we have created an industry-specific site which focuses exclusively on lighting. Here you can find our extensive line of products and solutions for lighting: tycoelectronics.com/lighting tycoelectronics.com/lighting Catalogue No. 1773449-5 6 Catalogue No. 1773449-5 tycoelectronics.com/lighting 7 tycoelectronics.com/lighting Catalogue No. 1773449-5 Street and Stadium Lighting 8 Street and stadium lighting is becoming increasingly more sophisticated. For example, some traffic management systems now monitor traffic flow to determine the required light output. Street and Stadium lighting systems are high voltage (120-480 V depending on location) and they must withstand outdoor environmental factors such as vibration, pollution, temperature change, salt spray and humidity. Yet they must also have a long life and be easily maintained. Amongst a wide range of general interconnection and passive components, Tyco Electronics also offers the following products which address this market: " Transformers " Magnetic wire terminations " Sealed and unsealed interconnect systems " Grounding clips and terminals " High performance cabling Catalogue No. 1773449-5 tycoelectronics.com/lighting Digital Signage 9 Walk through any major city in the world and you 9ll see massive illuminated electronic signs which display advertising, branding and information. Sports stadiums and concert venues also employ large area, high definition signage to show video replays or to allow those at the back to see close-up action. Such systems must withstand all weather conditions and must also be very rugged and reliable, as advertisers won 9t pay if a sign goes dark! For concert venue applications they must also be very quick and easy to install and to remove. Amongst a wide range of general interconnection and passive components, Tyco Electronics offers the following products which address this market: " LED interconnect packaging " Sealed and unsealed data and power connectors " High durability labelling products " Fibre optic products " Over-molded lead frames " Cable assemblies tycoelectronics.com/lighting Catalogue No. 1773449-5 Indoor Lighting 10 There is a worldwide move away from power-hungry incandescent light bulbs, towards more energy-efficient fluorescent and LED lighting. But smaller tubes require dimmable electronic ballasts, whilst LED systems 3 which have very low power and long life 3 require a thorough understanding of solid state driver technology. Legislation aimed at reducing the amount of power we waste, just to illuminate our homes and workplaces, is being introduced in all geographic regions. Amongst a wide range of general interconnection and passive components, Tyco Electronics offers the following products which address this market: " Structured cabling systems " Custom and standard cable assemblies " Labels " Ballast disconnects " Wide range of standard terminals and splicers Catalogue No. 1773449-5 tycoelectronics.com/lighting Architectural Lighting 11 Las Vegas wouldn 9t be the same without the wonderful architectural lighting which emphasises its stunning casinos and hotels. Imagine Paris without an illuminated Eiffel Tower. These systems are often used outdoors, although some buildings are illuminated from within, so they need to be able to withstand all weather conditions. They must also have a long life, which is why many systems are now based on LED technology. And power consumption is also a major consideration of course. Amongst a wide range of general interconnection and passive components, Tyco Electronics offers the following products which address this market: " Sealed, high reliability connectors " Lighting controls " Flexible and modular wiring systems " Structural wiring systems " Shielded interconnects " High performance cable " Sensors " Small pitch connectors tycoelectronics.com/lighting Catalogue No. 1773449-5 Channel/Sign Lighting 12 The massive illuminated company names and advertisements which sit on top of buildings and dominate city skylines are really quite simple backlit constructions. However, they must be durable enough to survive in all weather conditions, and must also be energy-efficient. Solid state (LED) light sources are very popular for this application. Amongst a wide range of general interconnection and passive components, Tyco Electronics offers the following products which address this market: " Sealed IDC connectors " Power connectors " Heat shrink tubing " Sealing materials " Wire management products " Terminal blocks Catalogue No. 1773449-5 tycoelectronics.com/lighting Emergency Lighting 13 As well as providing illumination in case of emergency, illuminated emergency exit signs are now mandatory in public buildings such as stadiums, theatres or offices worldwide. More and more of these systems are moving from incandescent light sources to fluorescent and even LED products, as designers look to find longer lasting, lower power alternatives. Amongst a wide range of general interconnection and passive components, Tyco Electronics offers the following products which address this market: " Energy-efficient bi-stable relays " Battery packs " Wide range of interconnection solutions including wire-to-board and board-to-board products tycoelectronics.com/lighting Catalogue No. 1773449-5 14 Tyco Electronics offers an almost endless range of electrical and electronic interconnection products, as shown throughout this brochure. Our continually- expanding capabilities include new copper and fibre-optic connectors, which are designed to meet the communications and computer industries 9 demands for higher signal speeds and high-density packaging. We strive to provide you with the right connector solution, whether it is a simple wire terminal or a highly sophisticated connector for your next-generation product. Connectors SMT Poke-in Connector This 2-position, low profile SMT wire poke-in connector is designed for LED lighting applications. Available in surface mount tape and reel packaging, the connector is designed to accept a wide range of wire sizes and types. Product Features " Tape and reel packaging for high speed SMT processes " RoHS compliant redundant SMT pads prevent peeling " Rounded corners to minimise shadowing " Side to side stackable, with pads on 4mm centres " Accepts 18, 20, 22 AWG solid wire; 18, 20 AWG pre-bond stranded; 18 AWG stranded " Cost-effective alternative to hand soldering wires " Low profile design " Flat top surface allows for vacuum pick up " High temperature material for reflow processing tycoelectronics.com/lighting LIGHT-N-LOK Connectors A new connector for fluorescent ballast lighting applications, providing a hot-pluggable disconnect to allow safe field servicing, without exposing personnel to electrical shock hazards. Product Features " Available in 2 and 3-position sizes " Poke-in termination for 18 AWG solid wire, for easy tool-less field or factory installation " Integral strain relief prevents inadvertent wire twist-out or pull-out " Designed for hot plugging " Snag-resistant rounded housings " Compact connector housings: 2-position assembly fits through a 5/8 d diameter knock-out opening; 3-position assembly fits through a 7/8 d diameter knock-out opening " Connector latches prevent unintentional disconnect of connector " Standard 3/8 d wire strip length " Can be supplied as pre-assembled mated connector sets, with or without factory installed flying leads " Product is marked (English/French) in support of CSA Luminaire labelling requirements 15 tycoelectronics.com/lighting LED Light Pipe Linear light source using a proprietary large core optical Fibre rod which projects a band of LED-driven light along the entire length of the rod. Product Features " Complete solution with LED, light guide, driver, brackets and cables " Various colours of high power LEDs " Low cost " Options for dimming control " LED light source located on end of light guide rod for remote lighting applications " RoHS compliant tycoelectronics.com/lighting Catalogue No. 1773449-5 IDC Poke-in Wire Tap/Splice Combination tap/splice design to accommodate quick termination of power wiring (tap) out to individual light fixtures (splice). Product Features " Tap termination allows feed-through in 12 AWG (solid or stranded) or 18 AWG THHN/THWN wire " Splice poke-in accommodates two pre-stripped 18 AWG solid wires " Cost-effective termination system for installation of ballast lighting systems 7.5mm Mini HVL Connector The new Tyco Electronics 7.5mm Mini HVL connector series is designed according the IEC 60320 standard for lighting industry applications, where size and easy interconnection are key requirements. It is installable in small fixtures into furniture, ceilings, walls and floors. Applicable in power connection and coupling between lamps such as: " lighting wiring in offices " kitchen, bathroom, shop and household furniture " display cabinets and mountable lighting Description " Connector system available in wire-to-wire configuration " Outlet and plug assemblies with two contact positions " Using widely known MQS contacts " 6 way distributor with additional switch feature Product Features " 7.5mm outer diameter of plug to fit into 8mm furniture holes " Several versions available: 250 VAC, polarised 250 VAC, 125 VAC, 42 VAC and 42 VDC " Ring clip for wire retention, to meet pull test according IEC 60320 " Coupling designed according IEC 60320 " 6 way distributor: " Fast one-stroke IDC termination (pre-assembled contacts) " Switch version available. Special coded red plug for external switch input " Specific red code ring to identify the 7th switch input " Outlet bridge, splitter, panel mount outlet and bus bar. Splitter to expand interconnection 16 Connectors Catalogue No. 1773449-5 tycoelectronics.com/lighting MATE-N-LOK Bulkhead Connector Universal MATE-N-LOK Connector for Sealed Bulkhead Applications Bulkhead mount Universal MATE-N-LOK connector which facilitates sealed panel mounting and works with existing Universal MATE-N-LOK seals, to provide a fully-sealed interconnection system. Product Features " Available in 4, 6, 9 and 12 positions " Sealed flange mount design " Mates to standard Universal MATE-N-LOK plug housings " Accepts standard Universal MATE-N-LOK contacts " Works with standard Universal MATE-N-LOK connector interface and wire seals " Anti-rotation feature aids installation 17 tycoelectronics.com/lighting NECTOR Connector System Description " Connection system for flexible power wiring applications. Suitable for use in suspended ceilings and under raised floors " Intermateable with Wieland's gesis® GST18i3 connector system Product Features " Pluggable electrical installation system " Three possible contact styles: Spring clamp or screw for field installation, and crimped for mass production " Keyed housing to prevent mismatches " COSI housing plus crimp contacts available for high volumes " Frame and shells available to allow both free-hand and panel-mount styles " Pre-assembled leads also available " Locking devices to give improved latching between both interconnection sides according VDE " Tool removable contact tabs according VDE gesis is a trademark of Wieland Electric GmbH tycoelectronics.com/lighting Catalogue No. 1773449-5 Connectors 18 Mini-Universal MATE-N-LOK Sealed Connector System The Mini-Universal MATE-N-LOK sealed connector system is a small wire-to-wire and wire-to-board connector system which provides all the advantages of using a proven product (Mini Universal MATE-N-LOK) but in a splash-proof environment. Conversion to a splash-proof product can be achieved with minimal changes to current Mini Universal MATE-N-LOK connectors. Splash-proof design allows connector system to be used in areas where high humidity, intermittent liquid splashing or foam-in applications cause a requirement for a sealed connector, for improved electrical performance. Applications include appliances, vending and HVAC. Product Features " Dual row, 2 to 10 positions (even only) " Mates with all standard Mini Universal MATE-N-LOK connector housings " Positive, polarised keyed and latched orientation to ease application " Utilises proven Mini Universal MATE-N-LOK contact interface system " Uses existing Mini Universal MATE-N-LOK application tooling " Product has been tested to IP Level 5/7 for 1.02-2.11 [.040-.083] insulation diameter wire Micro MATE-N-LOK Connector The Micro MATE-N-LOK 3mm connector system is a wire-to-wire and wire-to board connector system with contacts on a 3mm [.118] centreline. Both single-row and dual-row configurations are available. Crimp, snap-in pin and receptacle contacts are used to terminate 24-20 [0.2-0.6] and 30-26 [0.05- 0.15] AWG wire. Plug and receptacle housings allow wire-to-wire and wire-to-panel configurations. Header assemblies for wire-to-board interconnections include vertical and right angle components. These IR reflow process compatible headers are available in through-hole and surface mount configurations. Typical uses of the Micro MATE-N-LOK 3mm connector system include the appliance, instrumentation, industrial machinery, home equipment and security system industries. Product Features " Wire-to-wire and wire-to-board pin and receptacle connector system " Contacts are on 3mm [.118] centreline spacing " 2 to 12 contact positions 3 single row " 2 to 24 contact positions 3 dual row " Panel mount or free-hanging wire-to-wire configurations " Dual beam contact design for reliable interconnection " Contacts accept 24-20 [0.2-0.6] and 30-26 [0.05-0.15] AWG wire with insulation diameter of .060 [1.52] maximum " Contacts available in strip form or loose piece " PCB mount pin header assemblies in both vertical and right-angle styles " Surface mount or through hole PCB pin header attachment " PCB headers are IR reflow process compatible " Recognised under the Component