te product overview

Product OverviewAutomotive Components & Systems

RoHSReady

TYCO ELECTRONICS GLOBAL AUTOMOTIVE DIVISION

1

THE 5 APPLICATION AREAS

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.

G L O B A L A U T O M O T I V E D I V I S I O N

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

TYCO ELECTRONICS “TECHNOLOGY PORTFOLIO”

•Connector Systems /Electromechanical Components

•Relays

•Sensors

•Fiber Optic Products

•Wire & Cable

•Application Tooling

•Tubing & Harnessing Products

•Circuit Protection Devices

•Touch Screen Displays

•Resistors & Inductors

•Heat Sinks & Thermal Solutions

•Switches and Knobs

•Battery Connectors & Assemblies

•Identification Labeling Products

•Racks & Panels

•Smart Cards / Leadframes

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

Internet Homepage www.tycoelectronics.com

www.tycoelectronics.com/automotive

Electronic Internet Catalog www.catalog.tycoelectronics.com

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

Product Information Center(PIC)

You can rely on Tyco Electronics PIC Team to

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

TYCO ELECTRONICS “AT YOU SERVICE”


Terminal bend

Conductor Brush protruding into terminal body

Bellmouth on wrong end

Insulation inside the wire crimp Crimp height too tight

Asymmetric crimp

Unacceptable formation excessiveflash and/or cracks

Terminal feed incorrectly adjusted

Anvil and crimper not aligned or worn

Insulation legs are not closed

Insulation material is pierced

Insulation is not securely held Legs do not overlap

Insulation is not securely

held

Insulation is over crimped

Incorrect applicator adjustment

INSULATION CRIMP

Wire size too large

Wire size too small

Crimp barrel does not close

Legs too close to bottom of crimp.

Insufficient deformation of

strands, showing voids

Incorrect terminal/wire selection

Crimp height too loose

Crimp height too tight

Insufficient deformation,

showing voids

Flash at under side of crimp, due to over -crimping

Incorrect crimp height adjustment

WIRE CRIMP

Terminal damaged

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

Terminal twisted Incorrect

Insulation is pierced and coulddamage conductor


Correct selection of wire, terminal and applicator

Correct Test

F-C

RIM

P

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

Insulation is securely held. Crimp barrel closed

Bellmouth must always be present

Locking lances and terminal body notdeformed

Bellmouth permissible

Cut off tabs present

Crimp barrel is closed, legs support each other

Sufficient gap between legs and bottom of crimp

All strands are equally distributed and deformed

Insulation is securely held. Legs overlap

Insulation securely held. Legs must pass each other

OV

ER

LA

PC

RIM

PW

RA

PO

VE

RC

RIM

P

WIRE CRIMP

WIRE CRIMP

INSULATION CRIMPCorrect Insulation Diameter, Applicator and Terminal

Digital Crimp Height Micrometer

(0.001 mm increments)

acc. to DIN ISO 9001

Part No. 547203-1

Crimp Height Measurement

Crimp Heights and Tolerances

For crimp height tolerances for any given

contact, please refer to the relevant

application specification.

INSULATION CRIMP

Insulation present

Conductorpresent

Insulation must be securelyheld after bend test

30°

30°

Wire crimp without conductor

C R I M P Q U A L I T Y G U I D E L I N E S


E N G I N E E R I N G N O T E S


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


AWG Conversion Table (Average Value)

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

Conversion Tables Most of the wire sizeranges are mentioned inmm2, as well as theinsulation diameterswhich are in many casesonly in mm’s. We therefore included theconversion tables onpages 10 and 11. Please note that wire andinsulation sizes are for guidance only. Consult the customer drawing for precise detail.

AWG Code Diameter (Inch) Diameter (mm) F (mm2)

000000 0.5800 14.733 170.000000 0.5165 13.130 135.0

0000 0.4600 11.684 103.8000 0.4096 10.400 079.000 0.3648 9.270 067.5

0 0.3249 8.25 053.41 0.2893 7.34 042.22 0.2576 6.55 33.73 0.2294 5.82 26.64 0.2043 5.18 21.05 0.1819 4.62 16.96 0.1620 04.115 13.257 0.1443 3.66 10.258 0.1285 3.26 8.349 0.1144 2.90 6.6

