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catalog c-039 rev. nc 1
p ower c onnection s ystems positronic industries connectpositronic.com mixed density power connectors t est conducted in accor dance with ul1977. all po wer contacts under load. 10w2 : curve developed using plb10w2f9300a1 and plb10w2m0000 connectors with mc4008d contacts terminated to 8 awg wire . 16w4 : curve developed using plc16w4f9300a1 and plc16w4m0000 connectors with mc4008d contacts terminated to 8 awg wire. 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 110 120 temperature rise (?) rated current (amps) plb10w2 standard contacts plc16w4 standard contacts t est conducted in accor dance with ul1977. all po wer contacts under load. 10w2 : curve developed using plbh10w2f9300a1 and plbh10w2m0000 connectors with mc4008ds contacts terminated to 8 awg wire . 16w4 : curve developed using plch16w4f9300a1 and plch16w4m0000 connectors with mc4008ds contacts terminated to 8 awg wire. 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 110 120 temperature rise (?) rated current (amps) plbh10w2 high conductivity contacts plch16w4 high conductivity contacts temperature rise curves unless otherwise specified, dimensional tolerances are: 1) ?.001 inches [0.03 mm] for male contact mating diameters. 2) ?.003 inches [0.08 mm] for contact termination diameters. 3) ?.005 inches [0.13 mm] for all other diameters. 4) ?.015 inches [0.38 mm] for all other dimensions. products described within this catalog may be protected by one or more of the following us. patents: #4,900,261 #5,255,580 #5,329,697 #6,260,268 #6,835,079 #7,115,002 patented in canada, 1992 other patents pending positronic industries believes the data contained herein to be reliable. since the technical information is given free of charge , the user employs such information at his own discretion and risk. positronic industries assumes no responsibility for results obtained or damages incurred from use of such information in whole or in part. positronic industries federal supply code (cage code) for manufacturers is 28198 st and ard cont a ct ma terial high conductivity cont a ct ma terial connectors designed to customer specifications positronic connectors can be modified to customers specifications. examples: select loading of contacts for cost savings or to gain creepage and clearance distances; longer pcb terminations; customer specified hardware. contact technical sales with your particular requirements.
p ower c onnection s ystems positronic industries connectpositronic.com 3 dimensions are in inches [millimeters]. all dimensions are subject to change. mixed density power connectors materials and finishes: insulator: glass-filled polyester, ul 94v-0. contact technical sales for availability of high temperature insulator material. contacts: precision machined copper alloy with gold flash over nickel, or 0.000030 inch [0.76? gold over nickel, or 0.000050 [1.27? gold over nickel. solder coated terminations optional. mounting clip: beryllium copper with tin plate. hood: glass filled polyester, ul 94v-0. mounting bracket: brass with tin plate. push-on fastener: spring tempered copper alloy, tin plate electrical characteristics: signal cont a cts contact current rating: 7.5 amperes nominal. initial contact resistance: 0.007 ohms max. per iec 512-2, test 2b po wer cont a cts contact current rating: see temperature rise curves on page 2. for additional information see page 7. initial contact resistance: standard conductivity: 0.0005 ohms max. per iec 512-2, test 2b. high conductivity: 0.0003 ohms max. per iec 512-2, test 2b. shielded cont a cts initial contact resistance: 0.008 ohms maximum. nominal impedance: 50 ohms. insertion loss: -0.46 db at 1 ghz -1.5 db at 2 ghz vswr: 1.15 average at 1 ghz 1.56 average at 2 ghz above values measured using frequency domain techniques. proof voltage: 1000 v r.m.s. high v ol t a ge cont a cts flash over voltage: 3600 v r.m.s. proof voltage: 2700 v r.m.s. initial contact resistance: 0.008 ohms maximum. connect or insulation resistance: 5 g ohms per iec 512-2, test 3a, method a. working voltage: 600 v rms. voltage proof: 2200 v rms per iec 512-2, test 4a, method c. clearance and creepage distance: 0.080 inch [2.03 mm] working temperature: -55? to +125?. mechanical characteristics: signal cont a cts removable: insert contact to rear face of insulator, release from front face of insulator. size 20 contacts, 0.040 inch [1.02 mm] diame- ter male contacts, closed entry design female contacts. fixed: straight solder, 90 solder and straight compliant press-fit printed board mount terminations. size 20 contacts, 0.040 inch [1.02 mm] diameter male contacts, open entry design female contacts. po wer cont a cts: removable: insert contact to rear face of insulator, release from front face of insulator. size 8 contacts, 0.142 inch [3.61 mm] diameter male contacts, closed entry design female contacts. printed board mount: straight solder, 90 solder and straight compliant press-fit printed board mount terminations. size 8 contacts, 0.142 inch [3.61 mm] male contacts, closed entry design female contacts. shielded cont a cts: removable: insert contact to rear face of insulator, release from front face of insulator. size 8 contacts. see page 9 table of cable sizes for contact termination dimensions. high v ol t a ge cont a cts: removable: insert contact to rear face of insulator, release from front face of insulator. size 8 contacts. straight and 90 terminations. 