Programme of Underwriters Laboratories Inc. to US and Canadian Standards, File No. E28476 " Passed Tests for VDE under registration number 40005280/Continuous Surveillance Catalogue No. 1773449-5 tycoelectronics.com/lighting 19 tycoelectronics.com/lighting Product Features " Compression crimp eliminates cold solder points, weld burns or wire enbrittlement usually associated with thermal-type terminations " Excellent tensile strength-vibration resistant " Provides a superior electrical connection that is free of contaminants such as stripper residue and solder flux " Precision formed, strip-fed terminals and splices terminated in Tyco Electronics automatic machines assure highest possible production rates at the lowest applied cost " Low wire consumption and the elimination of rejects caused by solder flux or heat damage results " Precisely controlled crimp termination helps eliminate human error for maximum reliability AMPLIVAR Terminals and Splices The basic design of the AMPLIVAR wire barrel encompasses two main areas - the burrs at the top of the serrations and the serrations themselves. During the crimping operation, the burrs pierce the insulation of the magnet wire and extrude the bare conductors into the serrations, creating ultimate metal-to-metal contact. AMPLIVAR splices and terminals are specifically designed to terminate magnet wire to itself or in combination with standard solid or stranded lead wire. The AMPLIVAR product line will accommodate a wire range from 400 to 13,000 CMA. In a one-step crimping operation, the magnet wire is automatically ring-stripped of its insulation as it is forced into the wire barrel serrations. The result produces a high tensile strength, air-sealed connection that is as resistant to corrosion as the insulated conductor. As many as three magnet wires can be terminated simultaneously in one barrel. In addition, copper or aluminum magnet wire, or a combination of both, can be terminated. When required, copper or aluminum magnet wire can be combined with pre-stripped standard solid or stranded lead wires. Depending on your specific application, AMPLIVAR splices are available in 5, 7 and 9 serration versions as well as miniature and subminiature designs, for terminations in the 400 to 1600 CMA range. AMPOWER Terminals and Splices The AMPOWER terminal and splice product line is available in a variety of styles to suit your design requirements. AMPOWER terminals and splices are ideally suited for power generation and distribution. This makes electrical equipment such as generators, motors and welders, which are subject to continuous operation, a perfect application for AMPOWER products. In addition, other applications include interconnections of power supplies to computers and peripheral equipment. Product Features " Designed for large cables and leads " Ideally suited for power generation and distribution " Accepts a wide range of stranded copper wires (6 AWG to 1,000 MCM [13-507mm 2 ]--for terminals and up to 1500 MCM [760mm 2 ] for splices) " Available in a variety of terminal and splice styles " High-quality, seamless tubular copper for maximum conductivity " Listed by Underwriters Laboratories, Inc. File No. E12388, Spec. 486 " Certified by the Canadian Standards Association File No. LR7189 tycoelectronics.com/lighting Catalogue No. 1773449-5 AMP Pre-Insulated Closed End Splices AMP Pre-insulated closed end splices have been designed specifically to answer the need for inexpensive, insulated electrical terminations. They can be used in almost every type of commercial application where multiple wires need to be brought together for a reliable termination - e.g. large and small appliances, and the lighting industry. The closed end splice products accommodate wire sizes from 24 through 6 AWG [0.2 to 16mm] 509 to 42,700 CMA. The appeal of closed end splice products lies in their broad range of wire sizes, built-in pre-insulation, ease and speed of application, uniform reliability and low installed cost. As is true of all AMP terminals and splice lines, carefully engineered application tooling has been developed for the closed end splice line to provide uniformly high quality terminations. Tool and terminal have been designed as a team to promote ease and speed of application, whilst at the same time to provide precise crimping pressure for every wire size combination. This connection provides maximum conductivity, tensile strength and high resistance to corrosion. The quality of performance, the facility of installation and the inherent simplicity of closed end splices make them ideal for many industrial applications. Product Features " For single and multiple wire applications " Nylon or vinyl or PVFC insulated " Temperature ratings of 90°C, 105°C, 150°C " 300V, 600V or 1,000V rated " Crescent crimp configuration " Covers wire ranges from 24 to 6 AWG [0.2 to 16mmC] 509 to 42,700 CMA " Copper or steel splice material " Plated or unplated " Solid or stranded copper wire " UL and CSA approved SOLISTRAND Terminals and Splices The proven cW d crimp, applied with precisely controlled pressure, permits the use of a shorter terminal barrel. An excellent feature for confined area termination. The SOLISTRAND terminals and splices, in combination with the cW d crimp, create terminations of optimum electrical properties and are completely reliable, giving long service in hard environments. SOLISTRAND terminals are made of high conductivity copper, electro tinned for improved corrosion resistance. The completely closed barrel with serrations inside provides an optimum tensile strength and maximum electrical contact after crimping. The barrel has a conical entry for easy wire insertion. The cW d crimp is actually two longitudinal crimps, providing that the conductor within the barrel flows together into the serrations or dimples of the terminal barrel, creating one homogeneous mass of copper. The two indents also help to centre the conductor within the barrel for uniform crimping of the barrel around the wire. Because Tyco Electronics matches the terminal to the tool, each termination is uniform, making quality control easy and performance consistent. SOLISTRAND products are UL listed file E 13288 and certified by CSA file LR 7189. Product Features " Utilise a brazed seam " Applied with "W" crimp tooling " Available in wire sizes 26 AWG-600 MCM [0.1-304mm 2 ] " For terminating solid and stranded wires " U.L. listed " CSA certified " Military approved " Budget terminals and splices " Utilise a butted seam " Applied with "F" crimp tooling " Available in wire sizes 26 - 10 AWG [0.1-6.64mm 2 ] " For terminating stranded wire only Connectors 20 Catalogue No. 1773449-5 tycoelectronics.com/lighting 21 tycoelectronics.com/lighting PIDG Terminals and Splices PIDG pre-insulated Diamond Grip terminals and splices are designed for complete and uniform reliability. The pre- insulated termination ensures a