10 0.1019 2.59 5.2711 0.0907 2.30 4.1512 0.0808 2.05 3.313 0.0720 1.83 2.6314 0.0641 1.63 2.0815 0.0571 1.45 1.6516 0.0508 1.29 1.30517 0.0453 1.14 1.0118 0.0403 1.02 0.7919 0.0359 0.91 0.6520 0.0320 0.81 0.5121 0.0285 0.72 0.40722 0.0253 0.64 0.3223 0.0226 00.57 0.255 24 0.0201 00.51 0.20525 0.0179 00.455 0.16226 0.0159 00.400 0.12527 0.0142 00.360 0.10228 0.0126 00.320 0.0829 0.0113 00.287 0.064630 0.0100 00.254 0.051631 0.0089 00.226 0.0432 0.0080 00.203 0.032433 0.0071 00.180 0.025534 0.0063 00.160 0.0235 0.0056 00.142 0.015836 0.0050 00.127 0.012737 0.0045 00.114 0.0138 0.0040 00.101 0.00839 0.0035 00.089 0.006240 0.0031 00.079 0.004941 0.0028 00.071 0.0039542 0.0025 00.064 0.0032143 0.0022 00.056 0.0024644 0.00198 00.050 0.0019645 0.00176 00.04546 0.00157 00.04047 0.00140 00.03648 0.00124 00.03149 0.00110 00.02850 0.00099 00.025


