TE Product Overview

RoHS
Ready

Product Overview
Automotive Components & Systems

T YCO E L E C T R O N I C S G LO B A L AU TO M OT I V E D I V I S I O N

T H E 5 A P P L I C AT I O N A R E A S

1

GLOBAL AUTOMOTIVE DIVISION

Tyco Electronics Ltd. is a leading global provider of engineered
electronic components, network solutions and undersea
telecommunication systems with customers in more than 150
countries. We design, manufacture and market products for
customers in industries from automotive, appliance and aerospace
and defense to telecommunications, computers and consumer
electronics. With worldwide engineering and manufacturing, sales
and customer service capabilities, Tyco Electronics' commitment is
our customers' advantage.

Tyco Electronics offers a broad range of high quality electronic
component products. We provide solutions for OEM applications,
utility and energy, outside plant and premise networking
installations and more. Products from well-known-brands include
connectors and interconnection systems, terminal blocks, relays,
circuit protection devices, fiber optic components, wires and cables,
switches, sensors, touch screens and application tooling. We also
provide products to insulate, protect, hold, bundle and identify
electrical harnesses.

Our electrical and electronic connectors and interconnection
products are used in an endless list of automotive applications.
Connector products are used to electrically and mechanically join
wires and cables, printed circuit boards, integrated circuit packages
and batteries. Our continually expanding capabilities include new
copper and fiber optic connectors, wires, cables and cable
management systems that are designed to meet automotive
industry demands. The Tyco Electronics brand encompasses the
broadest range of connectors in the world, including high-density,
high-speed designs for leading-edge communications equipment.

3

T YCO E L E C T R O N I C S “ T E C H N O LO GY P O R T F O L I O ”

• Connector SystemsComponents
Electromechanical
/ • Tubing & Harnessing
Products
• Battery Connectors &
Assemblies

• Relays • Circuit Protection Devices • Identification Labeling Products
• Sensors • Touch Screen Displays • Racks & Panels
• Fiber Optic Products • Resistors & Inductors • Smart Cards / Leadframes
• Wire & Cable • Heat Sinks & Thermal Solutions
• Application Tooling • Switches and Knobs

4 All specifications subject to change. Consult Tyco Electronics for latest specifications.

T YCO E L E C T R O N I C S “AT YO U S E RV I C E ”

Tyco Electronics Online
The Tyco Electronics website is an innovative and
interactive source for application information,
product updates and technical solutions.
Our step-by-step software makes our website
intuitive and user-friendly to better serve you!
Please contact us at:
www.tycoelectronics.com/automotive

Internet Homepage
www.tycoelectronics.com
www.tycoelectronics.com/automotive Product Information Center
(PIC)
Electronic Internet Catalog
You can rely on Tyco Electronics PIC Team to
www.catalog.tycoelectronics.com
provide you support for answers to your
general information or technical questions in
an efficient and effective manner.
To reach our PIC staff, please contact your
local Tyco Electronics organization.

Product and Machine Literature
Tyco Electronics offers a variety of product specific catalogs, brochures
and high impact flyers to help better serve you!
For more information on literature for Tyco Electronics’
Global Automotive Division, please contact your local Tyco Electronics
Organization or go to www.tycoelectronics.com/automotive

All specifications subject to change. Consult Tyco Electronics for latest specifications. 5

Incorrect Terminal twisted

Terminal damaged

Cut off tab too long Crimp barrel distorted Cut off tab deformed

Crimp height too tight Insulation inside the wire crimp

Conductor Brush protruding into terminal body

Bellmouth on wrong end
Terminal bend

INSULATION CRIMP

Insulation is pierced and could Insulation material is pierced Insulation Insulation
damage conductor is not securely is over crimped
held

Insulation legs are not closed Insulation is not securely held
Legs do not overlap

WIRE CRIMP
Incorrect applicator adjustment Incorrect terminal/wire selection Incorrect crimp height adjustment
Unacceptable
Asymmetric Wire size Wire size Crimp height Crimp height
formation excessive
crimp too large too small too loose too tight
flash and/or cracks

Terminal feed Anvil and crimper Crimp barrel Legs too close Insufficient Flash at under
incorrectly not aligned or worn does not close to bottom of crimp. deformation, side of crimp,
adjusted Insufficient showing voids due to over
deformation of -crimping
strands,
showing voids


CRIMP QUALITY GUIDELINES

Correct WIRE CRIMP Test
Insulation present Bellmouth must always be present

WIRE CRIMP
Conductor
present
Crimp Height Measurement

Bellmouth permissible

Locking lances and
Cut off tabs
terminal body not
present
deformed
Crimp Heights and Tolerances
Correct selection of wire, terminal and applicator
For crimp height tolerances for any given
contact, please refer to the relevant
application specification.

Crimp barrel is closed, Sufficient gap between legs
legs support each other and bottom of crimp
Digital Crimp Height Micrometer
All strands are equally distributed and deformed
(0.001 mm increments)
acc. to DIN ISO 9001
Part No. 547203-1
INSULATION CRIMP
Correct Insulation Diameter, Applicator and Terminal
F-CRIMP

Insulation is securely held.
Crimp barrel closed

For double wire applications with different size wires always
place wire with smallest outer diameter in the bottom
OVERLAP CRIMP

INSULATION CRIMP

Wire crimp without conductor
30

Insulation is securely held.
°

Legs overlap
°
30
WRAP OVER
CRIMP

Insulation must be securely
Insulation securely held. held after bend test
Legs must pass each other


ENGINEERING NOTES


C O N V E R S I O N TA B L E S

AWG Conversion Table (Average Value)

AWG Code Diameter (Inch) Diameter (mm) F (mm2)
Conversion Tables
Most of the wire size 000000 0.5800 14.733 170.0
ranges are mentioned in 00000 0.5165 13.130 135.0
mm2, as well as the 0000 0.4600 11.684 103.8
insulation diameters 000 0.4096 10.400 079.0
which are in many cases 00 0.3648 9.270 067.5
only in mm’s. 0 0.3249 8.25 053.4
1 0.2893 7.34 042.2
We therefore included the
2 0.2576 6.55 33.7
conversion tables on
3 0.2294 5.82 26.6
pages 10 and 11.
4 0.2043 5.18 21.0
Please note that wire and 5 0.1819 4.62 16.9
insulation sizes are for 6 0.1620 04.115 13.25
guidance only. 7 0.1443 3.66 10.25
Consult the customer 8 0.1285 3.26 8.34
drawing for precise detail. 9 0.1144 2.90 6.6
10 0.1019 2.59 5.27
11 0.0907 2.30 4.15
12 0.0808 2.05 3.3
13 0.0720 1.83 2.63
14 0.0641 1.63 2.08
15 0.0571 1.45 1.65
16 0.0508 1.29 1.305
17 0.0453 1.14 1.01
18 0.0403 1.02 0.79
19 0.0359 0.91 0.65
20 0.0320 0.81 0.51
21 0.0285 0.72 0.407
22 0.0253 0.64 0.32
23 0.0226 00.57 0.255
24 0.0201 00.51 0.205
25 0.0179 00.455 0.162
26 0.0159 00.400 0.125
27 0.0142 00.360 0.102
28 0.0126 00.320 0.08
29 0.0113 00.287 0.0646
30 0.0100 00.254 0.0516
31 0.0089 00.226 0.04
32 0.0080 00.203 0.0324
33 0.0071 00.180 0.0255
34 0.0063 00.160 0.02
35 0.0056 00.142 0.0158
36 0.0050 00.127 0.0127
37 0.0045 00.114 0.01
38 0.0040 00.101 0.008
39 0.0035 00.089 0.0062
40 0.0031 00.079 0.0049
41 0.0028 00.071 0.00395
42 0.0025 00.064 0.00321
43 0.0022 00.056 0.00246
44 0.00198 00.050 0.00196
45 0.00176 00.045
46 0.00157 00.040
47 0.00140 00.036
48 0.00124 00.031
49 0.00110 00.028
50 0.00099 00.025

Remark: Starting from 0.03 mm2 (AWG 32) a wire can be crimped.


Conversion Table – Inch/mm

Inch 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009
0 0.0000 0.0254 0.0508 0.0762 0.1016 0.1270 0.1524 0.1778 0.2032 0.2286
0.010 0.2540 0.2794 0.3048 0.3302 0.3556 0.3810 0.4064 0.4318 0.4572 0.4826
0.020 0.5080 0.5334 0.5588 0.5842 0.6096 0.6350 0.6604 0.6858 0.7112 0.7366
0.030 0.7620 0.7874 0.8128 0.8382 0.8636 0.8890 0.9144 0.9398 0.9652 0.9906
0.040 1.0160 1.0414 1.0668 1.0922 1.1176 1.1430 1.1684 1.1938 1.2192 1.2446
0.050 1.2700 1.2954 1.3208 1.3462 1.3716 1.3970 1.4224 1.4478 1.4732 1.4986
0.060 1.5240 1.5494 1.5748 1.6002 1.6256 1.6510 1.6764 1.7018 1.7272 1.7526
0.070 1.7780 1.8034 1.8288 1.8542 1.8796 1.9050 1.9304 1.9558 1.9812 2.0066
0.080 2.0320 2.0574 2.0828 2.1062 2.1336 2.1590 2.1844 2.2098 2.2352 2.2606
0.090 2.2860 2.3114 2.3368 2.3622 2.3876 2.4130 2.4384 2.4638 2.4892 2.5146
0.100 2.5400 2.5654 2.5908 2.6162 2.6416 2.6670 2.6924 2.7178 2.7432 2.7686
0.110 2.7940 2.8194 2.8448 2.8702 2.8956 2.9210 2.9464 2.9718 2.9972 3.0226
0.120 3.0480 3.0734 3.0988 3.1242 3.1496 3.1750 3.2004 3.2258 3.2512 3.2766
0.130 3.3020 3.3274 3.3528 3.3782 3.4036 3.4290 3.4544 3.4798 3.5052 3.5306
0.140 3.5560 3.5814 3.6068 3.6322 3.6576 3.6830 3.7084 3.7338 3.7592 3.7846
0.150 3.8100 3.8354 3.8608 3.8862 3.9116 3.9370 3.9624 3.9878 4.0132 4.0386
0.160 4.0640 4.0894 4.1148 4.1402 4.1656 4.1910 4.2164 4.2418 4.2672 4.2926
0.170 4.3180 4.3434 4.3688 4.3942 4.4196 4.4450 4.4704 4.4958 4.5212 4.5466
0.180 4.5720 4.5974 4.6228 4.6482 4.6736 4.6990 4.7244 4.7498 4.7752 4.8006
0.190 4.8260 4.8514 4.8768 4.9022 4.9276 4.9530 4.9784 5.0038 5.0292 5.0546
0.200 5.0800 5.1054 5.1308 5.1562 5.1816 5.2070 5.2324 5.2578 5.2832 5.3086
0.210 5.3340 5.3594 5.3848 5.4102 5.4356 5.4610 5.4864 5.5118 5.5372 5.5626
0.220 5.5880 5.6134 5.6388 5.6642 5.6896 5.7150 5.7404 5.7658 5.7912 5.8166
0.230 5.8420 5.8674 5.8928 5.9182 5.9436 5.9690 5.9944 6.0198 6.0452 6.0706
0.240 6.0960 6.1214 6.1468 6.1722 6.1976 6.2230 6.2484 6.2738 6.2992 6.3246
0.250 6.3500 6.3754 6.4008 6.4262 6.4516 6.4770 6.5024 6.5278 6.5532 6.5786
0.260 6.6040 6.6294 6.6548 6.6802 6.7056 6.7310 6.7564 6.7818 6.8072 6.8326
0.270 6.8580 6.8834 6.9088 6.9342 6.9596 6.9850 7.0104 7.0358 7.0612 7.0866
0.280 7.1120 7.1374 7.1628 7.1882 7.2136 7.2390 7.2644 7.2898 7.3152 7.3406
0.290 7.3660 7.3914 7.4168 7.4422 7.4676 7.4930 7.5184 7.5438 7.5692 7.5946
0.300 7.6200 7.6454 7.6708 7.6962 7.7216 7.7470 7.7724 7.7978 7.8232 7.8486
0.310 7.8740 7.8994 7.9248 7.9502 7.9756 8.0010 8.0264 8.0518 8.0772 8.1026
0.320 8.1280 8.1534 8.1788 8.2042 8.2296 8.2550 8.2804 8.3058 8.3312 8.3566
0.330 8.3820 8.4074 8.4328 8.4582 8.4836 8.5090 8.5344 8.5598 8.5852 8.6106
0.340 8.6360 8.6614 8.6868 8.7122 8.7376 8.7630 8.7884 8.8138 8.8392 8.8646
0.350 8.8900 8.9154 8.9408 8.9662 8.9916 9.0170 9.0424 9.0678 9.0932 9.1186
0.360 9.1440 9.1694 9.1948 9.2202 9.2456 9.2710 9.2964 9.3218 9.3472 9.3726
0.370 9.3980 9.4234 9.4488 9.4742 9.4996 9.5250 9.5504 9.5758 9.6012 9.6266
0.380 9.6520 9.6774 9.7028 9.7282 9.7536 9.7790 9.8044 9.8298 9.8552 9.8806
0.390 9.9060 9.9314 9.9568 9.9822 10.0076 10.0330 10.0584 10.0838 10.1092 10.1346
0.400 10.1600 10.1854 10.2108 10.2362 10.2616 10.2870 10.3124 10.3378 10.3632 10.3886
0.410 10.4140 10.4394 10.4648 10.4902 10.5156 10.5410 10.5664 10.5918 10.6172 10.6426
0.420 10.6680 10.6934 10.7188 10.7442 10.7696 10.7950 10.8204 10.8458 10.8712 10.8966
0.430 10.9220 10.9474 10.9728 10.9982 11.0236 11.0490 11.0744 11.0998 11.1252 11.1506
0.440 11.1760 11.2014 11.2268 11.2522 11.2776 11.3030 11.3284 11.3538 11.3792 11.4046
0.450 11.4300 11.4554 11.4808 11.5062 11.5316 11.5510 11.5824 11.6078 11.6332 11.6586
0.460 11.6840 11.7094 11.7348 11.7602 11.7856 11.8110 11.8364 11.8618 11.8872 11.9126
0.470 11.9380 11.9634 11.9888 12.0142 12.0396 12.0650 12.0904 12.1158 12.1412 12.1666
0.480 12.1920 12.2174 12.2428 12.2682 12.2936 12.3190 12.3444 12.3698 12.3952 12.4206
0.490 12.4460 12.4714 12.4968 12.5222 12.5476 12.5730 12.5984 12.6238 12.6492 12.6746
0.500 12.7000
Inch 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009


C O N V E R S I O N TA B L E S

Conversion Table – Inch/mm (continued)