0.041 inch [1.04 mm] minimum hole diameter. contact terminations: 20-24 awg [0.5-0.25mm 2 ] removable crimp signal, 0.028 inch [0.71 mm] diameter straight and 90 solder printed board mount, 8-16 awg [10.0-1.0mm 2 ] removable solder and crimp power, 0.125 inch [3.18 mm] diameter straight and 90 solder printed board mount, power, shielded, high voltage cable, and straight compliant press-fit terminations. contact retention in insulator: fixed signal - 9 lbs. [40 n]. removable signal - 10 lbs. [44n]. power, shielded and high voltage - 22 lbs. [98 n]. resistance to solder iron heat: 500 f [260 c] for 10 second duration per iec 512-6, test 12e, 25 watt soldering iron. connection systems: connector provides cable to cable, cable to printed board, cable to panel mount and printed board to printed board application. locking system: insulators provide locking between cable to cable, cable to printed board and cable to panel mount applications. polarizations: provided in insulator design. mounting to printed board: rapid installation push-on fasteners. self-tapping screws for compliant connectors. mechanical operations: 500 operations per iec 512-5. technical characteristics p o s i t r o n i c i n d u s t r i e s ? p e r e u d i r e c t i v e 2 0 0 2 / 9 5 / e c ? rohs r o h s compliant for rohs options, see page 15. ul and csa recognition is in process.
p ower c onnection s ystems positronic industries connectpositronic.com mixed density power connectors 4 dimensions are in inches [millimeters]. all dimensions are subject to change. male and female insulator dimensions for cable connectors featuring integral locking system and removable contacts code 0 male female male female for removable contact options, see page 6, 7, 8 and 9. for panel cutout, see page 14. plb(h)10w2 plc(h)16w4
p ower c onnection s ystems positronic industries connectpositronic.com 5 dimensions are in inches [millimeters]. all dimensions are subject to change. mixed density power connectors male and female insulator dimensions for panel mount connectors with removable contacts code 1 male female male female for removable contact options, see page 6, 7, 8 and 9. for panel cutout, see page 14. plb(h)10w2 plc(h)16w4
p ower c onnection s ystems positronic industries connectpositronic.com mixed density power connectors 6 dimensions are in inches [millimeters]. all dimensions are subject to change. male contact female contact removable crimp signal contacts contacts must be ordered separately. female contact part number wire size awg [mm 2 ] a b fc720n2 20 / 22 / 24 [0.5 / 0.3 / 0.25] 0.045 [1.14] 0.068 [1.73] male contact part number wire size awg [mm 2 ] a b mc720n3 20 / 22 / 24 [0.5 / 0.3 / 0.25] 0.045 [1.14] 0.068 [1.73] material: copper alloy plating: standard finish: 0.000010 [0.25 ? gold over nickel or copper. optional finishes: 0.000030 [0.76 ? gold over nickel by adding ?14 suffix onto part number. example: fc720n2-14 0.000050 inch [1.27? gold over nickel by adding ?15 suffix onto part number. example: mc720n3-15 . for information regarding crimp tool and crimping tool techniques, consult technical sales. sa ve time and money ! let positronic support your connector requirements by cablizing your power connector selection. positronic offers technical support and manufacturing capability for cablized connectors. contact your factory direct sales representative for details! design and t esting ser vice positronic industries engineering department: 1. works closely with customers. 2. prepares component and cablized connector systems, hardware design, and performance specifications. 3. designs each system in accordance with applicable customer, domestic, and international standards. 4. defines and directs required performance and verifi cation testing. positronic cablized connectors springfield cable assembly quality assurance puerto rico cable assembly engineering management