vibration-safe connection with maximum conductivity, and its tensile strength approaches that of the wire itself. Each PIDG terminal consists of a tin plated copper body, with a specially designed copper sleeve and insulation sleeve fitted over the terminal barrel. The carefully engineered application tooling has been designed for the PIDG programme, to ensure high quality terminations time after time. Terminal and insulation sleeve are crimped simultaneously, resulting in an excellent tensile strength and vibration resistance. During crimping dot code is applied to the insulation sleeve, to confirm the use of the correct tooling. In order to obtain the best termination results it is important to select the correct tool. Each terminal is matched to a compatible tool. CERTI-CRIMP hand tools are provided with a patented ratchet device to ensure the crimp cycle is completed before releasing. There is a CERTI-CRIMP tool available for each terminal range. Description " Connector system available in wire-to-wire configuration " Outlet and plug assemblies with two contact positions " Using widely known MQS contacts " 6 way distributor with additional switch feature Product Features " Basic terminal is made of high conductivity copper, electro tin plated, for improved corrosion resistance " Applicable wire size is marked on the tongue. " Inner serrations on the wire barrel give maximum electrical contact and tensile strength with the conductor " Copper sleeve provides circumferential insulation support to the wire and allows it to be bent in any direction without damaging the insulation or conductors " Insulation sleeves and corresponding tooling are colour- coded by wire size for easier identification " Tyco Electronics 9 PIDG terminals and splices meet the requirements of MIL-T-7928 " A variety of PIDG terminals and splices are UL listed file E 13288 and certified by CSA file LR 7189 Miniature AMP-IN Terminals The miniature AMP-IN terminal is designed not as an electrical terminal but as a mechanical holding device, to enhance soldering of hookup wires to printed circuit boards. The combination of terminal and application tooling eliminates costly manual preparation of wires prior to soldering, and positions the wire to achieve reliable solder joints. Movement of the wire during soldering is restricted, assuring proper solder flow. tycoelectronics.com/lighting Catalogue No. 1773449-5 Connectors 22 MAG-MATE Terminals The MAG-MATE terminal provides a durable, gas-tight electrical connection without the need to pre-strip the wire. The system uses insulation displacement technology in conjunction with a pre-determined design of plastic terminal pocket, which is moulded into the bobbin frame. This product line is used primarily within the domestic appliance and automotive industries. High speed coiling machines utilise MAG-MATE products, to achieve very significant applied cost savings due to quick and efficient application, especially when compared with soldered assembly. AMP semi-automatic application tooling machines are available for this low cost product. Product Features " Terminates all magnet wire film insulations " Eliminates need for pre-stripping conductors " Eliminates need to post insulate termination " Excess magnet wire is automatically trimmed during the termination process " Simultaneously terminates two magnet wires of the same size in one terminal (for splicing or bi-filing) " Various lead wire attachment options available " Available in strip form, for semi-automatic or fully automatic insertions " Available in loose piece form for hand tool insertions " Varnish-resist tab terminals are available for special applications " High-speed, fully automated integrated systems provide uniform terminations reliability at the lowest possible applied cost " Clean metal-to-metal interface produces stable, gas-tight electrical terminations free of oxides and other contaminants " Recognised under the Component Recognition Programme of Underwriters Laboratories Inc., File No. E13288 Catalogue No. 1773449-5 tycoelectronics.com/lighting 23 tycoelectronics.com/lighting Terminal Block Connectors Terminal Block connectors feature the special rising cage clamp design. The modular design of Terminal Block connectors consists of one-piece board mount terminal blocks and plug connectors, with mating straight and right- angle shrouded headers. A special version - which can be mated either 90° or 180° - completes the product line. Terminal Block connectors offer several advantages: " IR Reflow compatible " Terminal Block connectors have a rising cage clamp which promotes numerous reliable connections and disconnections at field-installations " All blocks are supplied with open screws, which shortens the time for connection " The double captive screw system guards against lost screws " All metal parts are non-magnetic " The housing material used is halogen-free Polyamide 6.6 according to UL 94V-0 (self-extinguishing) " The housing funnel entry design enables an easier product application " The open-bottom design facilitates the PCB washing and reduces trapping of soldering fumes and dirt, with better insulation " Test probe access is available on the board mount connectors to determine if an electrical connection has been made " Contacts are post tin plated with nickel underplate, which allows the product to be used in especially corrosive environments Board mount connectors, as well as PC board plugs and headers, are stackable end-to-end without loss of centreline spacing. Ease of assembly is facilitated by built- in interlocks on the housings. Pre-assembled products can be delivered upon request. Adhesive labels are available to number the cavities. Customer-specific labelling is also available upon request. Terminal Block connectors are interchangeable with most existing products and PC board footprint is fully compatible with existing Industry Standards. Product Features " Certified by the VDE Testing and Certification Institute VDE file No. 6917 (Two-Piece Version) VDE file no. 6920 (One-Piece Version) " Recognised under the Component Programme of Underwriters Laboratories Inc., file no. E60677 " Certified by Canadian Standards Association, file no. LR 703157 " Products under Quality Management System certified to ISO 9001 tycoelectronics.com/lighting Catalogue No. 1773449-5 Connectors 24 Sealed Circular Plastic Connectors (CPC) Sealed CPC connectors are the latest additions to the growing family of Tyco Electronics Circular Plastic Connectors. Sealed CPC connectors were developed as part of the Series 5 and 6 product line, specifically to meet the increasing demand for an economical environmentally sealed connector. Sealed CPC connectors are designed to meet the requirements of UL, CSA and VDE for environmentally sealed connectors used in industrial applications. In addition, sealed CPC connectors are designed to meet the latest SAE and ASAE