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 0.22860.010 0.2540 0.2794 0.3048 0.3302 0.3556 0.3810 0.4064 0.4318 0.4572 0.48260.020 0.5080 0.5334 0.5588 0.5842 0.6096 0.6350 0.6604 0.6858 0.7112 0.73660.030 0.7620 0.7874 0.8128 0.8382 0.8636 0.8890 0.9144 0.9398 0.9652 0.99060.040 1.0160 1.0414 1.0668 1.0922 1.1176 1.1430 1.1684 1.1938 1.2192 1.24460.050 1.2700 1.2954 1.3208 1.3462 1.3716 1.3970 1.4224 1.4478 1.4732 1.49860.060 1.5240 1.5494 1.5748 1.6002 1.6256 1.6510 1.6764 1.7018 1.7272 1.75260.070 1.7780 1.8034 1.8288 1.8542 1.8796 1.9050 1.9304 1.9558 1.9812 2.00660.080 2.0320 2.0574 2.0828 2.1062 2.1336 2.1590 2.1844 2.2098 2.2352 2.26060.090 2.2860 2.3114 2.3368 2.3622 2.3876 2.4130 2.4384 2.4638 2.4892 2.51460.100 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 3.02260.120 3.0480 3.0734 3.0988 3.1242 3.1496 3.1750 3.2004 3.2258 3.2512 3.27660.130 3.3020 3.3274 3.3528 3.3782 3.4036 3.4290 3.4544 3.4798 3.5052 3.53060.140 3.5560 3.5814 3.6068 3.6322 3.6576 3.6830 3.7084 3.7338 3.7592 3.78460.150 3.8100 3.8354 3.8608 3.8862 3.9116 3.9370 3.9624 3.9878 4.0132 4.03860.160 4.0640 4.0894 4.1148 4.1402 4.1656 4.1910 4.2164 4.2418 4.2672 4.29260.170 4.3180 4.3434 4.3688 4.3942 4.4196 4.4450 4.4704 4.4958 4.5212 4.54660.180 4.5720 4.5974 4.6228 4.6482 4.6736 4.6990 4.7244 4.7498 4.7752 4.80060.190 4.8260 4.8514 4.8768 4.9022 4.9276 4.9530 4.9784 5.0038 5.0292 5.05460.200 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 5.56260.220 5.5880 5.6134 5.6388 5.6642 5.6896 5.7150 5.7404 5.7658 5.7912 5.81660.230 5.8420 5.8674 5.8928 5.9182 5.9436 5.9690 5.9944 6.0198 6.0452 6.07060.240 6.0960 6.1214 6.1468 6.1722 6.1976 6.2230 6.2484 6.2738 6.2992 6.32460.250 6.3500 6.3754 6.4008 6.4262 6.4516 6.4770 6.5024 6.5278 6.5532 6.57860.260 6.6040 6.6294 6.6548 6.6802 6.7056 6.7310 6.7564 6.7818 6.8072 6.83260.270 6.8580 6.8834 6.9088 6.9342 6.9596 6.9850 7.0104 7.0358 7.0612 7.08660.280 7.1120 7.1374 7.1628 7.1882 7.2136 7.2390 7.2644 7.2898 7.3152 7.34060.290 7.3660 7.3914 7.4168 7.4422 7.4676 7.4930 7.5184 7.5438 7.5692 7.59460.300 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 8.10260.320 8.1280 8.1534 8.1788 8.2042 8.2296 8.2550 8.2804 8.3058 8.3312 8.35660.330 8.3820 8.4074 8.4328 8.4582 8.4836 8.5090 8.5344 8.5598 8.5852 8.61060.340 8.6360 8.6614 8.6868 8.7122 8.7376 8.7630 8.7884 8.8138 8.8392 8.86460.350 8.8900 8.9154 8.9408 8.9662 8.9916 9.0170 9.0424 9.0678 9.0932 9.11860.360 9.1440 9.1694 9.1948 9.2202 9.2456 9.2710 9.2964 9.3218 9.3472 9.37260.370 9.3980 9.4234 9.4488 9.4742 9.4996 9.5250 9.5504 9.5758 9.6012 9.62660.380 9.6520 9.6774 9.7028 9.7282 9.7536 9.7790 9.8044 9.8298 9.8552 9.88060.390 9.9060 9.9314 9.9568 9.9822 10.0076 10.0330 10.0584 10.0838 10.1092 10.13460.400 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 10.64260.420 10.6680 10.6934 10.7188 10.7442 10.7696 10.7950 10.8204 10.8458 10.8712 10.89660.430 10.9220 10.9474 10.9728 10.9982 11.0236 11.0490 11.0744 11.0998 11.1252 11.15060.440 11.1760 11.2014 11.2268 11.2522 11.2776 11.3030 11.3284 11.3538 11.3792 11.40460.450 11.4300 11.4554 11.4808 11.5062 11.5316 11.5510 11.5824 11.6078 11.6332 11.65860.460 11.6840 11.7094 11.7348 11.7602 11.7856 11.8110 11.8364 11.8618 11.8872 11.91260.470 11.9380 11.9634 11.9888 12.0142 12.0396 12.0650 12.0904 12.1158 12.1412 12.16660.480 12.1920 12.2174 12.2428 12.2682 12.2936 12.3190 12.3444 12.3698 12.3952 12.42060.490 12.4460 12.4714 12.4968 12.5222 12.5476 12.5730 12.5984 12.6238 12.6492 12.67460.500 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 12.92860.510 12.9540 12.9794 13.0048 13.0302 13.0556 13.0810 13.1064 13.1318 13.1572 13.18260.520 13.2080 13.2334 13.2588 13.2842 13.3096 13.3350 13.3604 13.3858 13.4112 13.43660.530 13.4620 13.4874 13.5128 15.5382 13.5636 13.5890 13.6144 13.6398 13.6652 13.69060.540 13.7160 13.7414 13.7668 13.7922 13.8176 13.8430 13.8684 13.8938 13.9192 13.94460.550 13.9700 13.9954 14.0208 14.0462 14.0716 14.0970 14.1224 14.1478 14.1732 14.19860.560 14.2240 14.2494 14.2748 14.3002 14.3256 14.3510 14.3764 14.4018 14.4272 14.45260.570 14.4780 14.5034 14.5288 14.5542 14.5796 14.6050 14.6304 14.6558 14.6812 14.70660.580 14.7320 14.7574 14.7828 14.8082 14.8336 14.8590 14.8844 14.9098 14.9352 14.96060.590 14.9860 15.0114 15.0368 15.0622 15.0876 15.1130 15.1384 15.1638 15.1892 15.21460.600 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 15.72260.620 15.7480 15.7734 15.7988 15.8242 15.8496 15.8750 15.9004 15.9258 15.9512 15.97660.630 16.0020 16.0274 16.0528 16.0782 16.1036 16.1290 16.1544 16.1798 16.2052 16.23060.640 16.2560 16.2814 16.3068 16.3322 16.3576 16.3830 16.4084 16.4338 16.4592 16.48460.650 16.5100 16.5354 16.5608 16.5862 16.6116 16.6370 16.6624 16.6878 16.7132 16.73860.660 16.7640 16.7894 16.8148 16.8402 16.8656 16.8910 16.9164 16.9418 16.9672 16.99260.670 17.0180 17.0434 17.0688 17.0942 17.1196 17.1450 17.1704 17.1958 17.2212 17.24660.680 17.2720 17.2974 17.3228 17.3482 17.3736 17.3990 17.4244 17.4498 17.4752 17.50060.690 17.5260 17.5514 17.5768 17.6022 17.6276 17.6530 17.6784 17.7038 17.7292 17.75460.700 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 18.26260.720 18.2880 18.3134 18.3388 18.3642 18.3896 18.4150 18.4404 18.4658 18.4912 19.51660.730 18.5420 18.5674 18.5928 18.6182 18.6436 18.6690 18.6944 18.7198 18.7452 18.77060.740 18.7960 18.8214 18.8468 18.8722 18.8976 18.9230 18.9484 18.9738 18.9992 19.02460.750 19.0500 19.0754 19.1008 19.1262 19.1516 19.1170 19.2024 19.2278 19.2532 19.27860.760 19.3040 19.3294 19.3548 19.3802 19.4056 19.4310 19.4564 19.4818 19.5072 19.53260.770 19.5580 19.5834 19.6088 19.6342 19.6596 19.6850 19.7104 19.7358 19.7612 19.78860.780 19.8120 19.8374 19.8628 19.8882 19.9136 19.9390 19.9644 19.9898 20.0152 20.04060.790 20.0660 20.0914 20.1168 20.1422 20.1676 20.1930 20.2184 20.2438 20.2692 20.29460.800 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 20.80260.820 20.8280 20.8534 20.8788 20.9042 20.9296 20.9550 20.9804 21.0058 21.0312 21.05660.830 21.0820 21.1074 21.1328 21.1582 21.1836 21.2090 21.2344 21.2598 21.2852 21.31060.840 21.3360 21.3614 21.3868 21.4122 21.4376 21.4630 21.4884 21.5138 21.5392 21.56460.850 21.5900 21.6154 21.6408 21.6662 21.6916 21.7170 21.7424 21.7678 21.7932 21.81860.860 21.8440 21.8694 21.8948 21.9202 21.9456 21.9710 21.9964 22.0218 22.0472 22.07260.870 22.0980 22.1234 22.1488 22.1742 22.1996 22.2250 22.2504 22.2758 22.3012 22.32660.880 22.3520 22.3774 22.4028 22.4282 22.4536 22.4790 22.5044 22.5298 22.5552 22.58060.890 22.6060 22.6314 22.6568 22.6822 22.7076 22.7330 22.7584 22.7838 22.8092 22.83460.900 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 23.34260.920 23.3680 23.3934 23.4188 23.4442 23.4696 23.4950 23.5204 23.5458 23.5712 23.59660.930 23.6220 23.6474 23.6728 23.6982 23.7236 23.7490 23.7744 23.7998 23.8252 23.85060.940 23.8760 23.9014 23.9268 23.9522 23.9776 24.0030 24.0284 24.0538 24.0792 24.10460.950 24.1300 24.1554 24.1808 24.2062 24.2316 24.2570 24.2824 24.3078 24.3332 24.35860.960 24.3840 24.4094 24.4348 24.4602 24.4856 24.5110 24.5364 24.5618 24.5812 24.61260.970 24.6380 24.6634 24.6888 24.7142 24.7396 24.7650 24.7904 24.8158 24.8412 24.86660.980 24.8920 24.9174 24.9428 24.9682 24.9936 25.0190 25.0444 25.0698 25.0952 25.12060.990 25.1460 25.1714 25.1968 25.2222 25.2476 25.2730 25.2984 25.3228 25.3492 25.37461.000 25.4000

