90

Catalog 82004

Dimensions are shown for

Dimensions are in inches and

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Revised 3-11

reference purposes only.

millimeters unless otherwise

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Specifications subject

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FASTON Terminals (Insulated and Uninsulated)

Test Specifications

The following information and accompanying graphs are

taken from TE Product Qualification Testing of Ultra-Fast

FASTON product. Tests were conducted on representative

production samples, and all values shown are averages of

group results. The values shown are typical results and

may vary due to differences in processing, application and

methods of testing.

The heat generated by the current passing through

a termination is a primary limit to the load-carrying

capabilities of the application. A low termination resistance

will produce a lower temperature rise as current is applied.

In order to evaluate this characteristic, UL has established

current ratings for each wire size and set a maximum

temperature rise to assure safe operation. For example, 16

AWG stranded wire has a UL 310 maximum temperature

rise of 30°C above ambient temperature at the rated current

of 10 amps. In the testing of the Ultra-Fast FASTON product

applied to 16 AWG wire, the temperature rise was found to

be below 10°C at the rated current. In fact, the temperature

rise did not exceed 30°C until the current was above 20

amps, more than twice the rated current.

Maintaining a safe temperature rise during cyclic

applications of excessive current is the toughest challenge

for the crimp-thru-plastic concept. The ability of the

Ultra-Fast FASTON product line to meet this goal sets it

apart from other preinsulated terminations. TE’s experience

in crimp development results in a termination that exhibits

stable heating characteristics which are well within the

safety requirements of the industry.

The forces caused by the rolls of FASTON style terminals

determine the contact interface integrity of a mated

receptacle and tab. These forces must be high enough to

prevent oxidation and corrosion from forming inside the

contact area. As these forces are raised to increase the

electrical performance, the engagement and separation

forces for mating the contacts are significantly increased.

For this reason, the Premier Low Insertion Force FASTON

concept of receptacle design has been carried over to the

Ultra-Fast FASTON products. This feature provides

consistent engagement and separation forces while

maintaining a high standard of electrical reliability.

The crimp tensile strength of a wire-to-terminal connection

is important in guarding against such hazards as wire

flexing, vibration and wire strain. However, maximum tensile

strength does not insure maximum electrical performance.

An acceptable compromise between tensile strength and

electrical performance must always be reached, using

recommended crimp heights.

1

UL does not have requirements for wire gauges below 22 AWG.

Note: Minimum requirements are per TE specifications.

To test a product, it must be subjected to 500 on and off

cycles at twice the rated current for the particular wire size.

The temperature rise is measured on the 24th cycle and

the 500th cycle. The maximum temperature rise is limited

to 85°C above ambient temperature with a maximum of

15°C increase on any sample between the 24th and 500th

cycles. Our testing of 16 AWG wire application indicated a

25.5°C maximum temperature rise up to 500 cycles, with a

maximum increase of 0.8°C from the 24th to the 500th

cycle for one sample in the test group.

Current vs. Temperature Rise (16 AWG)

Current Cycling vs. Temperature Rise (16 AWG)

Engagement/Separation

Crimp Tensile