Inch 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009
0.500 12.7000 12.7254 12.7508 12.7762 12.8016 12.8270 12.8524 12.8778 12.9032 12.9286
0.510 12.9540 12.9794 13.0048 13.0302 13.0556 13.0810 13.1064 13.1318 13.1572 13.1826
0.520 13.2080 13.2334 13.2588 13.2842 13.3096 13.3350 13.3604 13.3858 13.4112 13.4366
0.530 13.4620 13.4874 13.5128 15.5382 13.5636 13.5890 13.6144 13.6398 13.6652 13.6906
0.540 13.7160 13.7414 13.7668 13.7922 13.8176 13.8430 13.8684 13.8938 13.9192 13.9446
0.550 13.9700 13.9954 14.0208 14.0462 14.0716 14.0970 14.1224 14.1478 14.1732 14.1986
0.560 14.2240 14.2494 14.2748 14.3002 14.3256 14.3510 14.3764 14.4018 14.4272 14.4526
0.570 14.4780 14.5034 14.5288 14.5542 14.5796 14.6050 14.6304 14.6558 14.6812 14.7066
0.580 14.7320 14.7574 14.7828 14.8082 14.8336 14.8590 14.8844 14.9098 14.9352 14.9606
0.590 14.9860 15.0114 15.0368 15.0622 15.0876 15.1130 15.1384 15.1638 15.1892 15.2146
0.600 15.2400 15.2654 15.2908 15.3162 15.3416 15.3670 15.3924 15.4178 15.4432 15.4686
0.610 15.4940 15.5194 15.5448 15.5702 15.5956 15.6210 15.6464 15.6718 15.6972 15.7226
0.620 15.7480 15.7734 15.7988 15.8242 15.8496 15.8750 15.9004 15.9258 15.9512 15.9766
0.630 16.0020 16.0274 16.0528 16.0782 16.1036 16.1290 16.1544 16.1798 16.2052 16.2306
0.640 16.2560 16.2814 16.3068 16.3322 16.3576 16.3830 16.4084 16.4338 16.4592 16.4846
0.650 16.5100 16.5354 16.5608 16.5862 16.6116 16.6370 16.6624 16.6878 16.7132 16.7386
0.660 16.7640 16.7894 16.8148 16.8402 16.8656 16.8910 16.9164 16.9418 16.9672 16.9926
0.670 17.0180 17.0434 17.0688 17.0942 17.1196 17.1450 17.1704 17.1958 17.2212 17.2466
0.680 17.2720 17.2974 17.3228 17.3482 17.3736 17.3990 17.4244 17.4498 17.4752 17.5006
0.690 17.5260 17.5514 17.5768 17.6022 17.6276 17.6530 17.6784 17.7038 17.7292 17.7546
0.700 17.7800 17.8054 17.8308 17.8562 17.8816 17.9070 17.9324 17.9528 17.9832 18.0086
0.710 18.0340 18.0594 18.0848 18.1102 18.1356 18.1610 18.1864 18.2118 18.2372 18.2626
0.720 18.2880 18.3134 18.3388 18.3642 18.3896 18.4150 18.4404 18.4658 18.4912 19.5166
0.730 18.5420 18.5674 18.5928 18.6182 18.6436 18.6690 18.6944 18.7198 18.7452 18.7706
0.740 18.7960 18.8214 18.8468 18.8722 18.8976 18.9230 18.9484 18.9738 18.9992 19.0246
0.750 19.0500 19.0754 19.1008 19.1262 19.1516 19.1170 19.2024 19.2278 19.2532 19.2786
0.760 19.3040 19.3294 19.3548 19.3802 19.4056 19.4310 19.4564 19.4818 19.5072 19.5326
0.770 19.5580 19.5834 19.6088 19.6342 19.6596 19.6850 19.7104 19.7358 19.7612 19.7886
0.780 19.8120 19.8374 19.8628 19.8882 19.9136 19.9390 19.9644 19.9898 20.0152 20.0406
0.790 20.0660 20.0914 20.1168 20.1422 20.1676 20.1930 20.2184 20.2438 20.2692 20.2946
0.800 20.3200 20.3454 20.3708 20.3962 20.4216 20.4470 20.4724 20.4978 20.5232 20.5486
0.810 20.5740 20.5994 20.6248 20.6502 20.6756 20.7010 20.7264 20.7518 20.7772 20.8026
0.820 20.8280 20.8534 20.8788 20.9042 20.9296 20.9550 20.9804 21.0058 21.0312 21.0566
0.830 21.0820 21.1074 21.1328 21.1582 21.1836 21.2090 21.2344 21.2598 21.2852 21.3106
0.840 21.3360 21.3614 21.3868 21.4122 21.4376 21.4630 21.4884 21.5138 21.5392 21.5646
0.850 21.5900 21.6154 21.6408 21.6662 21.6916 21.7170 21.7424 21.7678 21.7932 21.8186
0.860 21.8440 21.8694 21.8948 21.9202 21.9456 21.9710 21.9964 22.0218 22.0472 22.0726
0.870 22.0980 22.1234 22.1488 22.1742 22.1996 22.2250 22.2504 22.2758 22.3012 22.3266
0.880 22.3520 22.3774 22.4028 22.4282 22.4536 22.4790 22.5044 22.5298 22.5552 22.5806
0.890 22.6060 22.6314 22.6568 22.6822 22.7076 22.7330 22.7584 22.7838 22.8092 22.8346
0.900 22.8600 22.8854 22.9108 22.9362 22.9616 22.9870 23.0124 23.0378 23.0632 23.0886
0.910 23.1140 23.1394 23.1648 23.1902 23.2156 23.2410 23.2664 23.2918 23.3172 23.3426
0.920 23.3680 23.3934 23.4188 23.4442 23.4696 23.4950 23.5204 23.5458 23.5712 23.5966
0.930 23.6220 23.6474 23.6728 23.6982 23.7236 23.7490 23.7744 23.7998 23.8252 23.8506
0.940 23.8760 23.9014 23.9268 23.9522 23.9776 24.0030 24.0284 24.0538 24.0792 24.1046
0.950 24.1300 24.1554 24.1808 24.2062 24.2316 24.2570 24.2824 24.3078 24.3332 24.3586
0.960 24.3840 24.4094 24.4348 24.4602 24.4856 24.5110 24.5364 24.5618 24.5812 24.6126
0.970 24.6380 24.6634 24.6888 24.7142 24.7396 24.7650 24.7904 24.8158 24.8412 24.8666
0.980 24.8920 24.9174 24.9428 24.9682 24.9936 25.0190 25.0444 25.0698 25.0952 25.1206
0.990 25.1460 25.1714 25.1968 25.2222 25.2476 25.2730 25.2984 25.3228 25.3492 25.3746
1.000 25.4000
Inch 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009


ENGINEERING NOTES


R E S T R I C T I O N O N H A Z A R D O U S S U B S TA N C E S

RESTRICTION ON THE USE OF
H A Z A R D O U S S U B S TA N C E S ( R O H S )

At Tyco Electronics, we’re ready to support your RoHS requirements. We’ve assessed more than
1.5 million end items/components for RoHS compliance, and issued new part numbers where
any change was required to eliminate the restricted materials. Part numbers in this catalog are
identified as:

ROHS COMPLIANT
Part numbers in this catalog are RoHS Compliant, unless marked otherwise.
These products comply with European Union Directive 2002/95/EC as amended 1 January
2006 that restricts the use of lead, mercury, cadmium, hexavalent chromium, PBB, and PBDE
in certain electrical and electronic products sold into the EU as of 1 July 2006.
Note: For purposes of this Catalog, included within the definition of RoHS Compliant are
products that are clearly “Out of Scope” of the RoHS Directive such as hand tools and other
non-electrical accessories.

NON-ROHS COMPLIANT
These part numbers are identified with a “ ” symbol. These products do not comply with the
material restrictions of the European Union Directive 2002/95/EC.

5 OF 6 COMPLIANT
A “ ” symbol identifies these part numbers. These products do not fully comply with the
European Union Directive 2002/95/EC because they contain lead in solderable interfaces (they
do not contain any of the other five restricted substances above allowable limits). However,
these products may be suitable for use in RoHS applications where there is an application-
based exception for lead in solders, such as the server, storage, or networking infrastructure
exemption.
Note: Information regarding RoHS compliance is provided based on reasonable inquiry of our
suppliers and represents our current actual knowledge based on the information provided by
our suppliers. This information is subject to change. For latest compliance status, refer to our
website referenced below.

G E T T I N G T H E I N F O R M AT I O N YO U N E E D
Our comprehensive on-line RoHS Customer Support Center provides a forum to answer your
questions and support your RoHS needs. A RoHS FAQ (Frequently Asked Questions) is
available with links to more detailed information. You can also submit RoHS questions and
receive a response within 24 hours during a normal work week. The Support Center also
provides:

• Cross-Reference from Non-compliant to Compliant Products
• Ability to browse RoHS Compliant Products in our on-line catalog:
http://ecommas.tycoelectronics.com/commerce/alt/RohsAltHome.do RoHS
• Downloadable Technical Data Customer Information Presentation Customer
• More detailed information regarding the definitions used above
Support
So whatever your questions when it comes to RoHS, we’ve got the Center
answers at www.tycoelectronics.com/leadfree


Page

Terminals & Connectors
Introduction 27
Technology 28
Micro Quadlok Interconnection System 29
AMP Timer Connector System 29
AMP MCP Interconnection System 30
MCON-1.2 mm Interconnection System 30
MULTILOCK Connectors 31
GET .64 Interconnection System 31
MIC Connectors I and IV Series 32
Econoseal III Connectors 32
Positive Mate Connectors 33
.140 MATE-N-LOK Connectors 33
AMP SUPERSEAL 1.0 mm Connector System 34
AMP SUPERSEAL 1.5 Series Connectors 34
AMPSEAL Connectors 35
AMPSEAL 16 Connector System 35
Positive Lock Connectors 36
ACTION PIN/Pressfit 36
Contact Systems for IDC 37
Contacts for Flexcircuit Applications 37
Flat Contact System 38
Sensor Flat Contact System 38
Heavy Duty Sealed Connector Series 39
Dia 1.5, 2.5 and 4.0 mm Circular Contact System 39
Coil Spring Power Contact 40
FASTON Terminals 40
Tyco Electronics PRONER Contact System 41
Magnet Wire Terminals and Splices 41

Cable Assembly Systems
Introduction 43
Technology 44
Wiring Products with Standard Contact System 45
Overmolded Wiring Products 45


Page

Cable Assembly Systems
High Voltage Cable Assemblies 46
Squib Assemblies 46
Pump Nozzle Assemblies 47
Power Distribution 47
Heating and Ventilation Cable Assemblies 48
FFC Cable Assemblies 48
Low Voltage Differential Signaling 49
Planar and Discrete Wiring Products 49
RF and Coax Cable Assemblies 50

Mechatronics
Introduction 51
Technology 52
Advanced in Mechatronics Components 53
Concept Study for Carrier 53
Component for CVT Control Unit 54
Controlled Actuator Module for Turbo Charger Applications 54
Controlled Actuator for Throttle or Exhaust Applications 55
Component for Controlled Actuator for Throttle Applications 55
Tight Connector for CCD-Chip Packaging 56
Housing for Manifold Air Pressure Sensor 56
Packaging for Micro-Mechanic Speed Sensor (SMD) “Low-G” 57
Packaging for Acceleration Sensor in ESP 57
Modules for Powersteering Application 58
Brush Holder for Generator 58
Switch Module for Seat Positioning 59
Housing for Crash Sensor 59

Sensors
Introduction 61
Technology 62
PLCD 15 63
PLCD 25 63
PLCD 50 64


Page

Sensor Technology
L40MC1 Contact-less Travel Sensor 64
R180M1 Contact-less 180° Rotary Sensor 65
R360MC1 Contact-less 360° Rotary Sensor 65
Cylinder Hall Switch 66
Chassis Hall Switch 66-67
Powertrain Hall Switch 67
Hall Sensor Cable Assemblies 68
Steering Height Position Sensor 68
Seat Position Sensor 69-70
Buckle Switch 70
Brake Light Switch 71
Brake Master Cylinder Sensor 72
Wheel Speed Sensor 72-73
Clutch Position Sensor 73-77
Dual Clutch Position Sensor 78
Drive Mode Sensor 78
Gear and Shift Sensor 79
Neutral Position Sensor 80
Transmission Controller Housing with Integrated Sensors 80
Transmission Sensor Module 81
Turbo Charger Sensor 81-82
EGR Actuator Sensor 82
Rotational Sensor for Engine Actuator 83
Truck Rear Axle Steering Sensor 83
Water Detection Sensor 84

Relays and Switching Modules
Introduction 85
Technology 86
Complete Range of Electromechanical Devices 87
Evolution of Relay Size and Performance 87
PCB Relays 88
Plug-In Relays 88
Application Specific Switching Solutions 89
High Current Solutions 89


Page

Power Distribution Systems
Introduction 91
Technology 92
General Central Electric Units 93
Integrated Body Control Modules 93
Prefuse Modules 94
Switching Modules 94

Inductive Systems
Introduction 95
Technology 96
Immobilizer Antenna 97
Keyless Entry Antenna 97
Brake Stability Modules 98
Actuator Assembly 98
Injector Coils 99
ABS Coil Family 99
Heavy Duty Break Modules 100

Alternative Power Systems
Introduction 101
Technology 102
Power Distribution and Protection Units 103
HVA Connector (2 Positions) 103
HVC 25 Connector 104
LV Connector (2 Positions) 105
HV Connector (2 Positions) 106
HV Connector (3 Positions) 106
1 Position IPT Shielded Terminal, Screwed, 25.0-50.0 mm 2
107
1 Position IPT Shielded Terminal, Screwed, 70.0-120.0 mm2 107
Kilovac EV500 Relay 108


Page

Alternative Power Systems
Kilovac LEV100 Relay 109
Kilovac PD5 Relay 110
Kilovac PD10 Relay 110
Typical Make / Break 111
Power Resistors 112
BDS-A 112
HCR 113
Clutch Position Sensor 113
Dual Clutch Position Sensor 114
Neutral Position Sensor 114
EV (Electric Vehicle) Sensor 115
Brake Pedal Position Sensor 116
HFT 5000 116

High Speed Data Networking
Introduction 117
Technology 118
Fakra RF Coax Products 119
MOST Micro Pigtail Range 119
MOST 2+4 Connection 120
MOST 4+40 Connection 120
MOST Inline Connections 121
High Speed Electrical Connections 121

Protection Products
Introduction 123
Technology 124
RBK-ILS-125 125
Raychem RNF-100 125
Raychem HFT 5000 126
Raychem Application Tooling 126

Application Tooling
Introduction 127


ENGINEERING NOTES



TERMINALS AND CONNECTORS

Tyco Electronics offers a broad range of high quality electronic
component products. We provide solutions for OEM applications,
utility and energy, outside plant and premise networking installations
and more. Products from well-known-brands include connectors and
interconnection systems, terminal blocks, relays, circuit protection
devices, fiber optic components, wires and cables, switches, sensors,
touch screens and application tooling. We also provide products to
insulate, protect, hold, bundle and identify electrical harnesses.

Our electrical and electronic connectors and interconnection products are used in an
endless list of automotive applications. Connector products are used to electrically
and mechanically join wires and cables, printed circuit boards, integrated circuit
packages and batteries. Our continually expanding capabilities include new copper
and fiber optic connectors, wires, cables and cable management systems that are
designed to meet automotive industry demands. The Tyco Electronics brand
encompasses the broadest range of connectors in the world, including high-density,
high-speed designs for leading-edge communications equipment.