Inch 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009

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


R E S T R I C T I O N O N T H E U S E O F 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:

R O H S C O M P L I A N T

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.

N O N - R O H S C O M P L I A N T

These part numbers are identified with a “t” symbol. These products do not comply with the

material restrictions of the European Union Directive 2002/95/EC.

5 O F 6 C O M P L I A N T

A “l” 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 Y O 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

• Downloadable Technical Data Customer Information Presentation

• More detailed information regarding the definitions used above

So whatever your questions when it comes to RoHS, we’ve got the

answers at www.tycoelectronics.com/leadfree

RoHSCustomerSupportCenter


Page

Terminals & Connectors

Introduction 27

Technology 28 3Micro Quadlok Interconnection System 29 3AMP Timer Connector System 29 3AMP MCP Interconnection System 30 3MCON-1.2 mm Interconnection System 30 3MULTILOCK Connectors 31 3GET .64 Interconnection System 31 3MIC Connectors I and IV Series 32 3Econoseal III Connectors 32 3Positive Mate Connectors 33 3.140 MATE-N-LOK Connectors 33 3AMP SUPERSEAL 1.0 mm Connector System 34 3AMP SUPERSEAL 1.5 Series Connectors 34 3AMPSEAL Connectors 35 3AMPSEAL 16 Connector System 35 3Positive Lock Connectors 36 3ACTION PIN/Pressfit 36 3Contact Systems for IDC 37 3Contacts for Flexcircuit Applications 37