* female contact closed entry, l.s.a. 0.142 [3.61] male contact 0.354 [8.99] 0.354 [8.99] 0.142 [3.61] *note: female contacts feature large surface area (l.s.a.) closed entry contact design which provides maximum mating surfaces between male and female contact and reduced contact resistance during operation. material: copper alloy. plating: standard finish: gold flash over nickel plate. optional finishes: 0.000030 [0.76 ? gold over nickel by adding ?14 suffix onto part number. example: fc4008d-14 0.000050 inch [1.27? gold over nickel by adding ?15 suffix onto part number. example: mc4012d-15 . for information regarding crimp tool and crimping tool techniques, consult technical sales. p ower c onnection s ystems positronic industries connectpositronic.com 7 dimensions are in inches [millimeters]. all dimensions are subject to change. mixed density power connectors male contact * female contact closed entry, l.s.a. removable crimp power contacts contacts must be ordered separately. female contact part number current rating wire size a b fc4008d see temp. rise curve, page 2. 8 0.858 [21.79] 0.181 [4.60] fc4008ds see temp. rise curve, page 2. 8 0.858 [21.79] 0.181 [4.60] fc4010d 30 amps 10 0.858 [21.79] 0.122 [3.10] fc4012d 20 amps 12 0.858 [21.79] 0.101 [2.57] fc4016d 10 amps 16 0.858 [21.79] 0.067 [1.70] male contact part number current rating wire size a b mc4008d see temp. rise curve, page 2. 8 0.882 [22.40] 0.181 [4.60] mc4008ds see temp. rise curve, page 2. 8 0.882 [22.40] 0.181 [4.60] mc4010d 30 amps 10 0.882 [22.40] 0.122 [3.10] mc4012d 20 amps 12 0.882 [22.40] 0.101 [2.57] mc4016d 10 amps 16 0.882 [22.40] 0.067 [1.70] removable solder cup power contacts contacts must be ordered separately. *note: female contacts feature large surface area (l.s.a.) closed entry contact design which provides maximum mating surfaces between male and female contact and reduced contact resistance during operation. part number current rating wire size a ref. b c fs4008d 40 amps 8 0.858 [21.79] 0.219 [5.56] 0.188 [4.78] fs4012d 20 amps 12 0.858 [21.79] 0.143 [3.63] 0.112 [2.84] fs4016d 10 amps 16 0.858 [21.79] 0.100 [2.54] 0.069 [1.75] part number current rating wire size a ref. b c ms4008d 40 amps 8 0.868 [22.05] 0.219 [5.56] 0.188 [4.78] ms4012d 20 amps 12 0.868 [22.05] 0.143 [3.63] 0.112 [2.84] ms4016d 10 amps 16 0.868 [22.05] 0.100 [2.54] 0.069 [1.75] material: copper alloy. plating: standard finish: gold flash over nickel plate. optional finishes: 0.000030 [0.76 ? gold over nickel by adding ?14 suffix onto part number. example: fs4008d-14 0.000050 inch [1.27? gold over nickel by adding ?15 suffix onto part number. example: ms4012d-15 . ? in part number indicates high conductivity material. compatible with pl*h pcb mount connectors. see ordering information.
p ower c onnection s ystems positronic industries connectpositronic.com mixed density power connectors 8 dimensions are in inches [millimeters]. all dimensions are subject to change. removable high voltage contacts contacts must be ordered separately. straight solder wire termination 90 solder wire termination 20 awg max. 20 awg max. 20 awg max. 20 awg max. 0.734 [18.64] ref. 0.697 [17.70] ref. 0.697 [17.70] ref. 0.142 [3.61] 0.142 [3.61] 0.040 [1.02] 0.040 [1.02] 0.734 [18.64] ref. ms4820d ms4920d fs4820d fs4920d materials and finishes: insulators: teflon, ptfe. contacts: male contacts, brass. female contacts, phosphor bronze. plating: standard finish: 0.000030 [0.76] gold over nickel optional finish: 0.000050 [1.27? gold over nickel available by adding -15 suffix on part number. example: ms4920d-15 . electrical characteristics: high voltage contacts flash over voltage: 3600 v r.m.s. proof voltage: 2700 v r.m.s. initial contact resistance: 0.008 ohms maximum. mechanical characteristics: size 8 removable contacts: rear insertion, front release. durability: 500 cycles minimum. vibration: 20g from 10 hz to 500 hz. shock: 30g-11ms. climatic characteristics: temperature range: -55?c to +125?c. technical characteristics male contact male contact female contact female contact
p ower c onnection s ystems positronic industries connectpositronic.com 9 dimensions are in inches [millimeters]. all dimensions are subject to change. mixed density power connectors removable shielded contacts contacts must be ordered separately. straight solder/crimp contacts straight solder/solder contacts straight crimp/crimp contacts 0.040 [1.02] 0.040 [1.02] 0.040 [1.02] 0.152 [3.86] 0.152 [3.86] 0.152 [3.86] type of contact part number a b rg cable number male female solder/crimp mc4101d fc4101d 0.929 [23.60] 0.040 [1.02] 178 b/u 196 b/u solder/crimp mc4102d fc4102d 0.929 [23.60] 0.067 [1.70] 179 b/u 316 /u solder/crimp mc4103d fc4103d 1.037 [26.34] 0.108 [2.74] 180 b/u solder/crimp mc4104d fc4104d 1.037 [26.34] 0.120 [3.05] 58 b/u solder/solder ms4101d fs4101d 0.929 [23.60] 0.040 [1.02] 178 b/u 196 b/u solder/solder ms4102d fs4102d 0.929 [23.60] 0.067 [1.70] 179 b/u 316 /u solder/solder ms4103d fs4103d 1.037 [26.34] 0.108 [2.74] 180 b/u solder/solder ms4104d