TECHNOLOGY

CONNECTORS AND INTERCONNECTION PRODUCTS
The Global Automotive Division of Tyco Electronics offers a fully
comprehensive range of electrical and electronic interconnection products
and solutions. Our continuously expanding capabilities are more than just
providing the automotive market place with cutting edge components for
advanced safety systems, highly integrated engine control components or
superior management modules. We at Tyco Electronics are also working
with customers on using proven components in evolving applications or
helping them engineer completely new solutions.

A D VA N C E D C O N TA C T D E S I G N
A reliable and high performance interconnection point is of greatest
importance for the function of the whole vehicle. In addition to this, the
working conditions are extremely tough. This creates very high demands on
the contact design.

A D VA N C E D P L AT I N G T E C H N O L O G Y
Applied plating technologies include high speed selective plating, hot
dipped alloy-tinning and lead-free tin plating of contact and solder area.
New development in plating technology includes nano dispersion layers
with built in particles or film hardening and additives of micro capsules
filled with different lubricants to improve durability. Plating technology,
together with contact design solutions also offers a way to handle the
problem of fretting corrosion. The reason for fretting corrosion is minimal
relative movement of contacts parts where oxides are formed.

A D VA N C E D C O N TA C T T O W I R E C O N N E C T I O N
Tyco Electronics has developed a brand new termination process by
utilising resistance welding for sensitive circuits in safety applications. A
resistance welding module is being adapted in a full automatic applicator.
Further advantage of this new technology combined with the contact
design is that the same contact can be used for several wire sizes.

LITERATURE NO. 1308092-2


TERMINALS CONNECTORS

Micro Quadlok Interconnection System

The Micro Quadlok System (MQS) combines the features of
a high packaging density, robust construction and highest
functional requirements. In spite of its miniaturized design,
the MQS Contact system is suitable for use in automobiles
and covers a wide range of application sectors in both
waterproof and non-waterproof areas. The electrical contact
is made by a square pin with an edge length of 0.63 mm.
The socket contact has four contact points and the electrical
contact is made with all four surfaces of the pin.

Features
• Available contacts: MQS, MQS 1.2, MQS 1.5, Micro
Power Quadlok, Power Quadlok
• Contact thickness 0.63 mm, available contacts sizes:
0.63, 1.2, 1.5, 2.8 and 5.2 mm
• Tab and receptacle contacts in two-piece design
with steel spring
• Contacts for sealed and unsealed applications
• For signal and power applications; range of wire
Product Literature No. 1307999 sizes from 0.14 mm2 up to 4 mm2
• Two independent contact lockings
• Current capacity up to 45 A
• Additional versions: FFC, Clean Body, Short Circuit, IDC
• Sealed and unsealed connector housings and
headers are available

AMP Timer Connector System

The AMP Timer Connector system is used extensively
in the automotive industry. The contact system
consists of a flat receptacle contact that mates with a
flat tab contact. The receptacle has two contacts with
four springs, which are independent of each other.
Tabs and receptacles can be applied in both
watertight and non- watertight connector housings.
AMP Timer connectors are available as receptacle and
tab housings or as receptacle housings and multiple
tabs (group connection).

Features
• Available contacts:
Micro Timer I, Micro Timer II, Micro Timer III, Junior Timer,
Junior Power Timer, Standard Timer, Standard Power
Timer, Maxi Power Timer
• Suitable for tabs 1.5, 2.8, 4.8, 5.8, 6.3 and 9.5 mm
wide
• Power versions in two-piece design with steel spring Product Literature No. 889759
• Range of wire size from 0.12 mm2 up to 10 mm2
headers are available


AMP MCP Interconnection System

The AMP MCP Interconnection System is designed for
electronic and electrical applications in motor vehicles.
The contact system consists of a flat receptacle, which
mates with a flat tab. Every contact has a steel spring
and a copper alloy body. The system offers receptacle
and tab housings with capability for waterproofing
and resistance to conditions of extreme vibrations.

Features
• Available contact sizes: 1.5, 2.8, 4.8, 6.3 and 9.5 mm
• Tab and receptacle contacts in two-piece design
with steel spring
• Range of wire sizes from 0.2 mm2 up to 16 mm2
• Base material with high current carrying capacity
• Contacts for high vibration load
• Secondary locking possible from four directions
Product Literature No. 1307998-1 headers are available

MCON-1.2 mm Interconnection System

The MCON-1.2 mm contact system brings added reliability
to the automotive and commercial vehicle industries
which have increased requirements for more reliable
electrical contacts to handle vibration-prone applications.
The MCON-1.2 mm contacts have eight defined contact
points (two contact points on each of the four
independent beams), which is characteristic of the
contact spring technology, and increases safety margin
at high vibration loads. The 15 Ampere at 80°C in
combination with a 1.2 mm x 0.63 mm tab contact allows
for reliable transmissions to be carried. The robust closed
box design guarantees optimized protection of the
springs. Any distortion of the springs will be prevented
by an integrated, overstress protection feature.
Tyco Electronics offers a spectrum of hand tools and
fully automated leadmakers for fast and economic
processing.

Features Product Literature No. 1308070-1
• Base material with high current capacity
• 8 defined contact points for increased reliability • Overstress protection of the contact springs
• Improved vibration resistance • Box with polarization and secondary locking
• Good guiding inside the cavity • Protected locking lance
• Protected contact spring due to closed box • Sealed and unsealed connector housings available



MULTILOCK Connectors

The MULTILOCK Series Connectors are used extensively
in the automotive industry in wire-to-wire and wire-to-
board applications. The connectors consist of a plug
housing with receptacle contacts and a cap housing
with tab contacts for wire termination. Additionally, the
MULTILOCK Connectors have a cap housing assembly
which can be mounted onto the printed circuit board
either vertically or horizontally.

Features
• Small yet durable wire-to-wire and wire-to-board
• .025/.040/.070 and hybrid versions available
• High density .025 features pitch of 2.2 mm
• Housing lance design
• Plug and cap connectors for wire termination with
integral double lock mechanism
• Cap housing assembly for PCB mounting
• Plug and cap housings
Product Literature No. 889780-2 • Improved Kojiri protection
• Various contact platings

GET .64 Interconnection System

The GET .64 Interconnection System is used worldwide
in various applications for automotive interconnections.
It fulfills requirements for passenger and engine
compartment. The GET .64 Interconnection system has
a mat seal capability which allows for high packaging
density in sealed applications.

Features
• Product offering includes wire-to-wire, wire-to-board
and wire-to-device configurations
• High range of pin count variants
• Tangle free contact offered as tin, silver and gold
plating
• Female terminal accepts blades from 0.64 x 0.64 mm
up to 1.2 x 0.64 mm
• Sealed and unsealed connector housings available
(straight mate or lever actuated)
• Mat seals allow high packaging density
• Design allows for specific pinout versions, no blind Product Literature No. 1307992-1
plugs necessary in sealed applications


MIC Connectors I and IV Series

MIC represents a series of high contact density
receptacle housings and connectors for wire-to-wire
connections from front to rear vehicle harnesses, panel
mount and wire-to-board connections on equipment.
The female box type contact is provided with an anti-
stress device in its cavity and allows simple corrections
of any tab misalignment.

Features
• Housings MIC I available with 2, 3 or 4 rows with 5,
9, 13, 17, 20 or 27 positions
• Housings MIC IV include 5, 7, 9, 11, 13 and 21 positions
in two rows
• Low mating force and very reliable electrical contact
• Wire size for MIC I 0.35 mm2 up to 3.0 mm2
• MIC IV allows 0.35 mm2 up to 5.0 mm2
• Polarized housings include locking system with an
audible snap-lock on mating
Product Literature No. 889780-2 • Hand tools and semi-automatic tooling available

Econoseal III Connectors

The Econoseal III Connector Series .070 and .250 have
been designed to meet the exacting requirements of
the automotive industry. Each series offer a choice of
housings from 2 positions to 36 positions, polarized
mating, discrete cable sealing and contact secondary
locking.

Features
• Lanceless contacts, tin or gold finish
• Wire-to-board and wire-to-wire connections
• Wire range 0.5-3.0 mm2
• Insulation: thin wall 1.6-3.4 mm
• Sealed or unsealed
• Secondary contact locking
• Available 2-36 positions
• Single wire seal or cavity plug
• Up to 20 A rating

Product Literature No. 889780-2



Positive Mate Connectors

The Positive Mate connector was designed to overcome
the problems resulting from the incorrect mating of
connectors during assembly. The molded connector
housings incorporate an integral latching device, called
the “Go-NoGo” principle. This latching device utilizes the
spring characteristics of the nylon material to provide a
positively mated connection or no connection at all.

Features
• Box-type contact with an internal double spring
• High current flow with low insertion force
• Housings include secondary contact retention feature
• Mark IV connectors for most difficult operating
conditions
• Application tooling, ranging from hand tools to fully-
automatic machines is available


.140 MATE-N-LOK Connectors

The UL recognized .140 MATE-N-LOK connectors with
3.5 mm dia pin and sockets have a 25 A current
carrying capacity and are capable of accepting wire
with insulation diameters up to 4.5 mm. Both pins and
sockets are equipped with dual locking lances, which
assure positive contact retention when installed in the
housings.

Features
• Available in 2, 3 and 9 configurations for panel
mounting; 4 and 9 for free hanging applications
• Housings fully polarized
• Contacts fully protected in housings
• Wire size range 0.5 up to 5.0 mm2
• Low insertion/extraction forces
• Dual locking lances provide optimum contact
retention
• Contacts are on 6.09 mm centerline spacing


AMP SUPERSEAL 1.0 mm Connector
System

Designed for the automotive industry, AMP SUPERSEAL
1.0 mm connectors meet the sealing requirements
outlined in IEC 529 and DIN 40050 I.P 6.7 specifications.
The cap and plug connector housings incorporate pre-
assembled secondary locks to help insure correct and
complete contact insertion. The secondary lock cannot
be closed if the contacts are not correctly inserted
into the connector housing.

Features
• Wire-to-board and ECU applications, under hood or
any location where sealing is required
• Suitable for automotive, truck, bus or off-road
vehicles
• Compact system minimizes packaging requirements
• Sealing reliability proven under harsh conditions
• Double spring contact design insures low insertion
Product Literature No. 1308072-2 and high contact forces
• Designed for ease of manual harness assembly,
engine mounting and under hood environments

AMP SUPERSEAL 1.5 Series Connectors

The AMP SUPERSEAL 1.5 Series Connectors was
developed to meet the increasing requirements for
reliability and water resistance. The 1.5 Series exceed
the requirements prescribed by IP 67 according IEC
60529 and DIN 40050-9 standards and is applied in
the automotive, agricultural and industrial machinery
industry and sensor applications.

Features
• Lanceless contact, tin or gold finish
• Wire size range 0.35-2.5 mm2
• Insulation diameter 1.2-3.3 mm
• Single wire seals or cavity plug
• Contact with secondary locking
• Plug and cap housings in 1 to 6 positions
• Polarized mating
• Up to 14 A rating




AMPSEAL Connectors

AMPSEAL automotive connectors provide rugged
reliability, easy use and superior environmental sealing.
They are available in cable plugs and pc board-
mounting headers that are designed to stand up high-
temperature underhood applications. The pre-
assembled plug connector features built-in contact
sealing to eliminate individual wire-sealing grommets,
while an integral interfacial seal protects mated
connectors

Features
• Sealing of interface, wires and panel provides for
environmental integrity
• Secondary contact locking and lanceless contacts
ensure positive contact seating
• High temperature materials available to withstand
surface mount applications
• Lanceless receptacle contacts reduce tangling
Product Literature No. 1654285-1 during storage and handling
• Wire with insulation dia of 1.7-2.7 mm
• Available in tin or gold
• Housings available in 8, 14, 23 and 35 positions

AMPSEAL 16 Connector System

The AMPSEAL 16 Connector System is targeted for
off-road and heavy duty industrial applications. This
wire-to-wire and wire-to-device connector line was
designed to meet the rigorous demands of an industry
that requires the highest standards in performance.
This connector family will feature the HDSF Size 16 Pin
and Socket contacts as a terminal system. These
contacts are stamped and formed versions of the
screw machined MIL-C-39029 contacts.
The 2, 3, 4, 6, 8, 12 position housings will offer a one
piece assembly for both plug and cap.

Features
• Keyed/polarized, prevents mismating
• Lanceless contacts, no damaged tangs or tangled
contacts
• Integral CPA, protects against accidental unlocking
• Sleeved assembly for contact beam protection
provides 50 durability cycles Product Literature No. 1654281-1
• Attachment feature on receptacle housing provides
connector clip mounting
• Integral TPA provides terminal position assurance
with no additional assembly
• Sealing of interface and wires provides for
environmental integrity


Positive Lock Connectors

The Positive Lock connectors are wire-to-tab
termination connectors designed to provide fast
connect/disconnect and positive locking capabilities
by using a combination of specially designed
receptacles and housings. These unique features are
possible due to the reduced insertion force and the
locking dimple. The receptacle locks onto mating tabs
containing holes and is removable only by deflecting a
depressor prior to withdrawal

Features
• Fast connect/disconnect
• Positive locking capabilities
• Confirmation of tab insertion
• Good electrical contact
• Loading of receptacle terminals in housing
• Housing insulates and serves as removal tool
• Available sizes: 2.8 mm - 4.8 mm - 6.3 mm

ACTION PIN / Multispring
Pressfit Connection

Advanced electronic control units for Safety Restraint System
Airbags, Engine Control Modules, and Anti-Lock Brake
System functions require extremely reliable connections for
signal and power applications. Tyco Electronics’ press-fit
technology compliant pin provides a solder-free, reliable
electrical assembly with improved performance and
environmental benefits over traditional solder connections.
Tyco Electronics compliant ACTION PIN contacts and
Multispring contacts produce a tight contact zone between
the pin and the plated-through hole and provide long-term
reliable electrical interconnection and mechanical reliability.
The spring-action is repairable up to 3 times for ease of PCB
troubleshooting. The residual force of the elastic deformation
maintains stored energy, providing long-term reliability of
compliant contact press-fit connections. Tyco Electronics
offers stand alone solutions such as connectors (stitched,
over-molded), housings and application tooling machines.

Features
• Gas-tight contact zone • Especially suited for multilayer PCB’s
• Higher process reliability v.s. solder process • More economic board manufacturing due to larger
• High retention force hole tolerances compared with the use of a solid pin
• No damage to plated thru-holes during application • Application can be made by end-user



Contact Systems for IDC
(Insulation Displacement Connection)

In the past 20 years, the need to have economical and
compact electronic components for the automotive
industry has increased. To meet this demand,
connectors in grid 2.54 mm were introduced.
Tyco Electronics developed connectors based on the
Insulation Displacement Technique, in which the
contacts were already protected in the housings, thus
avoiding damage during production and finishing as
well as distribution. The IDC technique introduced the
0.35 mm2 cable, which resulted in weight reduction.