requirements as outlined in the standards listed here. Sealed CPC connectors incorporate the latest technology in thermoplastic design and use the Powerband precision-formed high current contact. Seen above are the Series 5 (power) and Series 6 (power/signal mix) sealed connector configurations. Other sizes are available in a Series 1 (signal/low current) configuration. Product Features " Economical environmentally sealed connector, designed for industrial applications " Meets major Industrial Standards " High strength, impact resistant thermoplastic housing, rated UL 94V-0 " Contains wire entry, peripheral and full interfacial seals " Type III+ precision formed signal/low current contacts (Series 6) " Other configurations in Series 1 can be made available. Miniature Circular Plastic Connector (Mini CPC) This connector system is available in wire-to-wire, wire-to- board and wire-to-panel configurations. Available in shell size 8 (1 to 4 contact positions) or size 11 (5 to 9 contact positions), this connector system utilises the existing Mini Universal MATE-N-LOK stamped and formed contacts. The contacts are designed for up to 500 mating cycles when plated with gold or up to 50 cycles with tin plating. Industrial, Instrumentation and Transportation applications are ideal for this connector system, where contact density and environmental exposure are primary concerns. Nylon housings offer good resistance to a wide range of chemical agents while the IP67 sealing helps prevent ingress of dirt or fluids, which could have an adverse effect on the contact interface. Product Features " Pre-positioned 1/4 turn coupling ring with positive lock and alignment features " Unique contact pattern for each position size helps prevent accidental mating with other position sizes " Sealed to IP67 " Front or rear jam nut mounting " No assembly required " Receptacle available in free-hanging or panel-mount versions " Alternate keys available Catalogue No. 1773449-5 tycoelectronics.com/lighting 25 tycoelectronics.com/lighting CT (Common Termination) Connector System The Tyco Electronics CT connector system is an automatic harness-making system which provides a range of harness styles by AMP high-speed automatic crimping machines, using three types of 2mm centreline connectors -- MT connectors, MT AMP-IN vertical connectors and MT AMP- IN horizontal connectors. Contacts are on 2mm centreline with all connectors and the spacing between the housing end and the centreline of the contact cavity at either end is also 2mm. Harnesses can be assembled in any of the six configurations shown in the following pages. A variety of harness-making machines are available, ranging from hand tools for low volume production to high-speed automatic crimping machines for medium to high volume productions. Both discrete wire and flat shielded cable can be used for this system, and a new generation of high-speed automatic crimping machine is now available, which allows these two types of cable to be used singly or mixed in one connector. Tyco Electronics 9 high-speed automatic crimping machines are easy to operate, eliminating the need for the tedious job of changing parts inside the equipment in order to adapt to changes in harness styles. Product Features " 2.0mm pitch " SMT and through-hole headers available " Pre-loaded housings available " Various colour options AMPMODU Interconnection System The AMPMODU interconnection system continues to be one of the most significant product families within Tyco Electronics. Widely used across all industries, these products provide core interconnect functionality, allowing our customers 9 designs to be reliably and efficiently realised. Within the AMPMODU interconnection range, requirements for board-to-board, wire-to-board and wire-to-wire connection are provided through a comprehensive range of interconnect components - in a wide choice of packaging densities, mounting styles and product features. Our capability in product breadth is unrivalled. As many of these products are mature in nature, it is all too easy to overlook their important ongoing contribution, and their continual necessity to our customers. Product Features " Key interconnection standard with ongoing market need " Wide product range, offering versatile solutions tycoelectronics.com/lighting Catalogue No. 1773449-5 Connectors 26 AMP-Latch Connectors The mass termination capabilities of the AMP-LATCH connector family have helped make ribbon cable, and particularly .050 [1.27] centreline cable, popular within the electronics industry. The ability to terminate up to 64 conductors simultaneously, without stripping or otherwise preparing the cable, presents obvious labour savings. AMP-LATCH connectors are wire-to-board devices which are used to make the transition between cable and PC board circuitry. They are used heavily within equipment which is designed to connect one board to another, or one subsystem to another. The connectors are also used in input/output applications, to connect different pieces of equipment. Product Features " Connectors recognised under the Component Programme of Underwriters Laboratories Inc. File No. E28476 " Cable recognised under the Component Programme of Underwriters Laboratories Inc. " Connectors CSA certified, file no. LR-7189 " No cable stripping; simultaneous termination of all conductors " One-step termination with AMP application tooling " Terminates varying thicknesses of flat, woven, shielded (properly prepared) and other ribbon cable with conductors on .050 [1.27] centres as well as discrete wires " Self-registration of wires--compatible product and tooling designs eliminates registration problems Micro-MaTch Miniature Connector The demand for high-density packaging of electronic equipment is ever-increasing. For these applications Tyco Electronics has developed the Micro-MaTch connector system. The primary benefit of this system, when compared to miniature connectors, is its robust construction - with separated contact spring functions for optimum contact. The centreline is 1.27mm, staggered. The connector system is available in an even number of positions, from 4 to 20 for wire-to-board connections with AWG 28 wires and board- to-board applications in standard or surface mount soldering technique. The tin plated contact system is fretting corrosion proof. Product Features " Vertical and right-angle header configurations " Board-to-board stacking possible " Cable of terminating discrete wire " Wide selection of sizes in all configurations " Positive, uniform latching of contacts and housing with cover eliminates cover warpage " Easy, visual inspection of terminations during assembly; electrical probing capability after assembly " All polymeric parts manufactured from a UL Recognised 94V-0 rated material " Receptacles with recessed covers provide positive locking feature for ejection style pin headers with latches " Pinless