fs4104d 1.037 [26.34] 0.120 [3.05] 58 b/u crimp/crimp mcc4101d fcc4101d 0.929 [23.60] 0.040 [1.02] 178 b/u 196 b/u crimp/crimp mcc4102d fcc4102d 0.929 [23.60] 0.067 [1.70] 179 b/u 316 /u crimp/crimp mcc4103d fcc4103d 1.037 [26.34] 0.108 [2.74] 180 b/u crimp/crimp mcc4104d fcc4104d 1.037 [26.34] 0.120 [3.05] 58 b/u two-step crimping action for signal and shielding conductors. for information regarding crimp tool and crimping tool techniques, consult technical sales. material: copper alloy with ptfe teflon insulator. plating: standard finish: signal contact: 0.000030 [0.76 ? gold over nickel contact body: gold flash over nickel. optional finishes: signal contact: 0.000050 inch [1.27? gold over nickel by adding ?15 suffix onto part num- ber. example: ms4102d-15 . contact body: 0.000030 [0.76 ? gold over nickel male contact male contact male contact female contact female contact female contact
p ower c onnection s ystems positronic industries connectpositronic.com mixed density power connectors 10 dimensions are in inches [millimeters]. all dimensions are subject to change. straight printed board mount connectors code 3, 0.146 [3.71] contact extension male female male female plb(h)10w2 plc(h)16w4 typical part numbers: plb10w2m300a1 plbh10w2m300a1 typical part numbers: plb10w2f300a1 plbh10w2f300a1 typical part numbers: plc16w4m300a1 plch16w4m300a1 typical part numbers: plc16w4f300a1 plch16w4f300a1
p ower c onnection s ystems positronic industries connectpositronic.com 11 dimensions are in inches [millimeters]. all dimensions are subject to change. mixed density power connectors 90 printed board mount connectors code 4, 0.146 [3.71] contact extension male female male female plb(h)10w2 plc(h)16w4 typical part numbers: plb10w2m400a1 plbh10w2m400a1 typical part numbers: plb10w2f400a1 plbh10w2f400a1 typical part numbers: plc16w4m400a1 plch16w4m400a1 typical part numbers: plc16w4f400a1 plch16w4f400a1
p ower c onnection s ystems positronic industries connectpositronic.com mixed density power connectors 12 dimensions are in inches [millimeters]. all dimensions are subject to change. compliant press-fit connectors code 93 male female male female plb(h)10w2 plc(h)16w4 typical part numbers: plb10w2m9300a1 plbh10w2m9300a1 typical part numbers: plb10w2f9300a1 plbh10w2f9300a1 typical part numbers: plc16w4m9300a1 plch16w4m9300a1 typical part numbers: plc16w4f9300a1 plch16w4f9300a1
suggested printed board hole sizes compliant press-fit connectors traditionally, tin-lead has been a popular plating for pbc holes. however, many pcb hole platings must now be rohs compliant. positronic is pleased to offer pcb hole size for rohs pcb plating as shown below. omega compliant press-fit contact hole board type contact size drill hole size recommended plating finished hole sizes tin-lead solder pcb 20 ?.0453 0.0010 [?.150?.025] 0.0006 [15? minimum solder over 0.0010 [25? min. copper ?.0394+0.0035-0.0024 [?.000+0.090-0.060] r o hs pcb plating options copper pcb 20 ?.047 0.002 [?.19?.05] 0.0010 [25? min. copper ?.043 0.002 [?.09?.05] immersion tin pcb 20 ?.047 0.002 [?.19?.05] 0.000033?.000006 [0.85?.15? immersion tin over 0.0010 [25? min. copper ?.043 0.002 [?.09?.05] immersion silver pcb 20 ?.047 0.002 [?.19?.05] 0.000013?.000007 [0.34?.17? immersion silver over 0.0010 [25? min. copper ?.043 0.002 [?.09?.05] electroless nickel/ immersion gold pcb 20 ?.047 0.002 [?.19?.05] 0.000002 [0.05? min. immersion gold over 0.000177?.000059 [4.5?.5? electroless nickel per ipc-4552 over 0.0010 [25? min. copper ?.043 0.002 [?.09?.05] bi-spring compliant press-fit contact hole board type contact size drill hole size recommended plating finished hole sizes tin-lead solder pcb 8 ?.125 0.001 [?.18?.03] 0.0006 [15? minimum solder over 0.0010 [25? min. copper ?.119 0.002 [?.02?.05] note: for pcb plating compositions not shown, consult technical sales. press-fit contact hole ?i-spring termination ?mega termination p ower c onnection s ystems positronic industries connectpositronic.com 13 dimensions are in inches [millimeters]. all dimensions are subject to change. mixed density power connectors compliant press-fit connector installation tools use indicated positronic tools for best results positronic recommended tools for plb & plc series connectors and contacts contact variant connector seating male female plb10w2 9513-7-0-41 9513-30-0-41 plc16w4 9513-11-0-41 9513-31-0-41 arbor press for connector seating tools 9530-1-0 1 ton capacity 4 inch throat replacement pins for connector seating tools size 8 power 855-347-19-41 size 20 signal 855-347-18-41