Features
• High quality level
• Mechanical protection of the contacts in the chamber
• Economical second contact security
• Economical processing of the contacts on various
application tools
Product Literature No. 889780-2 • High process security during processing
• Use of economical, one-piece contacts since the
contacts are supplied in the chambers

Contacts for Flexcircuit Applications

For decades the automotive industry has been using
flexible foil circuits in instrument clusters and
passenger airbags. In order to implement these
internal and external electrical connections, Tyco
Electronics has an extensive product range of contacts
to meet current quality and technical requirements to
use flexible circuits in automotive applications.

Features
• Flexible, foil can be bent, twisted and folded
• Lighter, thinner and flatter than conventional wires
• Better current carrying capacity and heat dissipation
• Lighter, weight saving
• Less volume
• Direct and indirect connections
• Contacting with corresponding processing machines



Flat Contact System

The Flat Contact System is used extensively in the
automotive industry. The tabs mate with a rich variety
of receptacle contacts. The tabs can be applied in both
watertight and non-watertight connector housings.
The Flat Contact System can be quickly and economically
terminated to the lead using Tyco Electronics’ hand-,
semi-automatic- or fully-automatic tooling.

Features
• Contacts mate with a wide variety of receptacle
contacts
• Available contact sizes:
1.2 x 0.6 mm
1.5 x 0.6 mm
2.8 x 0.8 mm
5.8 x 0.8 mm
6.3 x 0.8 mm
9.5 x 1.2 mm
Product Literature No. 889780-2 • Tab and receptacle contacts in two-piece design
with steel spring
• Range of wire sizes from 0.2 mm2 up to 10 mm2
• Base material with high current carrying capacity

Sensor Flat Contact System

Fretting corrosion in the contact area of receptacle or
tab leads to surface oxidation, which can cause a
complete interruption of the electric circuit. To prevent
this corrosion, Tyco Electronics has developed the
sensor receptacle contact which has an integrated
spring in the body, that balances movement in all three
space axes. The sensor receptacle contact can be
applied in a single wire sealed and a non-waterproof
design.

Features
• Available contact sizes: 1.5 and 2.8 mm
• Specially developed to prevent fretting corrosion
• Able to compensate micro motions in all
three space axes
• Contacts for very high vibration load
• Secondary locking possible from four directions
• Suitable in the cavities of the AMP MCP contacts



Heavy Duty Sealed Connector Series

The Heavy Duty Sealed Connector Series, so called
HDSCS, is targeted for the commercial vehicle industry
and off-road applications. This wire-to-wire and wire-
to- device connector program was designed to meet
the rigorous demands of an industry that requires the
highest standards in performance.

Features
• High reliability status supported for long term use
• High vibration level supported
• Perfect design to avoid quality problems, reduce
manufacturing and service cost
• Integrated secondary locking device delivered in
pre-locked position
• Polarisation, several keyings
• Clear handling, low mating force with a reliable slide
locking mechanism delivered


Dia 1.5, 2.5 and 4,0 mm
Circular Contact System

The Dia 1.5, 2.5 and 4.0 mm circular contact system is
mainly used in the automotive industry. Due to its
wide range of performance possibilities, the contact is
used in the engine compartment for aggregate or
sensor connections. The two-piece contact design
means that the electrical and mechanical properties
are separated. The closed cantilever spring has several
functions and also different advantages for the
complete contact system.

Features
• Resistant against fretting corrosion
• Vibration resistant
• Excellent longevity
• Low contact resistance
• High position configurations
• Contact design accepts secondary locking device
• Several contact points Product Literature No. 1654286-1
• Sturdy contact design
• Guarantees constant insertion and extraction forces
• Sealed and unsealed connector housings available


Coil Spring Power Contact

The demand for shortest possible periods of machine
shutdowns and assembly times requires the use of
connectors at the interfaces of the connector
wires, as well as energy feeding and power circuits.
To satisfy the demand of the various applications the
series Power Connector was designed.

Features
• Wear-resistant basic material
• Worn parts can be individually exchanged
• Surface coating according to customer application
• Reduced mating and pulling forces
• Vibration test
• High current capability through many contact points
• Variable wire termination


FASTON Terminals

The FASTON terminals product line consists of
receptacles and tabs specifically designed for quick
connections. The large variety of sizes and available
types will enable you to select contacts to fit your
need. The product line offers speed of application,
uniform reliability and low cost per line. These
advantages have made FASTON products the number
one choice of leaders in the automotive industries.

Features
• Various base material and contact finishes available
• Products are rigorously and extensively tested
• Lowest temperature rise and millivolt drop
• Resistance to oxidation and corrosion
• Tensile strength satisfies requirements
• Reliable vibration resistance in crimp area
• Low Insertion Force (LIF) receptacles available



Tyco Electronics Proner Contact Systems

Tyco Electronics Proner Contact System produces
leadframes and connectors for electrical and
electronic devices, serving the automotive industry.

Features
• Power terminals: low insertion force 6.35 and 8.0
mm and high power contacts
• Power housings: sealed and unsealed versions
• High power contacts: HPC and ring terminals


Magnet Wire Terminals and Splices

Tyco Electronics offers a full selection of Standard MAG-
MATE Insulation Displacement Crimp (IDC) terminals for
magnet wire terminations. MAG-MATE terminals are
available in poke-in, poke-in tab, splice, crimp wire barrel,
solder post, quick connect tab, pin and receptacle styles.
MAG-MATE terminals are applied in motor windings and
connections, coil connections, transformer windings,
bobbin connections and power supplies.

Features
MAG-MATE Terminals
• For integration into coil bodies or specially designed
housings
• Employs insulation displacement crimp which
accepts unstripped magnet wire
• Standard MAG-MATE, Mini MAG-MATE and Slim line
MAG-MATE terminals
SIAMEZE Terminals
• Moving beam contact design connects a wide range
of magnet wire sizes
• Standard range, fine range and medium/heavy range
magnet wire terminals


ENGINEERING NOTES



C A B L E A S S E M B LY S Y S T E M S

Tyco Electronics is your partner for special cable assemblies. Tyco Electronics
offers research and development capabilities, prototyping, samples as
well as manufacturing facilities for special cable assemblies. This includes
overmold technology, semi- and fully automatic manufacturing, testing
equipment and appliances for handling of high volume production.

TECHNOLOGY

The Global Automotive Division of Tyco Electronics offers a fully comprehensive
range of cable assembly products and solutions. Coupled with our
continuously expanding range of capabilities, we are providing the
automotive place with highly integrated systems and cost effective
solutions. We at Tyco Electronics are also working with customers on using
proven terminal and connector components along with Tyco Electronics
application tooling in evolving applications or helping them engineer
completely new solutions.

The growing number of complexity and additional functions within the
vehicle, to provide the driver and passenger with increased comfort, safety,
reliability means the design of each capable assembly must be completely
dependable. The experience of Tyco Electronics in component design and
manufacture is extended to the cable assembly over the past decade to
offer our customers a complete solution within a complex system where a
cable assembly is required.

OUR SOLUTIONS INCLUDE
• Coax Cable Assemblies
• FFC Cable Assemblies
• Fuel Tank Wiring
• Squib Airbag Assemblies
• Fiber Optic Cable Assemblies
• Pump Nozzle and Engine Wiring
• Power Distribution Cable Assemblies
• ABS Sensor Cable Assemblies
• High Voltage Cable Assemblies
• Cable Assemblies for Driver Information
• Heating Ventilation and Air Conditioning Cable Assemblies

PRODUCT LITERATURE NO. 889778-2


CABLE ASSEMBLIES

Wiring Products with Standard Contact
Systems

Tyco Electronics provides many discrete cable
assemblies utilizing proven components. These cable
assemblies are designed to suit the customer and
application, all terminated with in-house application
tooling available in high and low volume production.

Application
• Head light leveling
• Rear window heating
• Seat
• Mirror
• Door
• Gear Box

Features
• Tyco Electronics contact systems like MQS, JPT,
MULTILOCK, MTA, AMP DUOPLUG
• Terminated with in-house application tooling
• Assemblies available in high-and low volumes
• Customer specific design

Overmolded Wiring Products

Tyco Electronics overmolding competency provides a
gas tight product ensuring high durability against the
effects of vibration, temperature and moisture.

Application
• Throttle value body
• Fuel tank

Features
• Macromelt for gas tightness keeping durability of
high vibration and temperature overmolded sealing
(contact)
• –40 °C up to +140 °C


High Voltage Cable Assemblies

Tyco Electronics high voltage cable assemblies for
lighting platforms provide products suitable for up
to 25 KV integrating passive components and fully
shielded design, coupled with easy to mate and
un-mate design.

Application
• Gas discharge lamps
• Xenon lights

Features
• Integrated passive components
• Silicon free
• EMC shielded design
• Isolation voltage up to 25 kV
• Easy mate and un-mate
• Robust design
• –40 °C up to +135 °C (peak temperature 155 °C)

Squib Cable Assemblies

Tyco Electronics provides a varied array of Squib cable
assemblies to cater for 10 mm, 11 mm and Universal
inter-faces. A choice of product for AC or DC wiring
systems along with fully or semi automated
manufacturing process to ensure high reliability for
this safety critical application.

Application
• Safety restraint systems

Features
• 11.0 mm 90° and 180° Universal Squib
• 11.0 mm 90° lockable Squib
• 10.0 mm jacketed cable Squib
• IDC or crimp contacts
• –40 °C up to +90 °C (+120 °C)


CABLE ASSEMBLIES

Pump Nozzle

These cable assemblies are located inside the cylinder
head of the vehicle, operating in a hostile environment
of temperature and hot oil whilst providing a sealed
interface to the outside of the engine.

Application
• Direct injection diesel engine

Features
• The cable assembly is used for pump nozzle
pre-wiring for direct injection diesel engine
• Sealing contacts FASTIN-FASTON
• 2.8 mm and Junior Power Timer
• Mating aid by bayonette mechanism
• –40 °C up to +135 °C

Power Distribution

High current applications exist on all vehicles including
Hybrids. Tyco Electronics manufactures power cable
assemblies from 25 mm to 75 mm with our own cable
and terminals to provide a cable that can be fitted
directly at the OEM.

Application
• Prefuse box
• Power distribution

Features
• High current application
• Compact and variable design (6–12 pos.)
• Designed for maxi fuses up to 80 A
• Low resistance crimped bus bar
• 200 A primary side
• 80 A secondary side
• –40 °C up to +85 °C


Heating and Ventilation Cable
Assemblies

These cable assemblies are design in conjunction
with the HVAC manufacturer to optimise the available
Tyco Electronics product portfolio of cable, terminals,
connectors and other wire related products, thus
ensuring a reliable product with a cost effective
solution.

Application
• Driver / Passenger comfort

Features
• Fully assembled cable assembly
• Specific fixings added for easy assembly
• Designed to eliminate the effects of vibration

FFC Cable Assemblies

Tyco Electronics laminated 2.54 mm pitch cable with
terminals and connectors applied with Tyco Electronics
application tooling.

Application
• Infotainment system
• Air Conditioning module
• Rear Window heating

Features
• Tyco Electronics laminated FFC (2.54 mm pitch)
• FFC contact portfolio and application tooling


CABLE ASSEMBLIES

Low Voltage Differential Signaling

These cable assemblies are fully shielded and used
within the driver information system providing a high
speed data link to the screen in the cockpit.

Application
• Driver information

Features
• Fully shielded assembly
• MQS terminal technology
• Tyco Electronics developed process technology

Planar and Discrete Wiring Products

Our own ribbon cable is utilized in conjunctions with
Tyco Electronics standard contact technology to
enable the production of a low cost flexible cable
assembly.

Application
• Radio
• Head light control module
• Internal control unit connections

Features
• Own manufactured cable
• Tyco Electronics low cost flex strip
• Tyco Electronics contact technology


RF and Coax Cable Assemblies

Suitable for various coax applications.

Application
• Tyre pressure sensor
• Door locking
• Radio
• GSM
• GPS

Features
• 50 Ohm/125 Ohm cable
• Small and compact design
• High quality signal transmission
• –40 °C up to +85 °C



M E C H AT R O N I C S

A variety of technical products is designed today by integrating
mechanical components and electronic hardware into one packaging
unit thus creating true mechatronic solutions. Mechatronic applications
offer amazing and versatile potentials related to functionality, cost,
space requirements and quality. Tyco Electronics contributes to those
applications with its wide range of innovative and cost-effective
product and process technologies.

Examples which are produced today in high volumes are housings for
hybrid circuits, premolded packages for semiconductor based sensors and
wirebondable lead frames for various automotive applications.

Advanced stamping, injection molding and assembly techniques are applied along
with highly selective surface plating methods.

TECHNOLOGY

THERMOPLASTIC MOLDING
Loose-piece, manual and highly automated processes or reel- to- reel
molding with a variety of polymers is our daily business. Specialities like
hermetic sealed molding as well as micro structured sensor packagings –
these are only two examples of a plurality of technologies engineered in the
mechatronic center.

S TA M P I N G
High performance stamping and forming technology for precision
leadframes from micro-structured-design as smartcards up to leadframes
of 2.5 mm of thickness.

P L AT I N G
This technological division employs systems for complete and selective
electroplating of individual parts, semi-finished strips and stamped grids.
The range of materials includes contact and wire-bond-gold, silver, nickel,
wire bondable nickel, tin and palladium.

A S S E M B LY T E C H N O L O G Y
In addition to the other technologies stamping, electroplating and plastics,
our emphasis is placed on assembly technology. Whether small or large
production runs, manually or fully automated assembly, we design the right
assembly concept and system for our customers’ respective application.
This includes highly complex and flexible assembly systems using robotics.
Advantages are interfaces and overlapping technological know-how.