headers with clearance-fit or press-fit onto .025 [0.64] sq. posts pre-installed in pc board " Shielded connectors provide RFI/EMI protection Catalogue No. 1773449-5 tycoelectronics.com/lighting 27 FASTON Terminals and Connectors/FASTON Connection System The Tyco Electronics FASTON terminals product line consists of receptacles, tabs and splices specifically designed for quick connections. The large variety of sizes and types available will enable you to select a contact to fit your needs. Receptacles are available in both straight and flag type, come in a variety of sizes and are designated numerically by a series number which corresponds to the width of the mating tab. Straight receptacles are available with or without insulation support. Insulation diameters of 1.2mm to 6.7mm are accommodated by the insulation support receptacle. The product line offers speed application, uniform reliability and low per line cost. Speed application is achieved through the use of application tools, for which a complete line has been developed specifically for these terminals. Over forty years of history has proven the reliability of this product line. Built-in features, also add to the reliability of FASTON products, include: " crimping dimensions for each terminal which are precisely controlled, providing all connections with excellent performance " low per line cost, derived from low initial product cost " high application speeds The combination of these features brings the user the lowest overall costs for quick connect/disconnect terminations. Product Features " Straight right-angle and receptacle-tab combinations available " Receptacles available for 6.3 - 4.8 - 2.8mm tab size (.250- .187- .110 Series) " Receptacles mate with 0.5 and 0.8mm thick tabs " Low insertion force (LIF) receptacles available " IEC 60335-1, Glow Wire 750° NO FLAME housings available " RoHS compliant Fibre Optic With more than 30 years experience, we are a world- leading manufacturer of fibre optic connectors, backplane interconnects, cable assemblies, adapters and accessories, complemented with active and passive components and fibre management systems. We provide high-level engineered solutions with reliable, advanced-technology optical products that connect, configure, create and control light. Connect Light " Fibre optic connectors, cable assemblies, adapters and accessories " High-density PARA-OPTIX cable assemblies " Optical backplane interconnects Create Light " LDI fibre optic communication components " LDI fibre optic high-power products Control Light " Fibre optic attenuators " Fibre optic switches Configure Light " Fibre management and packaged solutions Catalogue No. 1773449-5 tycoelectronics.com/lighting Battery Packs Tyco Electronics 9 battery systems offer customised solutions for portable electronic devices and stationary backup power applications. Our flexible volume manufacturing facilities, which are located in low cost regions, coupled with our in-house component, cell and pack qualification processes, add up to a total design, test and manufacturing solution. Our test laboratories are certified to UL1642 and UL2054 safety standards and are IEEE 1625 & 1725 compliant. With senior representation on the UL Standards Technical Panel (UL1642 & UL2054) and IEEE-P1725 Work Group, and established relationships with key supply chain vendors (especially cell suppliers and chipset providers) our dedicated development team provides quick and efficient customer support worldwide. Industrial Ethernet - Circular Sealed RJ-45 Connectors This new rugged connector series meets the Ethernet/IP RJ45 requirements/standards. Designed for use in harsh environments, the connector features a quick-connect bayonet coupling mechanism which meets the Open Device-Net Vendors Association (ODVA) interoperability interface specification. Applications include industrial machinery, diagnostic equipment, communications equipment, printers and any potential applications where Ethernet is used in connectors that require a sealed, rugged interface. Product Features " For Category 5e Cable " Sealing performance per IP 67 " Protective cover available for the receptacles " Positive lock coupling ring provides reliable connections in harsh environments " Available pass-through and field installable receptacle styles " Bulkhead receptacle mounts to either outside or inside panel cutout " Temperature Range is -40°C to +85°C [-40°F to +185°F] Connectors 28 Catalogue No. 1773449-5 tycoelectronics.com/lighting Ultra-Fast Fully Insulated, FASTON Receptacles and Tabs The Ultra-Fast fully insulated FASTON receptacle and tab offers the advantage of a completely protected terminal, and a wire crimp which has comparable electromechanical performance to open barrel cF d crimp FASTON terminals. The cuser-friendly d design combines easy mating with rounded corners. The .187 and .250 series receptacles incorporate a two-stage roll configuration and a cantilever 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 in order to help prevent shock hazards. In addition, electrical short circuits from exposed leads are eliminated, even in equipment which requires close contact spacing. The Ultra-Fast FASTON receptacle, flag receptacle and tab are pre-insulated assemblies, featuring a housing which is 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, Tyco Electronics provides a complete selection of terminating equipment, from hand tools to automatic lead makers. Product Features " 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 colour-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) 29 tycoelectronics.com/lighting Catalogue No. 1773449-5 Autotransformers These 4500 series autotransformers are designed to step 480 VAC, 60 Hz. line voltage down to 277 VAC, for fluorescent lighting fixture ballasts in commercial lighting systems. Standard units available in 230 VA and 460 VA models. Product Features " Excellent regulation in a cost-effective, single-winding design " Colour coded 18 AWG leads for wiring " Welded brackets for mounting convenience " Butt stack and weld construction with a molded bobbin " Molded coil cover provides integral strain relief for the leads " UL Recognised to US and Canadian standards " Custom sizes, termination and mounting options available Grounding Clips Tyco Electronics 9 grounding clips are designed to provide a secure push-on ground. The push-on installation technique eliminates the need for drilling holes and scraping paint, as is required in a typical ground termination. Product Features " Terminals provide hand applied, tool-less connections to metal panels " Designed to pierce through enamelled painted sheet metal panels " Accepts panel thickness ranging from .020 to .041 " Available to terminate to 22-14 AWG lead wire " Manufactured out of steel, stainless steel or tin plated phosphor bronze material Connectors 30 Catalogue No. 1773449-5 