p ower c onnection s ystems positronic industries connectpositronic.com mixed density power connectors 14 dimensions are in inches [millimeters]. all dimensions are subject to change. plb10w2 plc16w4 suggest 0.145 [3.68] hole in printed board for power contact termination positions. suggest 0.045 [1.14] hole for signal solder contact termination positions. see previous page for hole details for compliant contact termination positions. suggest 0.100 [2.54] hole in printed board when mounting connectors with #2 thread forming screws. suggest 0.123?.003 [3.12?.08] hole in printed board for mounting connector with push-on fasteners. straight solder and compliant contact hole pattern 90 printed board mount contact hole pattern panel cutout plb10w2 plc16w4 plb10w2 plc16w4
p ower c onnection s ystems positronic industries connectpositronic.com 15 dimensions are in inches [millimeters]. all dimensions are subject to change. mixed density power connectors step 3 - connector gender m - male f - female 1 2 3 4 5 6 7 8 plc 16w4 f 4 b3n 0 a1 /aa 9 ordering information - code numbering system specify complete connector by selecting an option from step 1 through 7 step 1 - basic series plb - 2 row plbh - 2 row high conductivity contacts plc - 3 row plch - 3 row high conductivity contacts step 9 - special options contact technical sales for special options step 6 - hoods and panel mount 0 - none. 51 - top opening hood. 6 - panel mount, quick release. 81 - panel mount, fixed for 0.040 [1.02] thick panel. 82 - panel mount, fixed for 0.060 [1.52] thick panel. 83 - panel mount, fixed for 0.090 [2.29] thick panel. 11 - blind mating system for 0.040 [1.02] thick panel. 12 - blind mating system for 0.060 [1.52] thick panel. 13 - blind mating system for 0.090 [2.29] thick panel. 14 - blind mating system for 0.120 [3.05] thick panel.. step 5 - mounting style 0 - no added accessories. b - metal 90 mounting bracket. bn - metal 90 mounting bracket with push-on fastener. b3 - plastic 90 mounting bracket with cross bar. b3n - plastic 90 mounting bracket with cross bar and push-on fastener. n - push-on fastener for straight printed board mount connectors st2 - self-tapping screws 2-28 x 0.250 [6.35] length for 0.093 [2.36] thick board. st3 - self-tapping screws 2-28 x 0.312 [7.92] length for 0.125 [3.18] thick board. step 4 - contact termination type 0 ?order contacts separately for cable connectors. 1 ?removable contact, panel mounted connector. order contacts separately. 3 ?solder, straight printed board mount with 0.146 [3.71] tail extension. 4 ?solder, 90 printed board mount with 0.146 [3.71] tail extension. 93 ?straight pcb mount, press-fit, length 0.218 [5.54] for 0.125 inch [3.18] thick board. step 2 - connector variants 2 row ? 10w2 3 row ? 16w4 step example step 8 - environmental compliance options /aa - compliant per eu directive 2002/95/ec (rohs) p o s i t r o n i c i n d u s t r i e s ? p e r e u d i r e c t i v e 2 0 0 2 / 9 5 / e c ? rohs r o h s compliant step 7 - contact plating for printed board connectors 0 - crimp contacts ordered separately. a1 - gold flash over nickel on mating end and termination end. a2 - gold flash over nickel on mating end and 0.00020 inch [5.00? tin-lead solder coat on termination end. not available with code 93 in step 4. c1 - 0.000030 inch [0.76? gold over nickel on mating end and termination end. c2 - 0.000030 inch [0.76? gold over nickel on mating end and 0.00020 inch [5.00? tin-lead solder coated termination end. not available with code 93 in step 4. d1 - 0.000050 inch [1.27? gold over nickel on mating end and termination end. d2 - 0.000050 inch [1.27? gold over nickel on mating end and 0.00020 inch [5.00? tin-lead solder coated termination end. not available with code 93 in step 4. note: once you have made a connector selection, contact technical sales if you would like to receive a drawing in dxf, pdf format or a 3-dimensional iges, step, or solidworks file. sk drawing 3-dimensional model note: if compliance to environmental legislation is not required, this step will not be used. example: plc16w4f4b3n0a1
p ower c onnection s ystems positronic industries connectpositronic.com 2 dimensions are in inches [millimeters]. all dimensions are subject to change. application tools application tools new! step 1: strip wire t o indica ted length. step 2: crimp wire t o cont a ct . for hand crimp tool: - place contact into crimping tool. - insert wire into contact. - center contact by slowly closing the crimping tool until the crimp indenters make contact with the crimp barrel. - complete the cycle of the crimping tool in one smooth motion. - remove the crimped contact. take care not to: - damage or remove strands. - untwist or overtwist strands. - leave insulation particles on strands. - damage insulation. for automatic crimp tool: - insert the wire into the contact, positioned in the crimp tool by the plastic carrier. - depress the activating device of the crimping tool to start the crimping cycle. - remove the crimped contact. l i nsulation stranded wire strands damaged or removed by stripping tool. insulation cut incorrectly. strands overtwisted. particles of insulation on the stripped part of the wire. wire insulation damaged. strands untwisted. examples of stripping faults correctly stripped wire connector series contact type l 0.020 [?.51] plb10w2 plbh10w2 plc16w4 plch16w4 signal 0.230 [5.84] power 0.350 [8.89] crimping information for removable crimp contacts use indicated positronic tools for best results c-039 rev. nc1