PRODUCT LITERATURE NO. 1307989



Advanced in Mechatronic Components

Complexity
Highly integrated modules

Wire Bondable Surfaces
Long term experience and new
developments

Sealed Housings
Fuel flange, control units, sensors
Le

ies

Integration of Functions
ad

ra
bl

me m
se
f

Contact-less sensors, inductive actuators,
s As relays, press-fit interconnection and connectors

Development and Qualification
Prepared for simultaneous engineering relationship,
development partner

Concept Study for Carrier in
Contact-less Sensor Application

Processes
• MID 2 shot molding
• Plating
• SMT assembly

Features
• MID, “Pure Plastic”
• LIN bus components


Mechatronic Component for
Continuous Variable Transmission
Control Unit

Processes
• Stamping, electroplating
• Molding and assembly

Features
• High complexity
• Wire bondable surfaces
• Oil-tight housing
• Integration of contact-less sensors

Controlled Actuator Module for
Turbo Charger Application

Processes

Features



Controlled Actuator for
Throttle or Exhaust Application

Processes
• Assembly and molding in ESD protected areas

Features
• High integration

Component for Controlled Actuator for
Throttle Application

Processes
• Stamping
• Electroplating
• Molding
• Assembly

Features


Tight Connector for
CCD-Chip Packaging

Processes
• Stamping and electroplating
• Pre-molding of reactive material
• Final molding and testing

Features
• Connector sealed up to 5* 10-8 mbar *l /s

Housing for Manifold Air
Pressure Sensor

Processes

Features
• Inlay-molded components
• 8 different variations



Packaging for Micro-Mechanic
Acceleration Sensor “Low-G” (SMD)

Processes
• Reel-to-reel inlay molding

Features
• High accuracy in flatness

Packaging for Acceleration
Sensor in ESP

Processes
• Trim and form of solder shape

Features
• Sealed for potting
• Gel stop


Module for Powersteering Application

Processes
• Stamping
• Molding
• Assembly

Features
• Tyco Electronics FSK contact system
• Tyco Electronics SPR relay

Brush Holder for Generator

Processes
• Stamping
• Electroplating
• Assembly
• Molding

Features
• Wire bondable Ni-Surface
• Lead frames made of steel
• Inlay molded components



Switch Module for Seat Positioning

Processes
• Stamping
• Electroplating
• Final molding

Features
• High accuracy in flatness

Housing for Crash Sensor

Processes
• Stamping
• Electroplating
• Pre-molding
• Final molding

Features
• PressFit “Multispring”


ENGINEERING NOTES



SENSORS

Contact-less measuring eliminates interference effects, wear and tear,
and provides increased reliability. Tyco Electronics, one of the largest
technology providers for the automobile industry, offers contactless
sensors for a variety of applications. As sensor manufacturer and
processing partner, Tyco Electronics also provides project planning
support for new sensor applications, assistance in the selection of the
appropriate sensor technology for the respective application, and
assistance with defining the corresponding mechanical, electrical and
magnetic interface. Tyco Electronics has a broad electromechanical
portfolio that includes robust housing technologies, connector systems, and
temperature stable designs based on foil and cable networks.
This combination of technologies and experience ensures that reliable and cost
effective sensor solutions are available for all application types.

TECHNOLOGY

Tyco Electronics has focused on contact-less sensor solutions special for
high performing and sophisticated measurement tasks. Wear influences as
well as mechanical interactions between sensor and application parts are
then avoided. Beside the actual measurement requirements, the application
conditions determine the choice of the appropriate sensor technology. For
contact-less measurements preferably magnetic sensor technologies are
used:

• Semi-conductor sensors with integrated Hall
• Semi-conductor sensors with MR elements
• Magneto-inductive PLCD sensors
• Temperature sensor devices

Semi-conductor solutions with Hall and MR effect show their advantages in
their very compact and slim design. They are also preferred in the design of
complex sensor clusters. The combination with different magnet configurations,
typical integrated or moving magnets obtains precise measurement results.

A very efficient and robust sensor technology is the Tyco Electronics
patented PLCD (Permanentmagnetic Linear Contact-less Displacement
Sensor) Technology. For the linear position measurements this principle has
various advantages. The magnetic-inductive measuring principle
distinguishes for its very large operation tolerance field. This enables the
renunciation for specially guided or stored slider and records
reliably its highly precise measuring performance without any loss, not
being influenced by metal abrasions. The necessary driving magnet can
herewith be fixed directly on the setting element, whereas even driving
distances through non-ferromagnetic walls with several millimetre thickness,
are not an exclusion criteria for this measuring principle. A fully enclosed
design guarantees the robustness of this measuring principle. Therefore the
encapsulated sensor is completely sealed and temperature resistant up to
160°C.



SENSORS

PLCD 15

Application
Transmission, chassis, body, steering, engine

Function
Measuring linear travel or angle

Technology
Active PLCD (moving magnet)

Features
• Contact-less measurement
• Measurement range: travel 5 - 18 mm
and angle up to 120°
• Highly insensitive to vibration
• Temperature up to 150°C
• Redundancy possible
• Analog or PWM interface
• Optional 5 V, 12 V or 24 V supply

PLCD 25

Application

Function

Technology

Features


PLCD 50

Application

Function

Technology

Features

L40MC1
Contact-less Travel Sensor

Application
Engine, Gearbox and Chassis

Function
Linear Travel Sensor for measurement
range up to 40 mm

Technology
Hall with external Magnet

Features
• Contact-less measurement principle
• Programmable measurement range
• Shock and vibration robust
• Measurement through non-ferromagnetic materials
• Small geometry


SENSORS

R180M1
Contact-less 180° Rotary Sensor

Application
Throttle, exhaust recirculation valve, air intake
manifold, variable turbocharger geometry, drive mode
for automatic transmission

Function
High precision rotary sensor up to 180°C measurement
range

Technology
MR with external Magnet

Features
• High measurement performance
• Redundancy available

R360MC1
Contact-less 360° Rotary Sensor

Application
Engine, gearbox and chassis

Function
Rotary sensor for angles up to 360°

Technology
Hall with external magnet

Features
• Small geometry


Cylinder Hall Switch

Application
Hydraulic cylinder for convertible roofs

Function
Digital position detection

Technology
Hall (magnet integrated in sensor)

Features
• Triggered piston = no moving magnet
• Current interface
• Pigtail with flexible connector interface
• Diagnostics ability due to two-wire interface

Chassis Hall Switch

Application
Convertible roofs

Function

Technology

Features
• Triggered kinematics of convertible tops
• No moving magnet
• Pigtail with flexible connector interface


SENSORS

Chassis Hall Switch

Application
Body and Chassis

Function

Technology

Features
• Triggered kinematics of convertible tops
• No moving magnet

Powertrain Hall Switch

Application
Powertrain

Function

Technology

Features
• Triggered by ferromagnetic part
(no moving magnet)
• Sealed connector interface


Hall Sensor
Cable Assemblies

Application
Convertible roof systems

Function

Technology

Features
• Triggered by ferromagnetic parts in retractable
hard or soft tops
• Pigtail with customized interface

Steering Height Position Sensor

Application
Steering column

Function
Measuring front-aft and height position
of steering column

Technology
Hall (turning multipoled ring magnet)

Features
• Adapted to actuator motor
• Customized geometry


SENSORS

Seat Position Sensor

Application
Dual staged airbag

Function
Measuring seat track position

Technology

Features
• Triggered by seat track = no moving magnet
• Small geometry


Application
Dual staged airbag

Function

Technology

Features
• Triggered by seat track = no moving magnet
• Small geometry



Application
Dual staged airbag

Function

Technology

Features
• Triggered seat track = no moving magnet
• Small geometry

Buckle Switch

Application
Airbag

Function
Detecting buckle up status

Technology
Hall (moving magnet)

Features
• Triggered latch in the buckle
• Customized geometry


SENSORS

Brake Light Switch

Application
Brake light switch

Function
Detection of brake pedal position

Technology

Features
• Triggered by brake pedal = no moving magnet
• Low and high side output
• Easy adjustment to brake pedal
• High switching point accuracy

Brake Light Switch

Application
Pedal box

Function
Dual digital position detection

Technology
Hall

Features
• Moving magnet triggered by brake pedal
• Self adjusting features
• Full redundancy due to two independent
signal channels


Brake Master Cylinder Sensor

Application
Regenerative brake system for hybrid vehicles

Function
Linear position of brake master cylinder

Technology

Features
• Travel measurement of 31 mm
• Analog voltage interface
• Sealed header connector
• Diagnostics ability with complimentary output signals
• Measurement capability through master cylinder
housing

Wheel Speed Sensor

Application
Anti-lock brake system

Function
Wheel speed detection

Technology
Hall

Features
• Long life time and high reliability
• Compact size and comparative price
• Flexible design depending on customer’s
requirements
• Contact-less hall effect sensor triggered by a shunt
(target)
• Rapid response time
• Tone wheel detection


SENSORS

Wheel Speed Sensor

Application
Anti-lock brake system (in-bearing type)

Function
Wheel speed detection

Technology
Hall

Features
• Long life time and high reliability
• Compact size and comparative price
• Flexible design depending on customer’s requirements
• Contact-less hall effect sensor triggered by a shunt
(target)
• Rapid response time.
• Tone wheel detection

Clutch Position Sensor

Application
Cruise control, engine management, interlock, EPB

Function
Measuring piston position at clutch master cylinder

Technology

Features
• Contact-less measurement through cylinder wall
• Up to three switching points or linear PWM output
over 32 mm available



Application
Automated manual transmission

Function
Measuring piston position at concentric slave cylinder
inside the gearbox

Technology
Passive PLCD (moving magnet)

Features
• Passive PLCD sensor due to high temperatures inside
the gearbox (up to 180°C)
• Measurement range: 22 mm absolute


Application
Cruise control, engine management, interlock

Function

Technology

Features
• Up to three switching points
• Small, flat design


SENSORS


Application

Function
Measuring piston position at clutch slave cylinder

Technology

Features


Application

Function
Measuring piston position at concentric slave cylinder
inside the gearbox

Technology

Features
• Passive PLCD Sensor due to high temperatures
inside the gearbox (up to 180°C)
• Complete overmolded and sealed design



Application
Electrical park brake

Function

Technology

Features


Application
Truck automated transmission

Function
Measuring clutch position at clutch slave cylinder

Technology

Features
• Robust design for truck applications


SENSORS


Application

Function
Measuring piston position at clutch slave cylinder

Technology

Features
• Integrated cable assembly for temperature and
pressure connection


Application
Truck automated transmission

Function
Measuring the clutch position on the concentric slave
cylinder (CSC)

Technology

Features
• 44 mm measurement range
• Highly insensitive against vibration and temperature
(up to 150°C)
• Pigtail interface with truck compatible DIN connector


Dual Clutch Position Sensor

Application
Dual clutch transmission

Function
Measuring the position of the clutch actuators

Technology

Features
• Two PLCD sensors in one housing concept
• Measuring range 2x26mm
• PWM interface
• Small, very flat design

Drive Mode Sensor

Application
Automatic transmission

Function
Measuring drive mode status (PRND) inside
transmission

Technology

Features
• Oil sealed packaging and high temperature
(max. 150°C)
• High measurement accuracy


SENSORS

Gear and Shift Sensor

Application

Function
Measuring gear and shift position

Technology

Features
• Angular and travel measurement integrated
in one housing
• Measurement range: 26 mm (gear) and 22° (shift)
each absolute

Gear and Shift Sensor

Application

Function
Measuring gear and shift position

Technolog
PLCD (moving magnet)

Features
• Angular and travel measurement integrated
in one housing
• Measurement range: 24 mm (gear) and 22° (shift)
each absolute


Neutral Position Sensor

Application
Start-Stop application (mild hybrid)

Function
Measuring neutral position of the transmission

Technology

Features
• Contact-less measurement through transmission wall
• Neutral position ±1% over temperature, life time, etc.

Transmission Controller Housing with
integrated Sensors

Application
Transmission controller

Function
Electronic housing with integrated position and speed
sensors

Technology

Features
• Sensors, connectors and solenoid interface
integrated in one housing concept
• Bondable interface to transmission electronic
• Oil sealed interconnection
• Highly robust design


SENSORS

Transmission Sensor Module

Application
Dual clutch transmission

Function
Measuring drive mode position / parking lock / input
and output speed

Technology
Active PLCD sensor (redundant)
Hall (turning multipol ring magnet)

Features
• Sensor module with aluminium carrier mounted
inside transmission housing
• Oil sealed 8 pin connector system (between ATF and
MTF area)
• Highly insensitive against vibration, temperature and
pollution inside the transmission
• Complete redundancy of drive mode detection due
to safety requirements

Turbo Charger Sensor

Application
Turbo charger

Function
Measuring pneumatic actuator position

Technology

Features
• High temperature resistance due to external
electronics
• High measuring and lifetime accuracy


Turbo Charger Sensor

Application
Turbo charger

Function
Measuring pneumatic actuator position

Technology

Features
• Sensor integrated in actuator cove
• High measuring and lifetime accuracy

EGR Actuator Sensor

Application
Exhaust gas recirculation

Function
Measuring position of the piston in the pneumatic
cylinder for Truck EGR

Technology
Active PLCD

Features
• Contact-less measuring through cylinder wall
• Measuring range max. 50 mm
• Integrated cylinder fixation


SENSORS

Rotational Sensor for Engine Actuator

Application
Air control valve, turbo actuator, EGR

Function
Measuring actuator position

Technology
AMR (moving magnet)

Features
• Contact-less measurement up to 180°
• High vibration resistance
• Integrated connector and motor interface
• Sensor integrated in actuator cover

Truck Rear Axle Steering Sensor

Application
Truck rear axle steering

Function
Rear axle steering wheel position

Technology

Features
• Truck specific DIN connector interface


Water Detection Sensor

Application
Fuel filter

Function
Water detection

Technology
Resistance measurement

Features
• Flexible electrical interface (AC or DC, 12 V or 24 V)
• Different measurement levels
• Bayonet or thread interface
• Optional header or pigtail interface



R E L AY S A N D S W I T C H I N G M O D U L E S

Automotive technology has developed at an amazing pace over the
past couple of years. Today’s vehicles feature a multitude of intelligent
systems, dramatically increasing all aspects of safety and comfort of
driving. Navigation systems with interactive traffic condition interface
have become common even in mid-size cars. Passive and active safety
systems such as antiskid brake/traction control, belt tensioners,
airbags are taken for granted meanwhile. Today, in high-spec cars, the
value of the electric and electronic content reaches almost a quarter of
the total vehicle value. The length of the wiring can reach several
thousands of meters.
In all these systems, the reliable switching of lights, motors, heaters, ECU’s has become a function that is
critical for the overall reliability of the vehicle. Since decades, Tyco Electronics’ automotive relays provide
the state-of-the-art solution to satisfy the industry’s constantly growing requirements in this area.

TECHNOLOGY
Tyco Electronics has a rich history of competencies in relay technology
gained over the past three decades thanks to continuous research and
development. Besides our complete range of automotive standard relays
we currently offer various specialized relays and utilize advanced
manufacturing technologies such as:

OVERMOLDING TECHNOLOGY
One of the most recent developments of Tyco Electronics, the
Nano relay, has been designed using insert molding technology
to produce the relay motor consisting of coil, frame and core. This
design concept ensures highest precision in the assembly and
reduces the risk of particle contamination to an absolute
minimum. It also allows for most accurate mechanical parameters
and adjustment free processes. In addition, the overmolding of
the relay motor improves the heat dissipation of the Nano relay
Overmolded Magnetic System:
Nano Relay and maximizes the relay performance.

S P E C I A L R E L AY S W I T H L AT C H I N G
( B I S TA B L E ) T E C H N O L O G Y
Latching (Bistable) Relays provide another smart alternative to
meet the miniaturization targets in higher ambient temperature
environments, using magnetic flux of a permanent magnet to
keep the armature in operating mode without keeping the coil
energized. In comparison to monostable relays, bistable relays,
such as the Micro K Latching, BDS-A, Power Relay PK2 and Mini
Relay Latching, feature three major advantages:
Downscaling:
Monostable Power K
vs. Latching Micro K • Relay downscaling without sacrificing the performance
• Higher ambient temperatures at given continuous current
• Increased continuous current capability at given ambient
temperature

E L E C T R O N I C R E L AY M O D U L E T E C H N O L O G Y
As the worldwide leader in relay technology, Tyco Electronics has
developed a broad range of customized electronic modules that
embody our switching technology know how. Many of these
products merge our core relay products with electronics to
produce modules with custom switching functionality. Some
typical examples include: custom timing modules, 24 V motor
reversing modules, and custom logic controlled modules.
Wiper Module Mounted on
Leadframe




Complete Range of Electromechanical
Devices

Producing more than 350 million automotive relays a
year, Tyco Electronics is the market leader and
supplies all major vehicle manufacturers worldwide.
Our products cover virtually any application, ranging
from lamps and electric sunroofs to battery
disconnection over to energy management.