Flat Contact System 38 3Sensor Flat Contact System 38 3Heavy Duty Sealed Connector Series 39 3Dia 1.5, 2.5 and 4.0 mm Circular Contact System 39 3Coil Spring Power Contact 40 3FASTON Terminals 40 3Tyco Electronics PRONER Contact System 41 3Magnet Wire Terminals and Splices 41 3

Cable Assembly Systems

Introduction 43

Technology 44 3Wiring Products with Standard Contact System 45

Overmolded Wiring Products 45



3 3 3 33 3 3 33 3 3 33 3 3 33 3 3 33 3 3 33 3 3 33 3 3 33 33 3 3 33 3 3 33 3 3 33 3 3 33 3 3 33 3 3 33 3 3 33 3 3 33 3 3 33 3 3 33 3 3 33

33 33 33 3 3 33 3 3 3

3

3 3 3 33

3 3


Page

Cable Assembly Systems

High Voltage Cable Assemblies 46

Squib Assemblies 46

Pump Nozzle Assemblies 47 3Power Distribution 47 3Heating 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 3Advanced in Mechatronics Components 53 3Concept Study for Carrier 53

Component for CVT Control Unit 54 3Controlled Actuator Module for Turbo Charger Applications 54 3Controlled Actuator for Throttle or Exhaust Applications 55 3Component for Controlled Actuator for Throttle Applications 55 3Tight Connector for CCD-Chip Packaging 56

Housing for Manifold Air Pressure Sensor 56 3Packaging 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 3Switch Module for Seat Positioning 59

Housing for Crash Sensor 59

Sensors

Introduction 61

Technology 62 3PLCD 15 63 3PLCD 25 63 3PLCD 50 64 3



33

33 3

33 3 33 3

3 3 3 33 3 3 33

3

333

3 3

3 3333


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Sensor Technology

L40MC1 Contact-less Travel Sensor 64 3R180M1 Contact-less 180° Rotary Sensor 65 3R360MC1 Contact-less 360° Rotary Sensor 65 3Cylinder Hall Switch 66

Chassis Hall Switch 66-67

Powertrain Hall Switch 67 3Hall 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 3Dual Clutch Position Sensor 78 3Drive Mode Sensor 78 3Gear and Shift Sensor 79 3Neutral Position Sensor 80

Transmission Controller Housing with Integrated Sensors 80 3Transmission Sensor Module 81 3Turbo Charger Sensor 81-82 3EGR Actuator Sensor 82 3Rotational Sensor for Engine Actuator 83 3Truck Rear Axle Steering Sensor 83

Water Detection Sensor 84 3

Relays and Switching ModulesIntroduction 85

Technology 86 3Complete Range of Electromechanical Devices 87 3Evolution of Relay Size and Performance 87 3PCB Relays 88 3Plug-In Relays 88 3Application Specific Switching Solutions 89 3High Current Solutions 89 3



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Power Distribution Systems

Introduction 91

Technology 92 3General Central Electric Units 93 3Integrated Body Control Modules 93 3Prefuse Modules 94 3Switching Modules 94 3

Inductive Systems

Introduction 95

Technology 96 3Immobilizer Antenna 97

Keyless Entry Antenna 97

Brake & Stability Modules 98

Actuator Assembly 98 3Injector Coils 99 3ABS Coil Family 99

Heavy Duty Break Modules 100

Alternative Power Systems

Introduction 101

Technology 102 3Power Distribution and Protection Units 103 3HVA Connector (2 Positions) 103 3HVC 25 Connector 104 3HVC 70 Connector 104 3HVC 230 Connector 105 3LV Connector (2 Positions) 105 3HV Connector (2 Positions) 106 3HV Connector (3 Positions) 106 31 Position IPT Shielded Terminal, Screwed, 25.0-50.0 mm2 107 31 Position IPT Shielded Terminal, Screwed, 70.0-120.0 mm2 107 3Kilovac EV500 Relay 108 3Kilovac EV250 Relay 108 3Kilovac EV200 Relay 109 3



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Alternative Power Systems

Kilovac LEV100 Relay 109 3Kilovac PD5 Relay 110 3Kilovac PD10 Relay 110 3Typical Make / Break 111 3Power Resistors 112 3BDS-A 112 3HCR 113 3Clutch Position Sensor 113 3Dual Clutch Position Sensor 114 3Neutral Position Sensor 114 3EV (Electric Vehicle) Sensor 115 3Brake Pedal Position Sensor 116 3HFT 5000 116 3

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 3RBK-ILS-125 125 3Raychem RNF-100 125 3Raychem HFT 5000 126 3Raychem Application Tooling 126 3

Application Tooling

Introduction 127



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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.

