Technical
A. Insertion and Withdrawal Force Limits
B. Tensile Strength - Crimped Tab or Receptacle
C. Maximum Operating Temperatures - Tab and Receptacle - 'For guidance only'
D. Conductor Wire Cross-sectional Area Reference Table
Characteristics of a correctly-crimped terminal
A. Insertion and Withdrawal Force Limits
(Extracts from BS 5057 : 1992 / IEC 760 : 1989 brass tab with brass receptacle)
| | First Insertion Max. Force | Sixth Withdrawl Min. Force (Average) | ||
| Tab Size | N | Kg | N | Kg |
| 2.8mm | 53 | 5.4 | 9 | 1.0 |
| 4.8mm | 67 | 6.8 | 13 | 1.5 |
| 6.3mm | 80 | 8.2 | 22 | 2.3 |
| 9.5mm | 100 | 10.2 | 30 | 3.1 |
B. Tensile Strength - Crimped Tab or Receptacle
(Extract from BS 5057 : 1992 / IEC 760 : 1989 - force to separate a connector from its attached conductor wire)
| Wire Cross sect (mm2) | 0.2 | 0.3 | 0.4 | 0.5 | 0.6 | 0.7 | 0.8 | 0.9 | 1.0 |
| Min. Tensile Force (N) | 28 | 38 | 48 | 58 | 68 | 78 | 88 | 96 | 110 |
| Wire Cross sect (mm2) | 1.3 | 2.0 | 2.1 | 3.0 | 3.3 | 4.0 | 5.0 | 5.3 | 6.0 |
| Min. Tensile Force (N) | 150 | 195 | 200 | 270 | 280 | 310 | 350 | 360 | 370 |
C. Maximum Operating Temperatures - Tab and Receptacle - 'For guidance only'
| Natural Brass (Cu Zn) | 90°C |
| Tinned Brass (Cu Zn gal Sn) | 100°C |
| Phosphor Bronze (Cu Sn) | 100°C |
| Tinned Phosphor Bronze (Cu Sn gal Sn) | 110°C |
| Tinned Copper (Cu gal Sn) | 110°C |
| Nickel Silver (Cu Ni Zn) | 200°C |
| Nickel Plated Steel (St gal Ni) | 250°C |
| Stainless Steel (St St) | 300°C |
D. Conductor Wire Cross-sectional Area Reference Table
| Wire Size | Cross Sec mm2 | AWG |
| 1/0.065 | 0.0033 | |
| 1/0.1 | 0.008 | |
| 7/0.1 | 0.06 | |
| 1/0.15 | 0.018 | |
| 28/0.15 | 0.5 | 20 |
| 42/0.15 | 0.75 | 18 |
| 1/0.2 | 0.03 | |
| 7/0.2 | 0.22 | 24 |
| 16/0.2 | 0.5 | 20 |
| 24/0.2 | 0.75 | 18 |
| 32/0.2 | 1.0 | 17 |
| 63/0.2 | 2.0 | 14 |
| 1/0.25 | 0.05 | |
| 14/0.25 | 0.7 | 19 |
| 30/0.25 | 1.5 | 15 |
| 50/0.25 | 2.5 | 13 |
| 1/0.3 | 0.071 | |
| 9/0.3 | 0.65 | 19 |
| 14/0.3 | 1.0 | 17 |
| 19/0.3 | 1.35 | 16 |
| 21/0.3 | 1.5 | 15 |
| 28/0.3 | 2.0 | 14 |
| 35/0.3 | 2.5 | 13 |
| 44/0.3 | 3.0 | 12 |
| 56/0.3 | 4.0 | 11 |
| 65/0.3 | 4.5 | 11 |
| 84/0.3 | 6.0 | 9 |
| 1/0.4 | 0.13 | 26 |
| 7/0.4 | 1.0 | 17 |
| 1/0.5 | 0.2 | 24 |
| 7/0.5 | 1.5 | 15 |
| 1/0.6 | 0.28 | 23 |
| 1/0.67 | 0.35 | 22 |
| 7/0.67 | 2.5 | 13 |
| 1/0.7 | 0.39 | 21 |
| 1/0.8 | 0.5 | 20 |
| 1/0.85 | 0.57 | 19 |
| 7/0.85 | 4.0 | 11 |
| 1/0.9 | 0.64 | 19 |
| 1/1.0 | 0.8 | 18 |
| 1/1.04 | 0.85 | 18 |
| 7/1.04 | 6.0 | 9 |
| 1/1.13 | 1.0 | 17 |
| 1/1.38 | 1.5 | 15 |
| 1/1.78 | 2.5 | 13 |
| 1/2.25 | 4.0 | 11 |
| 1/2.76 | 6.0 | 9 |
Crimp height charts are available, on request, for every terminal we produce which needs mechanical crimping action.