Evolution of Relay Size and
Performance

In the past few years relay engineers realized
tremendous improvements in several areas. The size of
a relay has been reduced to 1/4 compared to previous
types without performance loss. On top, the power
consumption of relays has been reduced by 50 %.

More and more individual switching solutions are requested by the automotive
market. Especially the continuously increasing number of convenience
features requires intelligent solutions. Tyco Electronics offers a complete
range of electromechanical components designed to switch a few
milliamps to several thousand amps. They are grouped in four categories:

1. PCB Relays
2. Plug-In Relays
3. Application Specific Switching Solutions
4. High Current Solutions


PCB Relays

To meet the increasing quality requirements of the
automotive industry and in response to the growing
demand for comfort and higher packaging density in
modern vehicles, Tyco Electronics offers extremely
performing and miniaturized PCB Relays.

The most recent developments are:

• The Nano Relay as the benchmark for successful
miniaturization. Developed as Twin and Single Relay
they are both the smallest PCB relays in their
respective classes and are deemed to be marvels of
miniaturization.

• The innovative PK2 that represents the new
generation of Automotive Power Relays for PCB
mounting. Compared to its predecessor the Power K,
its volume is reduced by 60 %.

Plug-In Relays

Tyco Electronics offers the full range of Micro, Mini and
Maxi Plug-In Relays with ISO or 280 footprint for 12 and
24 V applications.

Within the Mini Class the genuine 40/70 A relays remain
unbeatable due to their long lifetime; their coil power
consumption is reduced and results in minimized self-
heating.

The Micro Class comprises the standard Micro Relay A
available with different features and special types such
as High Current, Low Noise and Latching Relays.
All Plug-In relays are available with different contact
arrangements, cover colors, mounting brackets/notches
and release features. They combine highest quality and
reliability standards with a good price/performance ratio
for cross carline applications.



Application Specific Switching
Solutions

Application specific switching solutions are smart
products designed for your very specific needs.

The Power Module F available in the current classes
40 A and 70 A combines up to 3 separate relays in
one housing, together with an optional electronic
circuitry on a PCB or leadframe. In combination with a
leadframe this is a clever alternative for various smart
switching applications such as:

• Automatic wash/wiper control
• Cooling fan control
• Motor antennas
• Over voltage protection
• Power window actuator
• Power outlet control
• Seat adjustment
• Seat and stationary heating
• Vehicle lighting
• Wiper control

High Current Solutions

Modern vehicles have a growing number of applications
demanding relays with high current capability.

The Star Point Relay has particularly been developed
to operate EPS motors in the automobile. In the event
of a system failure the relay will reliably shut down the
EPS system.

A further high current device is our Battery Disconnect
Switch A suitable for extreme high current loads. It is
designed to be easily adapted to various battery and
harness system requirements and may additionally be
combined with electronics.

It has a wide range of applications, ranging from the
disconnection of starter, generator, fuel pump and
various loads in case of vehicle accident to prevent
fire, battery explosion and discharge. Other applications
are to disconnect the battery in case of short circuit,
over current or reverse polarity jump-start. Also
seasonal shut down, service disconnection and
transport deactivation as well as energy management
functions are typical applications.


ENGINEERING NOTES



POWER DISTRIBUTION SYSTEMS

Modules with intelligent technology combinations for power
distribution units with integrated switching and protection functions
together with a maximum of flexibility and modularity at highest
package density tuned 100% on customers needs, that´s what Tyco
Electronics is working on.

TECHNOLOGY

As a Multi-Technology supplier Tyco Electronics benchmarks in the early
stage of the development process different technologies for customer
applications to provide a 100% tuned customer specific and cost effective
solution. Technologies for power distribution modules are characterized by
the electrical circuit carrier like leadframes, power-pcbs and direct wired
connections. The smartest solutions are created using one of them or the
best mix of it.

LEADFRAME TECHNOLOGY
High density leadframe sandwiches up to 5 layer using a high performance
contact system adjusted to an optimized routing. Robust technology for
rough environmental conditions. Most preferable for high volumes or
underhood applications with best recycleability.

POWER PCB TECHNOLOGY
Printed Circuit Boards with up to 4 copper layers and copper thickness up
to 400µm. Migration resistant pcb concepts for highest reliability together
with high performance solder contact systems. For ELV compliance Tyco
Electronics provides the possibility of leadfree solder processes. Significant
characteristics are high flexibility and a low tooling invest.

DIRECT WIRED TECHNOLOGY
For the direct wired concepts the most important technology is the basic
crimp- and busbar-contact technology together with the knowledge in
customer specifications and philosophies building up contact cavities and
secondary locking systems. To provide this know how Tyco Electronics is
working with long experienced design teams dedicated to specific
customers. Mostly recommended for lots of variants with big differences in
high and very low equipped models.

Tyco Electronics global competencies in electromechanical components
enables us to have a holistic view on the system of power distribution units
covering harness interfaces, switching and protection components like
relays and fuses. This results in effective solutions for optimized connecting
and mounting process to the car harness and the mechanical attachments
as good as the optimized application of switching and fusing functionality.
Tyco Electronics provides the full support of an interdisciplinary team
covering all these competencies.



POWER DISTRIBUTION SYSTEMS

General Central Electric Units

These products covering specifically the power
distribution, carrying fuses and relays and providing
pass through connections from one harness to
another. According to customer requirements the
modules are designed in sealed or unsealed conditions
to fit in the specified environment. For optimized
space usage Tyco Electronics often realizes solutions
with integrated bolted fuse interfaces to cover the
prefuse functionality.

Showed Application
Central Electric Unit in leadframe technology for
engine compartment applications with integrated
prefuse functionality. Integrated optional relay carrier
for additional equipment.

Integrated Body Control Modules

On these modules Tyco Electronics is working very
close together with the First Tier customers to create
solutions with smart interfaces for optimized integration
of customers electronic control units in the power
distribution module. The result will be an optimized
module in space, weight and cost because of the
saving of the different harness connectors between
the CE box and the ECU.

Showed Application
Central Electric Unit with integrated Electronic Control
Module.


Prefuse Modules

The development of prefuse modules, former simple
boxes with some bolted fuses on a busbar is moving
more and more to power management units with
higher content of functionality then only protect some
big wires in the harness. Power switch-off components
in case of an accident or for an intelligent power
management to increase battery lifetime or to prevent
break down situations are integrated in these modules.

Showed Application
Prefuse module without power management
functionality.

Switching Modules

The switching modules are mostly an application of
power pcb’s equipped with solder relays and
additional electrical components. These small and
compact modules give the customer the possibility to
decentralize functionalities in unaccessable areas. The
advantage of these modules are significant savings in
weight, size and number of components as good as
the improved thermal performance and resistance
against vibrations.



INDUCTIVE SYSTEMS

The Global Automotive Division is your source for interconnection and
wireless technologies for automotive, truck and off-highway OEMs and
Tier 1 suppliers. With the design competency center in Oostkamp,
(Belgium), and strategic production centers in Evora (Portugal),
Bangalore (India), Shenzhen (China), and Oostkamp (Belgium), Tyco
Electronics Inductive Systems is ready to offer you any LF-application
component required in the automotive branches.

The Inductive Systems groups focus is on the customer requirement in
order to design to the exact demand. This is achieved by high-technological,
intelligent and cost-efficient engineering. In order to be a leader in design, Tyco
Electronics Inductive Systems has a vast product portfolio, which consists out of
antennas, actuators and integrated modules. Next to that, several specific
applications are designed.

TECHNOLOGY

The technologies used for the Inductive Designs are mainly the following:
• Thermoplastic molding:
A variety of high demanding plastics is used to envelop the critical
components and attachment features of the IS components
• Coil winding:
Different shaped wire cross-sections from 0.05 till 1.5 mm diameter can
be handled and winding installations for diverse application temperature
conditions
• Connection technologies:
To have a stable product the connection between coil wire and coil
terminal, between coil terminal and cable are significant. Therefore the
choice of the right connection technology and the knowledge of
processing is very important and treated as inhouse competency of the
Inductive Systems group
• Assembly and component integration:
Going from integrated connectors to electronic components and
complete PCB’s to give the maximum of functionalities to the products
• Overmolding or potting:
Sealing or protecting the vital organs of the modules to the working
environment (exterior applications, engine environment, etc)
• Testing:
All products are tested to ensure the produced quality level with highly
specified equipment. All above-mentioned technologies are in-house
competencies, which are fine-tuned to the specific product portfolio in
order to have an optimized product

The key to success in our products lays in the compatibility of these
technologies with our competencies.



INDUCTIVE SYSTEMS

Immobilizer Antenna

Application
Passive anti theft system

Function
Transponder read-write function

Technology
LF antenna coil with electronic controller

Features
• Customer specific design
• Overmold or cover technology
• Cable or integrated connector
• Optional integrated sealed pcb-box (motorcycle)

Product Literature No. 1308015

Keyless Entry Antenna

Application
Passive entry system

Function
Data acquisition from keyless entry card

Technology
LF resonator ferrite antenna

Features
• Overmolded product with attachment features
• Interior, trunk and doorhandle antenna available


Brake and Stability Module

Application
Brake and stability system

Function
Interface between hydraulic valves and electronic
control unit, pressure sensor housing, pump motor
power supply

Technology
Inductive actuator coils

Features
• Integrated multi-functional module
• Sealed module with pressure gauge
• Press-fit pcb assembly (+70 contacts)


Actuator Assembly

Application
Gear box axle shifting

Function
Automate shifting of gears in tractor gearbox

Technology
Self carried bonded wire coils in TPE overmold
with laminated core and cable packaging

Features
• Oil resistant assy
• High power actuator
• Minimum volumetric envelope by maximizing flux
density below saturation level


INDUCTIVE SYSTEMS

Injector Coils

Application
Diesel, gasoline and compressed natural gas injectors

Function
Actuator coils for fuel injector needles

Technology
High precision molding and thin thermoplast
overmolding

Features
• Standardized coil bobbin
• High speed actuator


ABS Coil Family

Application:
Wheel speed sensor actuator

Function
Measuring the wheel speed in high temperature
environments next to the brake disk and power
transfer for actuators

Technology
Ultra thin wire winding process (0.06 mm diameter),
magnet integration

Features
• High temperature resistant module
• Contact-less reliable speed measurement



Heavy Duty Brake Module

Application
Brake and stability system

Function
Interface between hydraulic valves and electronic
control unit, pressure sensor housing, pump motor
power supply

Technology
Housing molding, coil winding, assembly

Features
• Module with several coil types
• Double pump motor power connector (towers)
• Sealing overmold
• Clipped cover




A LT E R N AT I V E P O W E R S Y S T E M S
CO M P O N E N TS F O R H Y B R I D, E L E C T R I C A N D F U E L C E L L T E C H N O LO GY

Tyco Electronics is a leader in next-generation transportation
technologies and products for hybrid and electric vehicles. The Global
Automotive Division is your source for high voltage power distribution,
high current contacts, high voltage connectors and cables,
high voltage relays, sensors and temperature protection devices for
hybrid and other alternative powered vehicles.

TECHNOLOGY

Alternative power vehicles like Hybrid Electric Vehicles (HEV’s)
can reduce harmful pollutants and exhaust emissions. Recent
interest in HEV’s presents a new challenge for vehicle electrical
systems because of their need for high power electrical system
technology.

Electrical systems on conventional vehicles typically are designed
for a nominal 12 Volts, with the majority of loads less than 30
Amps. In contrast, HEV’s and electric vehicles have topologies
with voltage levels between 300–800 Volts and currents from
200–1000 Amps. These higher power levels require special designs and
packaging solutions for power switching, circuit protection, electrical
power distribution and interconnection systems.
Tyco Electronics offers a wide range of components and sub- systems for
HEV’s, including:
• High power contactors for battery switching and control,
• Circuit protection devices, like Raychem PolySwitch™ PPTC’s,
• High power electrical connectors and cables,
• Power distribution units
• Sensor solutions

Demand for high power electrical components has accelerated due to the
continued development of HEV’s. In addition, high power electrical
components are now commonly used on so-called “drive by wire” electro-
mechanical systems that are increasing specified to replace mechanical or
hydraulic systems.
As a result, Tyco Electronics high-amperage devices are also used for high-
power systems on vehicles with “conventional” voltage levels.




Power Distribution and Protection Units

Function
• Power routing 750 V DC lines
• Fusing or thermal protection
• Current sensing
• Emergency disconnect
- Main- and accessory HV relays
- Pre-charge relays and resistors
• Diagnostic functions
• HV cable assemblies

Application
• Protection of HV energy storage systems
• Power distribution at hybrid- and E-vehicles
• HV power outlets and connections

HVA Connector (2 Positions)

Application
• Accessory/Device interconnect

Description
• 2 Positions
• Sealed
• Touch-Safe
• 4.0 mm Pin / Socket contact system
• Wire Range 3.0–6.0 mm2
• Wire-to-Device or wire-to-wire
• Integrated interlock
• 360° EMC shielding

Performance
• Rated Voltage:
600 V DC
• Current Carrying Capacity:
33 A continuous @ +125 °C on 3.0 mm2 wire (free in air)
• Operating Temperature:
–40 °C to +125 °C
• Degree of Protection:
IP6K9K, IPX7 mated, IP2XB unmated
• Vibration Profile:
USCAR-2 (on engine)


HVC 25 Connector

Application
• Accessory interconnect

Description
• 2 Positions
• Sealed
• Touch-Safe
• AMP MCP 2.8 mm contact system
• Wire range 2.5–4.0 mm2
• Wire-to-Device
• Full integrated interlock

Performance
• Rated Voltage:
500 V DC
25 A continuous @ +85 °C on
Shielded Connector HVC 25 (AMP MCP 2.8 Contact System) 2.5 mm2 wire
–40 °C to +85 °C
IP6K9K, IPX7 mated, Shielded Tab Header,
Joint development with Ballard IP2XB unmated 2 Positions HVC 25
(Tab 2.8 3 0.8 mm)

HVC 70 Connector

Application
• Accessory interconnect

Description
• 2 Positions
• Sealed
• Touch-Safe
• AMP MCP 9.5 mm contact system
• Wire range 16.0 mm2
• Wire-to-Device

Performance
• Rated Voltage:
500 V DC
70 A continuous @ +85 °C on
16.0 mm2 wire Shielded Connector HVC 70 (AMP MCP 9.5 Contact System)
–40 °C to +85 °C
IP6K9K, IPX7 mated, With Shielded Tab Header,
IP2XB unmated 2 Positions, HVC 70 Joint development with Ballard
(Tab 9.5 3 1.2 mm)