tycoelectronics.com/lighting MTA 100 Connector MTA 100 connectors accept discrete and ribbon cable wire sizes ranging from 22-28 AWG [0.4-0.08mmC], with maximum insulation outside diameter of .060[1.52] for terminating single wire and .050[1.27] for mass termination of wires. Tin plated solid, fused stranded, or stranded (7 strands) wire with PVC insulation can be used on 22-28 AWG [0.4-0.9mmC] MTA 100 connectors, and 19 stranded wire on 22-24 [0.4-0.2mmC] MTA 100 connectors. Only one wire to be terminated into an IDC contact slot. The wire-to-post connector housing material is flame retardant thermoplastic, either UL94V-2 or UL94V-0 rated. A full line of .100[2.54] centreline headers completes the system. Headers are available with straight or right angle posts, in flat, polarised or friction lock styles. Headers are available in 2 to 28 positions. Shrouded headers are available in 2 to 14 positions. Product Features " Connectors and headers for 2 to 28 positions; wire sizes of 22, 24, 26, and 28 AWG [0.4-0.08] mmC " Wire-to-post connectors pre-loaded with dual beam contacts " Connectors and headers, except shrouded headers, are end-to-end stackable " Connector styles include both closed end and feed through connectors with locking ramps, with and without polarising tabs " Molded ribs on housing do not allow reverse mating " Posted connectors for 2 to 19 positions " Connectors pre-loaded with IDC contacts " All contacts are slotted for insulation displacement (IDC) terminal technique " Contacts are lubricated for fretting corrosion protection " Benefits derived from the MTA 100 system include increased quality and ease of handling such as: " One step assembly " No wire stripping " No contact damage " Reduced wiring errors " Simpler tooling " Simple maintenance and repair " Meets the material requirements of Table 23.1 of UL1410 standards for television receiver and video products (wire-to-wire post connectors only) 31 tycoelectronics.com/lighting Catalogue No. 1773449-5 Tyco Electronics provides wire and cable solutions for challenging environments and demanding applications. The product range includes high performance insulated wires, coaxial and data bus cables, power cables, electronics wire and multicore cables. Heat Shrink Tubing With today 9s installation techniques, heat shrinkable products can simply not be ignored. Due to easy processing and shrinking at relatively low temperatures, these products can be used in many applications. With a top performance at a low price, shrink products make it possible to accomplish lasting, safe mechanical and electrical protection of various parts. They also allow repairing of cables and cable connections. For the production of prototypes or small runs, we offer kits with several different types of shrink tubing. For other applications we also offer an extensive range of heat shrinkable tubing. Description " Low cost, flame retardant, standard grade polyolefin " Thin wall heatshrink, 2:1 shrink ratio " Available in key electrical colours " Supplied in dispenser packs, multi packs and bulk reels Wire, Harness and Protection 32 tycoelectronics.com/lighting Cable Ties, Mounts and Accessories Today, there is an increasing demand for cable ties, to bundle and fasten wires and cables quickly and economically in various application areas. Tyco Electronics has extended the existing AMP-TY cable tie range to satisfy the present and future market requirements. The range consists of the most commonly-used sizes, materials and colours with customer-friendly packaging. The AMP-TY range now offers an almost unlimited number of possibilities. As always, we have put great emphasis on the introduction of a quality range, attractively priced, with on-time delivery, backed up by qualified sales and technical staff. Product Features " Self-locking head ensures stable binding power even under extreme conditions - e.g. temperature and vibration " Interior serrations help to hold individual wires or bundles firmly in place through friction " Tapered tip, often with the cbent tail d facility for easy insertion, speeds up threading and reduces applied cost " Tough, smooth polyamide may be used for indoor and outdoor applications. Black UV resistant ties are recommended for outdoor use " The all synthetic one-piece design eliminates metal parts " AMP-TY cable ties can be hand applied or by using application tools 33 Raychem SolderSleeve Terminations Tyco Electronics' dependable, economical wire and cable termination products provide solutions for hundreds of wire and cable interconnect requirements. All Raychem wire termination products are housed inside transparent heatshrinkable insulation sleeves, which allow for inspection and can provide various levels of environmental protection. Most Raychem termination products incorporate a fluxed solder preform, which is essential for a highly controlled soldering process. Other products incorporate controlled crimping, or a unique process of combining a twist-on coil with controlled soldering, to provide high reliability joints on the widest variety of conductor types and platings. SolderSleeve termination technology ensures high-quality electrical and mechanical performance time after time. Pre-measured solder and flux create repeatable, reliable terminations, reducing rejects and field failures. When the SolderSleeve termination device is heated, the tubing shrinks and the solder preform melts to make a fully insulated, strain relieved protected solder connection. Heat-shrinkable tubing provides the benefits of insulation, strain relief, and protection for our controlled crimp products. Many Raychem interconnect products have earned UL recognition or MIL-Spec approval. Many SolderSleeve and related devices are made from polyvinylidene fluoride tubings that meet the requirements of AMS-DTL-23053/8 (formerly MIL-DTL-23053/8). Raychem interconnect devices combine high strength materials with innovative design for consistent, long-life performance. And because the insulation sleeve is transparent, operators can easily inspect the connection. Raychem shrink-to-fit technology even helps reduce inventory, because one device size will fit a wide range of wire gauges, cable diameters and component shapes. Raychem interconnect products are designed for many applications, from simple splices to terminators for sophisticated electronic systems, either sealed or unsealed, and for high or low temperature environments. tycoelectronics.com/lighting Catalogue No. 1773449-5 34 High Current Inrush Relay The RT-i Power (RT-inrush Power) relay is the new high- end member of the RT relay family. Designed for peak inrush currents up to 800Amps, and with a rated carry current of 16Amps, the RT-i Power relay is capable of switching a variety of capacitive and lighting type loads, especially incandescent and fluorescent lamps. The RT-i Power relay has an industry standard footprint to enable