T E R M I N A L S A N D C O N N E C T O R S

T E C H N O L O G Y

C O N N E C T O R S A N D I N T E R C O N N E C T I O N P R O D U C T S

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


Micro Quadlok Interconnection System

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

Features

• Available contacts: MQS, MQS 1.2, MQS 1.5, MicroPower 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 designwith steel spring

• Contacts for sealed and unsealed applications• For signal and power applications; range of wire

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 extensivelyin the automotive industry. The contact systemconsists of a flat receptacle contact that mates with aflat tab contact. The receptacle has two contacts withfour springs, which are independent of each other.Tabs and receptacles can be applied in bothwatertight and non- watertight connector housings.AMP Timer connectors are available as receptacle andtab housings or as receptacle housings and multipletabs (group connection).

Features

• Available contacts: Micro Timer I, Micro Timer II, Micro Timer III, Junior Timer,Junior Power Timer, Standard Timer, Standard PowerTimer, Maxi Power Timer

• Suitable for tabs 1.5, 2.8, 4.8, 5.8, 6.3 and 9.5 mmwide

• Power versions in two-piece design with steel spring• Contacts for sealed and unsealed applications• Range of wire size from 0.12 mm2 up to 10 mm2

• Sealed and unsealed connector housings andheaders are available


T E R M I N A L S & C O N N E C T O R S

Product Literature No. 1307999



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, whichmates with a flat tab. Every contact has a steel springand a copper alloy body. The system offers receptacleand tab housings with capability for waterproofingand 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• Contacts for sealed and unsealed applications• 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• Sealed and unsealed connector housings and

headers are available

MCON-1.2 mm Interconnection System

The MCON-1.2 mm contact system brings added reliabilityto the automotive and commercial vehicle industrieswhich have increased requirements for more reliableelectrical contacts to handle vibration-prone applications. The MCON-1.2 mm contacts have eight defined contactpoints (two contact points on each of the fourindependent beams), which is characteristic of thecontact spring technology, and increases safety marginat high vibration loads. The 15 Ampere at 80°C incombination with a 1.2 mm x 0.63 mm tab contact allowsfor reliable transmissions to be carried. The robust closedbox design guarantees optimized protection of thesprings. Any distortion of the springs will be preventedby an integrated, overstress protection feature. Tyco Electronics offers a spectrum of hand tools andfully automated leadmakers for fast and economicprocessing.

Features

• Base material with high current capacity• 8 defined contact points for increased reliability• Improved vibration resistance• Good guiding inside the cavity • Protected contact spring due to closed box

• Overstress protection of the contact springs• Box with polarization and secondary locking• Protected locking lance• Sealed and unsealed connector housings available

Product Literature No. 1307998-1




MULTILOCK Connectors

The MULTILOCK Series Connectors are used extensivelyin the automotive industry in wire-to-wire and wire-to-board applications. The connectors consist of a plughousing with receptacle contacts and a cap housingwith tab contacts for wire termination. Additionally, theMULTILOCK Connectors have a cap housing assemblywhich can be mounted onto the printed circuit boardeither 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• Improved Kojiri protection• Various contact platings

GET .64 Interconnection System

The GET .64 Interconnection System is used worldwidein 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-boardand 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

plugs necessary in sealed applications




MIC Connectors I and IV Series

MIC represents a series of high contact densityreceptacle housings and connectors for wire-to-wireconnections from front to rear vehicle harnesses, panelmount 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 correctionsof 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 positionsin 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 anaudible snap-lock on mating

• 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 ofthe automotive industry. Each series offer a choice ofhousings from 2 positions to 36 positions, polarizedmating, discrete cable sealing and contact secondarylocking.

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





Positive Mate Connectors

The Positive Mate connector was designed to overcomethe problems resulting from the incorrect mating ofconnectors during assembly. The molded connectorhousings incorporate an integral latching device, calledthe “Go-NoGo” principle. This latching device utilizes thespring characteristics of the nylon material to provide apositively 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 with3.5 mm dia pin and sockets have a 25 A currentcarrying capacity and are capable of accepting wirewith insulation diameters up to 4.5 mm. Both pins andsockets are equipped with dual locking lances, whichassure positive contact retention when installed in thehousings.