3 dimensions are in inches [millimeters]. all dimensions are subject to change. application tools crimping information for removable crimp contacts use indicated positronic tools for best results conductor tensile strength values are derived using silver-tin plated copper wires. values may change depending upon what type of wire is used. wire insulation, typical crimp to meet recommended tensile strength. stripped wires compressed for improved conduction. 8 crimp indents crimp indents too close to inspection hole. strands not visible through inspection hole. strands visible beyond insulation support. stripped part of the wire too long. stripped part of the wire too short. crimp indents incorrectly located. step 3: inspect the crimp . for all tools: - strands to be visible through the inspection hole. - strands not to be visible beyond the insulation support. - crimped contact to meet recommended conductor tensile force shown in chart. - check for peeled gold and bent contacts. correctly crimped contact cross section of correctly crimped contact examples of crimping faults positronic recommended conductor tensile strength wire size awg/[mm 2 ] axial load pounds/[n] 8 [10.0] 110 [489] 10 [5.3] 110 [489] 12 [4.0] 110 [489] 14 [2.5] 70 [311] 16 [1.5] 50 [222] 18 [1.0] 28 [125] 20 [0.5] 20 [89] 22 [0.3] 12 [53] 24 [0.25] 8 [36] p ower c onnection s ystems positronic industries connectpositronic.com application tools new! c-039 rev. nc1
positronic contact p/n handle & positioner p/n hand crimp tool p/n mf g . cross mil equiv positioner mf g . cross mil equiv insertion tool mf g . cross mil equiv removal tool mf g . cross mil equiv automatic crimp tool fc720n2 9507 afmb m22520/2-01 9502-22 k1196 9099-4-0-0 itp1076 9081-2-0-0 rng2103 9550-1 mc720n3 9507 afmb m22520/2-01 9502-27 k1506 9099-4-0-0 itp1076 9081-2-0-0 rng2103 9550-1 *c4008d 9504-19-0-0 9509-1-0-0 m310 9504-19-1-0 y524 n/a 4311-0 p+ 9555-0-2 *c4008ds 9504-19-0-0 9509-1-0-0 m310 9504-19-1-0 y524 n/a 4311-0 p+ 9555-0-2 *c4010d 9509-0-0-0 9509-1-0-0 m310 9509-2-0-0 tp-974 n/a 4311-0 p+ 9555-0-2 *c4012d 9509-0-0-0 9509-1-0-0 m310 9509-2-0-0 tp-974 n/a 4311-0 p+ 9555-0-2 *c4016d 9509-0-0-0 9509-1-0-0 m310 9509-2-0-0 tp-974 n/a 4311-0 p+ 9555-0-2 *s40**d n/a 4311-0 p+ *s4*20d n/a 4311-0 p+ *c4101d 9504-0 9504-1-0-0 hx4 m22520/5-01 9504-2-0-0 y322 n/a 4311-0 p+ *c4102d 9504-0 9504-1-0-0 hx4 m22520/5-01 9504-2-0-0 y322 n/a 4311-0 p+ *c4103d 9504-0 9504-1-0-0 hx4 m22520/5-01 9504-2-0-0 y322 n/a 4311-0 p+ *c4104d 9504-0 9504-1-0-0 hx4 m22520/5-01 9504-2-0-0 y322 n/a 4311-0 p+ *s410*d n/a 4311-0 p+ *cc4101d 9504-14-0-0 9504-1-0-0 hx4 m22520/5-01 9504-14-1-0 y878 n/a 4311-0 p+ *cc4102d 9504-13-0-0 9504-1-0-0 hx4 m22520/5-01 9504-13-1-0 y937 n/a 4311-0 p+ *cc4103d 9504-15-0-0 9504-1-0-0 hx4 m22520/5-01 9504-15-1-0 y877 n/a 4311-0 p+ *cc4104d 9504-15-0-0 9504-1-0-0 hx4 m22520/5-01 9504-15-1-0 y877 n/a 4311-0 p+ signal size 20 pcs mixed density removable contacts power, high voltage, and shielded size 8 contacts 4 dimensions are in inches [millimeters]. all dimensions are subject to change. application tools contact application tools cross reference list use indicated positronic tools for best results p ower c onnection s ystems positronic industries connectpositronic.com application tools new! c-039 rev. nc1
an easy-to-use contact insertion tool for 12 awg [4.0 mm 2 ] and small- er wires, part number 9099. the contact removal tool is spring-loaded to simplify the extraction of removable contacts from the connector insulators, part number 9081. for contact removal, simply insert the hollow tool tip over the male or female contact from the front face of the insulator, rotate the tool slight- ly while increasing the pushing force against the butt of the extraction tool. the contact will be released from the insulator retention system and will ?op out of the rear face of the insulator. for insertion and removal tool selection, see recommended tooling chart on page 4. 