product upgrade, with pinning compatibility to the Tyco Electronics Schrack 409 47/67, 429 03, RT Inrush and RP3SL relay types. Available in either monostable (DC) or bistable/latching (with the option of a manual actuator) coils the RT-i Power relay meets the requirements of most installation applications. Product Features " 1 N/O contact (W pre-make contact + AgSnO) " Rated current 16A " Inrush peak currents: 800A/100 s; 165A/20ms " Monostable DC coil (400 mW) or bistable coil versions " Reinforced insulation " Ambient temperature to 85°C " Manual operator optional on bistable versions " Meets RoHS and WEEE requirements (e.g. lead free, cadmium free contacts) Tyco Electronics offers the broadest range of relays and contactors in the world. Switching capabilities range from dry circuit to 1,600A, up to 70kV, and as high as 6 GHz. Electromechanical, solid state and hybrid types range from SMT PC board mount devices to large panel mount units. Our broad line of Relays features expansive sets of options for enclosure, termination, input, contact arrangement and rating. Tyco Electronics can provide virtually any type of switch you need. From miniature printed circuit board mounted DIP switches to rugged oil-tight switches for industrial controls, we provide reliable, cost-effective performance. Tyco Electronics 9 switch products also include knobs, boot, caps and other accessories. Relays and Switches tycoelectronics.com/lighting Pushbutton Switches The Tyco Electronics range of pushbutton switches is designed to be cost-effective, reliable and to enhance productivity. Product Features " High temperature plastics 3 liquid crystal polymer (LCP) " Tin-lead plated terminals " Washable process sealed construction 3 internal actuator O-ring " Silver and gold plating options " Sealed switches available " Through-hole or surface mount PC tails or panel mount options " Straight or right-angle option available " Large variety of button styles and switching functions " Wide range of physical sizes and current ratings DIP Switches The Tyco Electronics range of DIP switches is designed to be cost-effective, reliable and to enhance productivity. Product Features " Full line of DIP switches with different profiles " Different actuator styles available 3 piano, extended, rocker, flush " Piano and slide styles that don 9t require sealing in order to go through wash process " Half pitch .050 d terminal spacing (GDH version) " Variety of rotary DIP switches with different body sizes available (9mm and 7mm) " Available in through-hole and surface mount " Available in optional tape and reel packaging " Variety of SIP switches available " Multiple sizes of DIP shunts available 35 tycoelectronics.com/lighting Catalogue No. 1773449-5 Identification 36 Identification Tyco Electronics offers a wide range of products that will last and perform in the most extreme indoor/outdoor conditions. Our focus is on supplying high quality materials and adhesives that meet or exceed industry standards. We specialise in custom and pre-print adhesive-backed labels that support the needs of aerospace, electronics, rail, defence/marine, industrial and medical markets. In addition, we offer a complete line of laser engraved labels and markers. Product Features " We can design these for you, or use existing customer- specific logos, artwork and brand identification " Colour matching " Custom shapes " UL and CSA certified base materials " Equipped to hold tight tolerances " Custom data to print: Static, sequential numbers, " 2D data matrix and bar codes available " High and low temperature materials " Special adhesives " Laminates available Additional Identification Products T107M Handheld printer CWM Wire marker cards WCD Write-on self-laminating label dispensers CMD Cable and wire marker dispenser EP Economy paper labels M Metalised polyester labels Catalogue No. 1773449-5 tycoelectronics.com/lighting 37 Application Tooling Our application tooling capability includes a comprehensive portfolio of hand tools, semi-automatic bench machines and fully-automatic machine systems for processing terminal products. We provide customers with the best possible and most economical overall system solutions. Application Tooling " Hand tools " Semi-automatic bench machines " Magnet wire terminating equipment " Advanced wire processing machines " High-speed blockloaders " Lead makers " Harness makers " Mass termination machines " Insertion and seating machines " Crimping machines " IDC/Ribbon cable assembly machines " Wire seal applicators " Precision applicators PC Board Assembly Equipment " Press-fit assembly equipment " De-panelling equipment Application Tooling tycoelectronics.com/lighting Catalogue No. 1773449-5 Finding Lighting Solutions online Find Our Web Site tycoelectronics.com/lighting is your single location for comprehensive product information, including CAD models, product and application specifications, drawings and competitive cross references. Our advanced parametric search engine allows you to find the exact part you need, and all the documentation that goes with it. E-commerce gives you access to ordering, order tracking, distributor inventories, samples and much more. Visit Our Lighting Portal for All Things Lighting To make things easy, we have created an industry-specific site that focuses exclusively on lighting. Here you can find our extensive line of products and solutions for lighting: tycoelectronics.com/lighting Fast Access to Information We make it quick and easy for you to find the information you need and to order samples and production parts, as well as to obtain documentation and CAD models. tycoelectronics.com/lighting 38 39 tycoelectronics.com/lighting Reference Guide 40 Crimp Technology Quality Guidelines Catalogue No. 1773449-5 tycoelectronics.com/lighting 41 Conductor brush protruding into termial body tycoelectronics.com/lighting Catalogue No. 1773449-5 42 Wire size in AWG and mmffi to CMA CMA Nominal Wire Size Strands Strands Diameter Approximate Conductor Diameter AWG mm 2 Number inch mm inch mm 159 28 0.08 1 .0126 0.320 .013 0.32 175 28 0.09 7 .0050 0.127 .015 0.38 181.5 28 0.09 19 .0031 0.079 .016 0.40 198 27 0.10 51 .0020 0.050 .016 0.42 202 27 0.10 1 .0142 0.361 .014 0.36 238 26 0.12 6 .0063 0.160 .018 0.46 250 26 0.13 10 .0050 0.127 .018 0.46 250 26 0.13 26 .0031 0.079 .018 0.46 251 26 0.13 8 .0056 0.142 .018 0.46 253 26 0.13 1 .0159 0.404 .016 0.40 256 26 0.13 16 .0040 0.100 .018 0.46 278 26 0.14 7 .0063 0.160 .019 0.48 279 26 0.14 72 .0020 0.050 .022 0.56 279 26 0.14 18 .0039 0.102 .022 0.56 300 26 0.15 3 .0100 0.254 .020 0.51 304 26 0.15 19 .0040 0.100 .020 0.51 314 25 0.16 1 .0177 0.450 .018 0.45 314 25 0.16 10 .0056 0.142 .020 0.51 318 25 0.16 8 .0063 0.160 .021 0.53 320 25 0.16 1 .0179 0.455 .018 0.46 388 24 0.2 1 .0197 0.500 .020 0.50 395 24 0.2 102 .0020 0.050 .020 0.51 397 24 0.

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