Features

• Available in 2, 3 and 9 configurations for panelmounting; 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 ConnectorSystem

Designed for the automotive industry, AMP SUPERSEAL1.0 mm connectors meet the sealing requirementsoutlined 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 andcomplete contact insertion. The secondary lock cannotbe closed if the contacts are not correctly insertedinto the connector housing.

Features

• Wire-to-board and ECU applications, under hood orany location where sealing is required

• Suitable for automotive, truck, bus or off-roadvehicles

• Compact system minimizes packaging requirements• Sealing reliability proven under harsh conditions• Double spring contact design insures low insertion

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 wasdeveloped to meet the increasing requirements forreliability and water resistance. The 1.5 Series exceedthe requirements prescribed by IP 67 according IEC60529 and DIN 40050-9 standards and is applied inthe automotive, agricultural and industrial machineryindustry 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 ruggedreliability, 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 contactsealing to eliminate individual wire-sealing grommets,while an integral interfacial seal protects matedconnectors

Features

• Sealing of interface, wires and panel provides forenvironmental integrity

• Secondary contact locking and lanceless contactsensure positive contact seating

• High temperature materials available to withstandsurface mount applications

• Lanceless receptacle contacts reduce tanglingduring 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 foroff-road and heavy duty industrial applications. Thiswire-to-wire and wire-to-device connector line wasdesigned to meet the rigorous demands of an industrythat requires the highest standards in performance.This connector family will feature the HDSF Size 16 Pinand Socket contacts as a terminal system. Thesecontacts are stamped and formed versions of thescrew machined MIL-C-39029 contacts. The 2, 3, 4, 6, 8, & 12 position housings will offer a onepiece 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• 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




• Gas-tight contact zone• Higher process reliability v.s. solder process• High retention force• No damage to plated thru-holes during application

• Especially suited for multilayer PCB’s• More economic board manufacturing due to larger

hole tolerances compared with the use of a solid pin• Application can be made by end-user

Positive Lock Connectors

The Positive Lock connectors are wire-to-tabtermination connectors designed to provide fastconnect/disconnect and positive locking capabilitiesby using a combination of specially designedreceptacles and housings. These unique features arepossible due to the reduced insertion force and thelocking dimple. The receptacle locks onto mating tabscontaining holes and is removable only by deflecting adepressor 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 SystemAirbags, Engine Control Modules, and Anti-Lock BrakeSystem functions require extremely reliable connections forsignal and power applications. Tyco Electronics’ press-fittechnology compliant pin provides a solder-free, reliableelectrical assembly with improved performance andenvironmental benefits over traditional solder connections.Tyco Electronics compliant ACTION PIN contacts andMultispring contacts produce a tight contact zone betweenthe pin and the plated-through hole and provide long-termreliable electrical interconnection and mechanical reliability.The spring-action is repairable up to 3 times for ease of PCBtroubleshooting. The residual force of the elastic deformationmaintains stored energy, providing long-term reliability ofcompliant contact press-fit connections. Tyco Electronicsoffers stand alone solutions such as connectors (stitched,over-molded), housings and application tooling machines.

Features





Contact Systems for IDC (Insulation Displacement Connection)

In the past 20 years, the need to have economical and compact electronic components for the automotiveindustry has increased. To meet this demand,connectors in grid 2.54 mm were introduced.Tyco Electronics developed connectors based on theInsulation Displacement Technique, in which thecontacts were already protected in the housings, thusavoiding damage during production and finishing aswell as distribution. The IDC technique introduced the0.35 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• 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 usingflexible foil circuits in instrument clusters andpassenger airbags. In order to implement theseinternal and external electrical connections, TycoElectronics has an extensive product range of contactsto meet current quality and technical requirements touse 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 varietyof receptacle contacts. The tabs can be applied in bothwatertight and non-watertight connector housings. The Flat Contact System can be quickly and economicallyterminated 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 mm1.5 x 0.6 mm2.8 x 0.8 mm5.8 x 0.8 mm6.3 x 0.8 mm 9.5 x 1.2 mm

• Tab and receptacle contacts in two-piece designwith steel spring

• Contacts for sealed and unsealed applications• 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 ortab leads to surface oxidation, which can cause acomplete interruption of the electric circuit. To preventthis corrosion, Tyco Electronics has developed thesensor receptacle contact which has an integratedspring in the body, that balances movement in all threespace axes. The sensor receptacle contact can beapplied in a single wire sealed and a non-waterproofdesign.