5 dimensions are in inches [millimeters]. all dimensions are subject to change. application tools insertion and removal tools (shown for reference only) reels for automatic pneumatic crimp tools contacts may be supplied in plastic carriers, packaged in reels holding 2,000 contacts for use with the automatic pneumatic crimp tools, catalog part number 9550-1 and packaged in reels holding 1,000 contacts for use with the automatic pneumatic crimp tools, catalog part number 9555-0-2. the same type carrier is used for both male and female contacts. all male and female crimp contacts can be ordered in reels by adding letter ? after the contact part number, such as mc6020dr for a male contact and fc6026dr for a female contact. automatic crimp tools, pneumatically actuated part no. 9550-1 this fast cycling automatic feed strip and crimp tool produces an 8 indent crimp on wire sizes 20 awg [0.5mm 2 ] through 24 awg [0.25mm 2 ]. contacts must be ordered on reels. to order, specify part number 9550-1. foot control valve is supplied as a standard accessory. miniature step adjustable tool m22520/2-01 part no. 9507 this miniature 8 step adjustable hand crimping tool produces an 8 indent crimp configuration and will crimp wire sizes 20 awg [.05mm 2 ] through 24 awg [0.25mm 2 ]. each positioner is equipped with a data plate which gives the correct crimp-depth setting for each wire size, and must be used with 9507 tool frame for best results when crimping contacts. for complete crimp tool and positioner selection, see recommended tooling chart on page 4. part no. 9555-0-2 this fast cycling automatic feed strip and crimp tool produces an 8 indent crimp on wire sizes 8 awg [10.0mm 2 ] through 12 awg [4.0mm 2 ]. contacts must be ordered on reels. to order, specify part number 9555-0-2. foot control valve is supplied as a standard accessory. enlarged section of plastic contact carriers p ower c onnection s ystems positronic industries connectpositronic.com application tools new! removal tool part no. 90 8 1 insertion tool part no. 9099 c-039 rev. nc1
6 dimensions are in inches [millimeters]. all dimensions are subject to change. application tools soldering and crimping information for pcs mixed density series shielded contacts step 1: strip wire t o indica ted length t ake care no t t o: ?amage or remove strands. ?ntwist or overtwist strands. ?eave insulation particles on strands. ?amage insulation. insulation a b c dielectric center conductor braid *contact gender is designated by m for male contacts and f for female contacts. ferrule ferrule jacket jacket barrel barrel cap solder or crimp solder shielded contact hand crimp tool for crimp tool part numbers, see contact application tools cross reference chart on page 4. part number rg cable number a b c * c4101d 178 b/u 0.281 [7.14] 0.250 [6.35] 0.078 [1.98] * s4101d * c4102d 179 b/u 316 /u 0.281 [7.14] 0.250 [6.35] 0.078 [1.98] * s4102d * c4103d 180 b/u 0.375 [9.53] 0.312 [7.92] 0.078 [1.98] * s4103d * c4104d 58 b/u 0.375 [9.53] 0.312 [7.92] 0.078 [1.98] * s4104d * cc4101d 178 b/u 0.281 [7.14] 0.250 [6.35] 0.120 [3.05] * cc4102d 179 b/u 316 /u 0.281 [7.14] 0.250 [6.35] 0.120 [3.05] * cc4103d 180 b/u 0.375 [9.53] 0.312 [7.92] 0.120 [3.05] * cc4104d 58 b/u 0.375 [9.53] 0.312 [7.92] 0.120 [3.05] step 2: crimp wire t o cont a ct - trim cable. - slide ferrule over jacket. insert dielectric and center conductor into barrel. crimp center con- ductor into contact. - butt ferrule against shoulder. crimp ferrule over braid. step 2: solder wire t o cont a ct - trim cable. tin center conductor. - slide ferrule over jacket. insert dielectric and center conductor into barrel. solder center conductor into contact. - butt ferrule against shoulder. solder cable to barrel through hole in ferrule. solder cap into body. step 2: solder/crimp wire t o cont a ct - trim cable. tin center conductor. - slide ferrule over jacket. insert dielectric and center conductor into barrel. solder center conductor into contact. - butt ferrule against shoulder. crimp ferrule over braid. solder cap into body. typical part number: fc4101d p ower c onnection s ystems positronic industries connectpositronic.com application tools new! c-039 rev. nc1
contact sizes: 0, 8, 12, 16, 20 and 22 current ratings: to 100 amperes terminations: crimp, wire solder, straight solder, right angle solder, straight press-fit and right angle press-fit configurations: multiple variants in a variety of package sizes compliance: picmg 2.11, picmg 3.0, vita 41 features: hot swap capability ?ac/dc operation in a single connector ?signal contacts for hardware management ?blind mating ?sequential mating ?large surface area contact mating system ?wide variety of accessories ?customer spec- ified contact arrangements power contact sizes: 8, 20 and 22 current ratings: to 40 amperes nominal terminations: crimp, wire sol- der, straight solder, right angle solder and straight press-fit configurations: multiple variants in both standard and high densities qualifications: mil-dtl-24308, goddard space flight 311p, sae as 39029, ip65, ip67 features: three performance levels available: professional quality, military quality and space-flight quality provide multiple performance-to-cost