Since there are dimensional tolerances on both wire and terminals the final crimp height can only be determined by quality control tests on shop floor samples.These checks should proceed until the required mechanical strength is achieved.
| Reference | Size mm |
| USA No.2 | 2.18 |
| 8 B.A. | 2.20 |
| 3/32” | 2.38 |
| 6 B.A. | 2.80 |
| USA No.4 | 2.84 |
| M3 | 3.00 |
| 1/8” | 3.18 |
| USA No.6 | 3.51 |
| 4 B.A. | 3.60 |
| 5/32” | 3.97 |
| M4 | 4.00 |
| 3 B.A. | 4.10 |
| USA No.8 | 4.17 |
| 2 B.A. | 4.70 |
| 3/16” | 4.76 |
| USA No.10 | 4.83 |
| M5 | 5.00 |
| 1 B.A. | 5.30 |
| USA No.12 | 5.49 |
| 7/32” | 5.56 |
| 0 B.A. | 6.00 |
| M6 | 6.00 |
| USA No.14 | 6.15 |
| 1/4” | 6.35 |
Characteristics of a correctly-crimped terminal
- Cut-off from carrier strip should not extend further than 0.5mm from end of terminal.
- Bell-mouthing should be formed at both ends of the conductor bucket.
- Wire strands should not protrude more than 0.8mm at the contact end of the crimp bucket.
- Both insulation and wire strands should be visible between the crimp bucket and the insulation support areas.
- There should be no air gaps in the conductor bucket. The diagram shows a correctly crimped terminal and its features - examples on the first three rows show a ‘B’type crimp and on the second three rows a ‘Wrap-around’type.
The specifications and illustrations displayed on this web page were correct at their creation date.The company policy is one of continual improvement we therefore reserve the right to modify designs without prior notice.
All technical information is given in good faith,but customers should ensure that any chosen product is suitable for the intended application. Utilux products are subject to rigorous inspection before shipment. Any imperfect material,which may occasionally occur in any production run,will be replaced. Under no circumstances will Utilux be responsible for damage beyond the cost of the connectors themselves.Title to all goods remains with Utilux regardless of location until paid for in full. A copy of our Terms and Conditions of Sale is available on request.
The European Union's directive on the ‘Restriction of Hazardous Substances Directive' (RoHS) was published on 13th February 2003. The purpose of the directive is to control the use of certain substances in electrical and electronic products, including:
- lead
- mercury
- cadmium
- hexavalent chromium
and certain flame retardants used in plastics:
- polybrominated biphenyls (PBB)
- polybrominated diphenyl ethers (PBDE).
The directive applies to all electrical and electronic products, and their component parts, placed on the market after 1st July 2006.
Utilux is committed to compliance with all applicable laws and regulations, including the restriction of hazardous substances in electronic products.
The RoHS Directive specifies that an electronic product or component may not contain a listed substance except as specifically provided for in the directive.
Utilux will comply with the RoHS Directive prior to the 1st July 2006 implementation date for all products, and expects to be fully compliant by the end of 2005. This will allow our customers and anyone in the supply chain, to deplete any non-compliant products well before the deadline.
For further information on RoHS compliance please contact the Quality Department.