HVC 230 Connector

Application
• Main interconnect

Description
• 1 Position
• Sealed
• Touch-safe
• 16.0 mm Socket contact system
• Wire range 70.0 mm2
• Wire-to-Device

Performance
• Rated Voltage:
500 V DC
260 A continuous @ +85 °C on 70.0 mm2 wire
Shielded Connector HVC 230 (B 16.0 mm Socket Contact System) • Operating Temperature:
–40 °C to +85 °C
Joint development with Ballard IP6K9K, IPX7 mated, IP2XB unmated

LV Connector (2 Positions)

Application
• Accessory/main interconnect

Description
• 2 Positions
• Sealed
• Wire-to-Device

Performance
• Rated Voltage:
12 V DC
–40 °C to +130 °C
IP6K9K, IPX7 mated


HV Connector (2 Positions)

Application

Description
• 2 Positions
• Sealed
• Touch-Safe
• Wire-to-Device

Performance
• Rated Voltage:
800 V DC
–40 °C to +130 °C
IP6K9K, IPX7 mated,
IP2XB unmated

HV Connector (3 Positions)

Application

Description
• 3 Positions
• Sealed
• Touch-Safe
• Wire-to-Device

Performance
• Rated Voltage:
800 V DC
–40 °C to +130 °C
IP6K9K, IPX7 mated,
IP2XB unmated



1 Position IPT Shielded Terminal,
Screwed, 25.0–50.0 mm2

Application

Description
• 1 Position
• Sealed
• Ring tongue
• Wire-to-Device

Performance
• Rated Voltage:
800 V DC
–40 °C to +130 °C
IP6K9K, IPX7 mated

1 Position IPT Shielded Terminal,
Screwed, 70.0–120.0 mm2

Application

Description
• 1 Position
• Sealed
• Ring tongue
• Wire-to-Device

Performance
• Rated Voltage:
800 V DC
–40 °C to +130 °C
IP6K9K, IPX7 mated


Kilovac EV500

Application
• Main relay

Description
• Form X, A (auxiliary)
• Hermetically sealed

Performance
• 600 A DC continuous carry
• 1600 A DC 10 second carry
• 3300 A, 320 V DC emergency interrupt
• 1800 V DC contact maximum
• Capacitive Make Switching
- 90% pre-charge, 50,000 cycles, 230 Amps peak
- 70% pre-charge, 50 cycles, 700 Amps peak
• 12 V DC, 24 V DC coil voltage
• 8.8 Watts coil power

Kilovac EV250

Application
• Main relay

Description
• Form X

Performance
• .500 A DC 10 second carry



Kilovac EV200

Application
• Main relay
• Accessory relay
• High-Speed Pre-Charge relay

Description
• Form A, H

Performance
• 9 to 95 V DC coil voltage

Kilovac LEV100

Features
• Low cost 100 A sealed contactor
• Side or bottom mount – not position sensitive

Application
• Main relay
• Accessory relay
• Pre-Charge relay

Description
• SPST – NO Form X

Performance
• 200 A DC 3 minute carry
• 12, 24, and 48 V DC coil voltage


Kilovac PD5

Application

Description
• Form X, B

Performance
• 5 A DC, 320 V DC resistive load switching
• 12 V DC, 24 V DC, 125 V DC coil voltage
• 2 Watts coil power

Kilovac PD10

Application

Description
• Form A, B, P (latching)

Performance
• 10 A DC, 320 V DC resistive switching
• 12 V DC, 24 V DC, 125 V DC coil voltage
• 2 Watts coil power



Typical Make / Break

Application

Pre-Charge Relay and Resistor

Motor Controller

From Source
Main Relay
(Fuel Cell Batteries, Filter Caps To Load
Generator etc.)

Vehicle Start Sequence
• Pre-charge relay closes into resistor
• Capacitors charge under current-limit conditions
• Main propulsion relay closes into partially charged capacitors
• In-rush current is limited due to pre-charge conditions
• Contact welds are prevented

Capacitive Switching Test Protocols

Test Protocol 1 Test Protocol 2
1), 2)
Make/Break Life Capacitive and Resistive Loads at 320 V DC Make/Break Life Capacitive and Resistive Loads at 320 V DC 1), 2)
Cycles Cycles
@ 90% capacitive pre-charge (make only) see charts below 50,000 @ 90% capacitive pre-charge (make only) see charts below 50,000
@ 80% capacitive pre-charge (make only) see charts below 50 @ 70% capacitive pre-charge (make only) see charts below 50
@ 200 A make/break 2 consecutive, reverse polarity 1) 12 @ 250 A, 320 V make/break 2 consecutive, reverse polarity 1) 10
@ 2000 A break only (1700 A for auxiliary contact model 1) 1* @ Interrupt Current Maximum, 320 V break only 4*
(1700 A for auxiliary contact model) 1)

Capacitive Make Test Curves for Pre-Charged Capacitive Make Test Curves for Pre-Charged
Motor Controller (Test Protocol 1) Motor Controller (Test Protocol 2)

80% Pre-Charge

80% Pre-Charge
Current (Amps)
Current (Amps)

90% Pre-Charge

90% Pre-Charge

Time (ms) Time (ms)

1)
Resistive load includes inductance L = 25 µH. Load @ 2500 A tested @ 200 µH.
2)
Life based on projected Weibull Life with 95% Reliability.
* Does not meet dielectric and IR after test.


Power Resistors

Application
• Filter capacitor pre-charge

Description
• Thick film isotop (shown)
• Cement encased wirewound
• Aluminum housed
• Ceramic housed

Performance
• Typical 700 joules (360 V, 7 mF)
• 3 charges at 5 second intervals
• 500 V DC
• 2000 V AC flash tested

Available up to 5000 joules

Terminals:
Faston, screw

Mounting:
Screw, clip

BDS-A

Application
• High current loads (heaters, pumps)
• Dual power network
• Dual battery systems
• Energy management
• Quiescent current applications

Description
• Compact high current relay for multivalent
applications, sealed, mono and bi-stable

Performance
• 190 A DC continuous current @85 °C
• 40 mOhm voltage drop at 100 A (initial)
• 1500 A interrupt
• 15 ms operating time (approx. @14 V)
• Up to 60 V contact voltage



HCR

Application
• Main relay
• Accessory relay
• High-speed Pre-charge relay

Description
• Form A, X, C
• Sealed

Performance
• 300 A DC emergency interrupt
• To 200 V DC contact maximum


Application
• Alternative powertrain solutions

Function
• Measuring piston position at concentric slave
cylinder

Technology
• PLCD (Permanent-magnetic Linear Contact-less
Displacement) sensor

Product Features
• Small design in
• Highly temperature stable (up to +180 °C)


Dual Clutch Position Sensor

Application
• Dual clutch transmission for hybrid cars

Function
• Measuring the position of the clutch actuators

Technology

Product Features
• Two PLCD in one housing concept
• Measurement range: 2 x 26 mm
• PWM interface
• Small, very flat design

Neutral Position Sensor

Application
• Start-Stop application (mild hybrid)

Function
• Measuring neutral position of the transmission

Technology
• Active PLCD (moving magnet)

Product Features
• Contact-less measurement through transmission wall
• Neutral position 2% over travel, temperature,
life time, etc.
• Optional redundancy possible



EV (Electric Vehicle) Sensor

Thermal Indicator for Over-Temperature Detection
• Thermal Indicator with very steep R-T curve
• “Close to digital” resistance response
• Direct input into FET of BJT
• No comparator necessary
• Built-in hysteresis to avoid cycling
• Different temperatures possible from 70 °C up to 165 °C
• Flexible design: can be located wherever the
potential heat might appear
• Can be put in series to protect several cells or places
with one controller

Raychem’s Thermal Indicators (RTI’s) are used for
over-temperature (OT) signaling. They provide “silicon-
like” performance (in a passive component), reduce
footprint needs and support simple distributed
monitoring.
In contrast to ceramic PTC devices, RTI devices
provide clear, “near digital”, OT signals due to a steep
resistance change with temperature (~10 x resistance
change per 2 °C).

They also feature a temperature hysteresis response
that can minimize signal oscillation traditionally
achieved using active components.
The steep resistance response and hysteresis also
allow for a reduction in support com-ponents.
RTI devices require only one ballasting resistor to
directly control power FET’s and BJT’s. Solutions using
ceramic PTC’s might require a resistor network and
comparator to offer similar functionality.
This reduction in support components translates
directly to lower system cost and reduced board area
requirements.

Finally, the “near digital” resistance response allows for
multiple devices to be placed in series on the same
circuit without significant dilution in system
measurement accuracy. This allows for a simple, low
cost implementation of multi-point distributed
monitoring.


Brake Pedal Position Sensor

Application
• Regenerative brake for hybrid cars

Function
• Brake pedal position detection

Technology

Product Features
• Optional travel or rotational measurement possible
• PWM or analogue output
• Optional redundancy possible
• High linearity (2% over travel, temperature,
life time, etc.)
• Optional sensor location pedal works or brake
master cylinder

HFT 5000

Description
• Heat shrinkable fabric tubing
• Polyester/Polyethylene construction

Features
• Temperature rating 125 °C (3000 h), 150 °C (1000 h)
• 2:1 shrink ratio
• High performance polyester fibers
• Highly flexible
• Halogen free
• Available in many sizes
• Low shrink temperature

Benefits
• Excellent mechanical protection for power cables
even at high temperatures
• Fits perfectly to all cables therefore minimum space
consumption
• Highly flexible thus no constraints regarding routing
of power cables



H I G H S P E E D D ATA N E T W O R K I N G

High speed data networking within the automobile is becoming more
predominant. What was till now restricted to the high end of the
market utilising system such as the MOST network, high speed data
transmission based on optical fibers, now with the introduction of
iPOD’s, display screens and cameras results in the need for high speed
networking throughout all platforms.

Tyco Electronics is also active in the area of Electrical MOST and is
actively involved in the Physical Layer Specification development
through the MOST Cooperation Working Group. The majority of the tests to date have
being carried out using existing Tyco Electronics electrical connection systems.

With the development of the FlexRay Protocol, a next generation electrical
networking system to connect devices with speeds of up to 10 Mbit / sec.
Tyco Electronics is a Premium Member of the FlexRay Consortium and was actively
involved in the Physical Layer development. The first FlexRay application is based on
the existing Tyco Electronics MQS contact system.

Due to the growing need for USB connections in the automobile to connect iPOD’s or
other devices compatible to the USB interface, Tyco Electronics has developed a
product portfolio which can accommodate speeds of up to 1 Gbit/sec. The connecting
principles of this system are also compatible to connecting digital camera links and
display links based on the High Speed LVDS requirements.

MOST® is a trademark of OASIS

Device: Sender Device: Receiver

LED POF (PMMA)
Receiver
Transmitter Technology Technology Harness

Photodiode Basis of optical data
Header Harness Header
Technology transmission point to
point

TECHNOLOGY

High speed data transmission based on optical fibers is the transportation of the
signals by digital light pulses. The LED (Light Emitting Diode) will switch the
electrical signals in to optical signals, the conversion back to the electrical signal
at the receiving device will be done by the photodiode. For a point to point link
we have one side as transmitter of the optical signals and one side as receiver of
the signals. The “Physical Layer” of a network defines the conditions of the data
transport. To guaranty the integrity of the signals, especially in an automotive
application, it is necessary to use optimised optical fibers and connectors in these
fields. Due to the harsh automotive environment with many moving parts, high
density of electronic equipment and compact packaging requirements, we have
special requirements for these systems. To fulfil the special requirements of the
automotive application it is necessary to define and develop special components
and technologies. Based on the existing experience of the communication
industry in combination with the special conditions in the vehicles, the core of the
optical networks for automotive application was created.

The benefits of Optical Networking:
• Wide bandwidth • Light weight
• Electromagnetic immunity • Small packaging requirements

Current optical networking has been achieved based on the current design
building blocks:
• LED: Light Emitting Diode • Laser welded optical contacts (Ferrules),
• Polymer Optical Fibers (POF): a Tyco Electronics creation which
Multi-Mode Step Index Plastic combines the optimal between pull out
Optical Fibers force of the contact with optical loss of
the light power

When these features are coupled with the Tyco Electronics connector
systems then the following system features are available:
• Data transmission up to 50 MBit/s • Optical Loss of 0.25 dB/m
• Band width 200 MHz * 10 m (with 650 nm)
• Temperature range from -40°C to • Bending radius of 25 mm
+85°C (95°C)

Because MOST is a ring bus structure of single optical fibers which are
better to handle in a harness. At the end of each lead a ferrule is attached
which can easily be put into a header. The fixation of the optical fiber to
the ferrule must fulfil a pullout force of 60 N. Tyco Electronics
investigated various different methods to fix the ferrules. Tyco Electronics
researched the brass crimp, the ultrasonic welding and the laser welding
technology.In mass production the laser welding technology is used
because of the best process performance. The brass crimp will serve as a
fixing method in the field and for service.



Fakra RF Coax Products

Tyco Electronics offers a full product range of
connections compatible to the Fakra II RF Automotive
requirements. The Fakra II product range was
developed for automotive applications for AM/FM,
GSM and GPS signal distribution.

Features
• Ergonomically designed for ease of assembly and
disassembly
• Full keying/coding range for all automotive
applications
• Connector offerings in 1 and 2 Way housing for 90°
and 180° cable exists
• Full product range of header components
compatible to reflow soldering requirements
• RF Contacts compatible to the RG174 and RTK031
which offer ease of processing on reeled termination
process
• Product offering can also include cable assemblies

MOST Micro Pigtail Range

MOST (Media Orientation System Transportation) is an
optical Bus system for data communication for
infotainment and telematic systems in the car. Tyco
Electronics offers the complete physical layer product
portfolio and was a prominent design partner in the
development of the MOST Physical Layer specification.
The MOST Micro Pigtail is based on the MOST 2+0
Interface.

Features
• Product according to MOST Physical Layer, MOST
2+0 Interface which includes two MOST connections
• Micro Pigtail available in a variety of FOT’s options
• Compact design with ease of assembly to PCB
• Pigtail can be applied in device operating
temperatures up to 105°C
• Harness connector based on Tyco Electronics
welding contact system


MOST 2+4 Connection

infotainment and telematics systems in the car. Tyco
The MOST 2+4 connection is based on the MOST 2+4
Interface.

Features
• Product according to MOST Physical Layer MOST
2+4 Interface which includes two MOST connections
and 4 MQS positions
• 2+4 connection compatible with the Tyco Electronics
flexible or integrated pigtail system
• Flexible and integrated pigtail system available in a
variety of FOT’s options
• Option of separate delivery of FOT optical module
available
• Harness connection based on Tyco Electronics
• Tyco Electronics also offers products based on the
MOST interface 2+12, 2+20

MOST 4+40 Connection

The MOST 4+40 connection is based on the MOST
4+40 Interface.

Features
4+40 Interface and the Fakra Radio Interface
• 4+40 connection compatible with the Tyco Electronics
flexible pigtail system
• Flexible pigtail system available in a variety of FOT’s
options
• Option of separate delivery of FOT optical module
available
• Harness connection based on Tyco Electronics
• Tyco Electronics offers three versions of the two
8-Way connectors based on the Tyco Electronics
MPQ, JPT or MCP contact system
• Header available with or without fibre optic opening



MOST Inline Connections

MOST inline connections form the MOST cable to
cable connections.