choices ?options include thermocouple contacts, environmentally sealed and dual port package including mixed density ?broad selection of accessories d-subminiature contact sizes: 16, 20 and 22 current ratings: to 13 amperes terminations: crimp, wire solder, straight solder and right angle solder configurations: multiple variants in both standard and high densities qualifications: mil-dtl-28748, sae as 39029, ccitt v.35 features: two performance levels available: industrial quality and military quality provide two performance to cost choices ?large surface area contact mating system ?a wide variety of accessories ?broad selection of contact variants and package sizes rectangular contact sizes: 12, 16, 20 and 22 current ratings: to 25 amperes nominal terminations: crimp, wire solder, straight solder and right angle solder configurations: multiple variants qualifications: environmental protection to ip67 features: non-corrodible / lightweight composite construction ?emi/rfi shielded versions ?thermocouple contacts ?environmentally sealed versions ?rear insertion/ front release of removable contacts ?two level sequential mat- ing ?overmolding available on full assemblies circular all positronic connector products can be supplied as part of cable assemblies whose technical characteristics would reflect those of the connectors being used within the assembly. features: shorten the supply chain and reduce additional costs and delays by ?ablizing??overmolding available ?shielded and environmentally sealed versions available ?power cables and access boxes which meet the sae j2496 specification cable contact sizes: 8, 12, 16, 20 and 22 current ratings: to 40 amperes nominal terminations: feedthrough is standard; flying leads and board mount available upon request configurations: see d-subminiature and circular configurations above qualifications: space-d32 features: intended for use as an electrical feedthrough in high vacuum applications ?leakage rate: 5 x 10-9 mbar.l/s @ vacuum 1.5 x 10-5 atm ?signal, power, coax and high voltage versions available ?connectors can be mounted on flange assembly per customer specification hermetic positronic industries positronic products for more information, visit www.connectpositronic.com or call your nearest positronic sales office as given on the back of this catalog.
north american locations united states, springfield, missouri, corporate headquarters factory sales and engineering offices (800) 641-4054 puerto rico, ponce factory factory sales and engineering offices (800) 641-4054 mexico factory sales and engineering offices (800) 872-7674 canada factory sales and engineering offices (800) 327-8272 asia/pacific locations singapore, asia/pacific headquarters factory sales and engineering offices (65) 6842-1419 singapore@connectpositronic.com asia, direct sales offices china -shenzhen sales office (86) 755-2643-7578 shenzhen@connectpositronic.com china -shanghai sales office shanghai@connectpositronic.com korea sales office (82) 31-909-8047/8 korea@connectpositronic.com taiwan sales office (88) 62-2937-8775 taiwan@connectpositronic.com japan, direct sales offices sales and engineering offices (81) 3-5812-7720 japan@connectpositronic.com india, direct sales offices factory sales and engineering offices (91) 20-2439-4810 india@connectpositronic.com asia/pacific, technical agents technical agents in malaysia, australia, new zealand, philippines, hong kong, vietnam, thailand european locations france, auch factory, european headquarters factory sales and engineering offices 33 (0)5 62 63 44 91 contact@connectpositronic.com europe, direct sales offices northern france sales office 33 (0)1 45 88 13 88 jchalaux@connectpositronic.com southern france sales office 33 (0)4 67 72 80 28 plafon@connectpositronic.com italy sales office 39 (0)2 54 116 106 rmagni@connectpositronic.com northern germany sales office 49 (0)30 34 504 307 gzimmermann@connectpositronic.com southern germany sales office 49 (0)2351 63 47 39 cbouche@connectpositronic.com europe, technical agents technical agents in austria, benelux, eastern europe countries, greece, ireland, scandinavia, spain, switzerland and the united kingdom mideast, technical agents technical agents in israel and turkey positronic industries, inc. 423 n campbell avenue ?po box 8247 ?springfield, mo 65801 tel (417) 866-2322 ?fax (417) 866-4115 ?toll free (800) 641-4054 info@connectpositronic.com positronic industries, s.a.s. zone industrielle d?ngachies ?46 route d?ngachies france 32020 auch cedex 9 telephone 33 (0)5 62 63 44 91 ?fax 33 (0)5 62 63 51 17 contact@connectpositronic.com positronic asia pte ltd. 3014a ubi road 1 #07-01 ?singapore 408703 telephone (65) 6842 1419 ?fax (65) 6842 1421 singapore@connectpositronic.com

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