Features
performance requirements
• Inlines available in 1 way or 2 way versions
• 2 Way version available as spring loaded version or
based on MOST 2+0 interface
• Connection based on Tyco Electronics welding
contact system

High Speed Electrical Connections

With the increased requirement within the automobile
for high speed electrical networking, Tyco Electronics
has developed a product range which fulfils the
requirements for video link, camera and USB
connections.

Features
• Connector to accommodate data rates up to 1 Gbit/sec
• EMI tests according to automotive requirements
• Product offering to include 90°/180° cable exists,
inline connectors and water sealed connectors
• Connection based on the globally accepted and
automotive approved Tyco Electronics MQS system


ENGINEERING NOTES



AUTOMOTIVE PROTECTION PRODUCTS

Tyco Electronics Raychem brand is the world leader in developing,
supplying and manufacturing high quality, technologically advanced,
heat-shrink protection products. Our products provide a perfect
solution for your toughest engineering problems.
Tyco Electronics Raychem tubings are uniquely formulated materials
that have been enhanced by radiation cross-linking, a technology that
Raychem famously pioneered.
These easy-to-use products provide cost effective, proven solutions in
a wide range of Automotive applications from sealing and protecting
electrical splices to providing mechanical protection for fluid management systems in
harsh environments.
For over forty-five years, customers have recognised the global capabilities of
Raychem brand products. Combining these advanced products with superior
technical support and global sales and service organisations, our worldwide
customers count on Tyco Electronics to supply the knowledge and products they
require to solve specific problems, which can effectively enhance the overall
performance of their customers’ systems.

TECHNOLOGY

Since its founding in the 1950s, Raychem’s material science expertise has
pioneered many of the breakthrough technologies used to create today’s
most advanced environmental sealing and protection systems. Tyco
Electronics Raychem heat-shrink products are in service throughout the
world in automotive, telecommunications, power distribution, aerospace,
defence, industrial and commercial applications. Renowned for their
unrivalled performance and reliability in the most demanding of
environments, they include a comprehensive range of automotive sealing
and protection products. Produced using Tyco Electronics Raychem’s state-
of-the-art manufacturing facilities and processes, these products offer the
most cost-effective and robust solution to all your interconnection needs.

AUTOMOTIVE SEALING AND PROTECTION PRODUCTS
Tyco Electronics Raychem heat-shrinkable products have been developed to
provide robust and reliable protection of automotive electronic
components and electrical systems. Based on a broad range of cross-linked,
shape-memory, polymeric materials, these products provide long-term
protection against moisture ingress, corrosion, mechanical damage and
extremes of temperature.
Tyco Electronics Raychem experience of product design ensures a repeatable,
reliable, shrink to fit installation, compatible with present day manufacturing
processes. Adhesive precoatings on heat-shrinkable sleevings and moulded
shapes produce a positive watertight seal for wire-to-wire and wire-
connector splices and terminations for both automotive and truck
applications.



AUTOMOTIVE PROTECTION PRODUCTS

RBK-ILS-125

RBK-ILS-125 is an adhesive-lined, heat-shrinkable
tubing which provides excellent moisture proof sealing
of ring terminals in automobile applications, particularly
in wet areas of the vehicle. This product also provides
effective electrical insulation as well as strain relief and
mechanical protection against flexing, abrasion and
cut-through. RBK-ILS-125 is available in six sizes to
cover a wide range of ring terminals – depending on
terminal design. For multiple wire configurations it
may be necessary to consider additional adhesive
inserts.

Features
• Continuous operating temperature from -40°C
up to +125°C (3000 hrs)
• Mechanically tough, dual-wall polyolefin-based
material
• Adhesive-lined to environ-mentally seal ring
terminals – depending on terminal design
• High shrink ratio, allowing one size to fit a wide
range of terminal sizes
• Highly resistant to automotive fluids and solvents

Raychem RNF-100

RNF-100 is a tough, flexible and flame retardant heat-
shrinkable tubing. Designed to provide superior
mechanical strength, RNF-100 is ideal for wire and
cable heat protection where abrasion and cut-through
could also occur.

Features
• A complete range of heat insulation solutions up to
200°C – including tubings and flexible conduits,
heat-shrinkable fluoro-elastomer tubings and woven
fabric tubings
• High temperature protection – without the cost of
PTFE
• Cost-effective, non-melting substitutes for PVC –
with ratings including Class 2 and 3
• A choice of high temperature products – rated 125°C,
135°C, 150°C, 180°C and 200°C
• Very flexible woven fabric tubings


Raychem HFT 5000

HFT is a highly flexible heat-shrinkable fabric tubing
designed to provide excellent mechanical abrasion
protection for rubber hoses. HFT is woven from heat-
shrinkable circumferential cross-linked filaments and
non-shrinking longitudinal polyester fibres and is
completely halogen-free. HFT generally offers the
lowest installed cost per metre protected due to low
shrinkage compared to braids.

Features
• Provides outstanding abrasion protection – even at
temperatures as high as 150°C
• Highly flexible woven fabric construction for easy
installation onto awkward substrates such as bent
hoses
• Grips substrates tightly without additional fixing
• Resists harsh engine compartment environments
• Can be cut with conventional guillotines or even
scissors
• Resists hose pulsing effects

Conveyor Heater RBK-ILS Processor

The Model 19 conveyor heater is the latest generation The RBK-ILS-Processor MkII is a semi-automatic unit
of reliable and versatile process heaters for a wide designed specifically to install splice sealing products
variety of heat-shrinkable products. Two sets of timing onto ultrasonically welded or crimped splice joints
belts grip the individual assemblies and carry them used in automotive harnesses. The tool can operate in
through a closed-loop infrared heating zone, then several modes:
through a cooling zone, and deposit the completed • Stand-alone-operator sets time and temperature.
assemblies in a collection bin. The processor was • Sequenced-preset times and temperature can be
designed to meet the requirements of the European sequenced automatically (and can also be randomly
Safety Directives and is CE approved, allowing for selected from sequence stored).
worldwide use. The processor is designed to operate • Automatic-communication with upstream ultrasonic
on the following line voltages: 210 to 240 V ac, 20 A, 1 welder can allow time and temperature to be
Ø, 50/60 Hz. automatically set without operator intervention.



A P P L I C AT I O N T O O L I N G

Application Tooling from Tyco Electronics is designed to perform
perfect terminations, time after time. This results in productivity gains,
yielding more terminations for less money at the time of application,
and in service.
It is this combination of superior quality at a lower installed end cost
that distinguishes the Tyco Electronics system solution.

Because production requirements vary, GATD – Global Application
Tooling Division – can provide various levels of tooling to meet the full
spectrum of output requirements. The continuous support by our field service
completes the Tyco Electronics system. Our field service engineers ensure the
application equipment fulfil all requirements at any given time.

Please use the tooling website and the online search to find the tooling that best suits
your application.
Put your terminal part number either into the hand tool or applicator database and
the appropriate tool will be shown.
If you can’t find what you are looking for, it does not necessarily mean that there is
nothing available for your application.

For cross-referencing information – contact one of our Product Information Centers
(PIC). For more complex equipment and technical help contact your Tyco Electronics
representative.


ENGINEERING NOTES


G L O B A L C O N TA C T S

Americas
Argentina – Buenos Aires Canada – Toronto Mexico – Mexico City United States
Phone: +54-11-4733-2200 Phone: +1-905-475-6222 Phone: +52-55-1106-0800 Harrisburg, PA
Fax: +54-11-4733-2211 Fax: +1-905-474-5520 +01-800-733-8926 Phone: +1-717-564-0100
Product Information Center: Fax: +52-55-1106-0901 Fax: +1-717-986-7575
Brasil – São Paulo Phone: +1-905-470-4425 Product Information Center:
Phone: +55-11-2103-6105 Fax: +1-905-474-5525 Phone: +1-800-522-6752
Fax: +55-11-2103-6204 For Latin/South American Fax: +1-717-986-7575
Colombia – Bogota Countries not shown
Chile – Santiago Phone: +57-1-319-8959 Phone: +54-11-4733-2015 Troy, MI
Phone: +56-2-345-0361 Fax: +57-1-319-8960 Fax: +54-11-4733-2083 Phone: +1-248-273-3359
Fax: +56-2-223-1477 Fax: +1-248-273-3322

Asia/Pacific
Australia – Sydney Japan – Kawasaki, Kanagawa New Zealand – Auckland Singapore – Singapore
Phone: +61-2-9554-2600 Phone: +81-44-844-8111 Phone: +64-9-634-4580 Phone: +65-6482-0311
Fax: +61-2-9502-2556 Fax: +81-44-812-3207 Fax: +64-9-634-4586 Fax: +65-6482-1012
Product Information Center: Product Information Center:
Phone: +61-2-9840-8200 Phone: +81-44-844-8013 Philippines – Makati City Taiwan – Taipei
Fax: +61-2-9634-6188 Fax: +81-44-812-3200 Phone: +632-848-0171 Phone: +886-2-8768-2788
Fax: +632-867-8661 Fax: +886-2-8768-2268
India – Bangalore Korea – Seoul
Phone: +91-80-285-40800 Phone: +82-2-3415-4500 People’s Republic of China Thailand – Bangkok
Fax: +91-80-285-40820 Fax: +82-2-3486-3810 Hong Kong Phone: +66-2-955-0500
Phone: +852-2735-1628 Fax: +66-2-955-0505
Indonesia – Jakarta Malaysia – Selangor Fax: +852-2735-0243
Phone: +65-6482-0311 Phone: +60-3-7805-3055 Vietnam – Ho Chi Minh City
Shanghai Phone: +84-8-930-5546
Fax: +65-6482-1012 Fax: +60-3-7805-3066
Phone: +86-21-2407-1588 Fax: +84-8-930-3443
Fax: +86-21-2407-1599

Europe/Middle East /Africa
Austria – Vienna France – Cergy-Pontoise Cedex Lithuania and Latvia South Africa – Port Elizabeth
Phone: +43-1-905-60-0 Phone: +33-1-3420-8888 Lithuania – Vilnius Phone: +27-41-503-4500
Fax: +43-1-905-60-1333 Fax: +33-1-3420-8600 Phone: +370-5-213-1402 Fax: +27-41-581-0440
Product Information Center: Product Information Center: Fax: +370-5-213-1403
Phone: +43-1-905-60-1249 Phone: +33-1-3420-8686 Product Information Center: Spain – Barcelona
Fax: +43-1-905-60-1251 Fax: +33-1-3420-8623 Phone: +370-5-211-3016 Phone: +34-93-291-0330
Fax: +370-5-213-1403 Fax: +34-93-201-7879
Belarus – Minsk France Export Divisions –
Phone: +375-17-237-47-94 Cergy-Pontoise Cedex Netherlands – ’s-Hertogenbosch Sweden – Upplands Väsby
Fax: +375-17-237-47-94 Phone: +33-1-3420-8866 Phone: +31-73-6246-246 Phone: +46-8-50-72-50-00
Fax: +33-1-3420-8300 Fax: +31-73-6212-365 Fax: +46-8-50-72-50-01
Belgium – Kessel-Lo Product Information Center:
Phone: +32-16-352-300 Germany – Bensheim Switzerland – Steinach
Phone: +31-73-6246-999 Phone: +41-71-447-0447
Fax: +32-16-352-352 Phone: +49-6251-133-0 Fax: +31-73-6246-998
Fax: +49-6251-133-1600 Fax: +41-71-447-0444
Bulgaria – Sofia Product Information Center: Norway – Nesbru
Phone: +359-2-971-2152 Turkey – Istanbul
Phone: +49-6251-133-1999 Phone: +47-66-77-88-50 Phone: +90-212-281-8181-83
Fax: +359-2-971-2153 Fax: +49-6251-133-1988 Fax: +47-66-77-88-55 +90-212-282-5130/5430
Czech Republic and Slovakia Greece – Athens Poland – Warsaw Fax: +90-212-281-8184
Czech Republic – Kurim Phone: +30-210-9370-396/397 Phone: +48-22-4576-700
Phone: +420-541-162-111 Ukraine – Kiev
Fax: +30-210-9370-655 Fax: +48-22-4576-720 Phone: +380-44-206-2265
Fax: +420-541-162-223 Product Information Center:
Product Information Center: Hungary – Budapest Fax: +380-44-206-2264
Phone: +48-22-4576-704 Product Information Center:
Phone: +420-541-162-113 Phone: +36-1-289-1000 Fax: +48-22-4576-720
Fax: +420-541-162-132 Fax: +36-1-289-1010 Phone: +380-44-206-2265
Product Information Center: Romania – Bucharest Fax: +380-44-206-2264
Denmark – Glostrup Phone: +36-1-289-1016 Phone: +40-21-311-3479/3596
Phone: +45-43-48-04-00 United Kingdom –
Fax: +36-1-289-1017 Fax: +40-21-312-0574 Stanmore, Middlesex
Fax: +45-43-44-14-14
Ireland – Dublin Russia – Moscow Phone: +44-8706-080208
Egypt – Cairo Phone: +353-1-866-5612 Phone: +7-495-790-7902 Fax: +44-208-954-6234
Phone: +202-419-2334 Fax: +353-1-866-5714 Fax: +7-495-721-1893 Product Information Center:
Fax: +202-417-7647 Product Information Center: Freephone (UK only):
Israel – Petach-Tikva Phone: +7-495-790-7902-503 +0800-267-666
Estonia – Tartu Phone: +972-3-929-0999 Phone: +44-8706-080208
Phone: +372-5138-274 Fax: +7-495-721-1893
Fax: +972-3-919-1088 Fax: +44-208-420-8095
Fax: +372-7400-779 Russia – Nizhniy Novgorod
Italy – Collegno (Torino) Phone: +7-831-220-33-05/-06
Finland – Helsinki Phone: +39-011-4012-111
Phone: +358-95-12-34-20 Fax: +7-831-220-33-39/-40
Fax: +39-011-4031-116
Fax: +358-95-12-34-250 Product Information Center: Slovenia – Ljubljana
Phone: +39-011-4012-428 Phone: +386-1561-3270
Fax: +39-011-40-287-428 Fax: +386-1561-3240


Tyco Electronics AMP GmbH
AMPèrestr. 12–14
64625 Bensheim / Germany
Phone: +49-(0)6251-133-0
Fax: +49-(0)6251-133-1600

ACTION PIN, AMP DUOPLUG, AMP MCP,
AMP SUPERSEAL 1.5 SERIES,
AMPSEAL 16, FASTON, FASTIN-FASTON,
KILOVAC, MAG-MATE, MATE-N-LOK,
MULTILOCK, POLYSWITCH, PRONER,
RAYCHEM, SIAMEZE, TE Logo and
Tyco Electronics are trademarks

Tyco Electronics AMP GmbH certified
acc. ISO 14001 and ISO/TS 16949:2002

© 2008 Tyco Electronics Ltd.
1654289-2 Revised 9-2008 5M ST

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