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 calledHDSCS, is targeted for the commercial vehicle industryand off-road applications. This wire-to-wire and wire-to- device connector program was designed to meetthe rigorous demands of an industry that requires thehighest 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

• Resistant against fretting corrosion• Vibration resistant• Excellent longevity• Low contact resistance• High position configurations• Contact design accepts secondary locking device• Several contact points• Sturdy contact design• Guarantees constant insertion and extraction forces• Sealed and unsealed connector housings available

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 itswide range of performance possibilities, the contact isused in the engine compartment for aggregate orsensor connections. The two-piece contact designmeans that the electrical and mechanical propertiesare separated. The closed cantilever spring has severalfunctions and also different advantages for thecomplete contact system.

Features




Coil Spring Power Contact

The demand for shortest possible periods of machineshutdowns and assembly times requires the use ofconnectors at the interfaces of the connectorwires, as well as energy feeding and power circuits. To satisfy the demand of the various applications theseries 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 ofreceptacles and tabs specifically designed for quickconnections. The large variety of sizes and availabletypes will enable you to select contacts to fit yourneed. The product line offers speed of application,uniform reliability and low cost per line. Theseadvantages have made FASTON products the numberone 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 producesleadframes and connectors for electrical andelectronic devices, serving the automotive industry.

Features

• Power terminals: low insertion force 6.35 and 8.0mm 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 formagnet wire terminations. MAG-MATE terminals areavailable 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 andconnections, 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



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.

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


T E C H N O L O G Y

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.

O U R S O L U T I O N S I N C L U D E

• 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


Wiring Products with Standard ContactSystems

Tyco Electronics provides many discrete cableassemblies utilizing proven components. These cableassemblies are designed to suit the customer andapplication, 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 agas tight product ensuring high durability against theeffects of vibration, temperature and moisture.

Application

• Throttle value body • Fuel tank

Features

• Macromelt for gas tightness keeping durability ofhigh vibration and temperature overmolded sealing(contact)

• –40 °C up to +140 °C

C A B L E A S S E M B L I E S


High Voltage Cable Assemblies

Tyco Electronics high voltage cable assemblies forlighting platforms provide products suitable for up to 25 KV integrating passive components and fullyshielded 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 cableassemblies to cater for 10 mm, 11 mm and Universalinter-faces. A choice of product for AC or DC wiringsystems along with fully or semi automatedmanufacturing process to ensure high reliability forthis 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)


Pump Nozzle

These cable assemblies are located inside the cylinder head of the vehicle, operating in a hostile environmentof temperature and hot oil whilst providing a sealedinterface 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 includingHybrids. Tyco Electronics manufactures power cableassemblies from 25 mm to 75 mm with our own cableand terminals to provide a cable that can be fitteddirectly 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 CableAssemblies

These cable assemblies are design in conjunction with the HVAC manufacturer to optimise the availableTyco Electronics product portfolio of cable, terminals,connectors and other wire related products, thusensuring a reliable product with a cost effectivesolution.

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 withterminals and connectors applied with Tyco Electronicsapplication 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


Low Voltage Differential Signaling

These cable assemblies are fully shielded and usedwithin the driver information system providing a highspeed 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 withTyco Electronics standard contact technology toenable the production of a low cost flexible cableassembly.

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



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.

M E C H AT R O N I C S

T E C H N O L O G Y

T H E R M O P L A S T I C M O L D I N G

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

Leadframes Assem

blie

s

Advanced in Mechatronic Components

ComplexityHighly integrated modules

Wire Bondable SurfacesLong term experience and new developments

Sealed HousingsFuel flange, control units, sensors

Integration of FunctionsContact-less sensors, inductive actuators, relays, press-fit interconnection and connectors

Development and QualificationPrepared 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 forTurbo Charger Application

Processes

• Stamping, electroplating • Molding and assembly

Features

• Wire bondable surfaces• Integration of contact-less sensors



Controlled Actuator forThrottle or Exhaust Application

Processes

• Stamping, electroplating• Assembly and molding in ESD protected areas

Features

• High integration• Integration of contact-less sensors

Component for Controlled Actuator forThrottle Application

Processes

• Stamping• Electroplating• Molding• Assembly

Features

• Wire bondable surfaces


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

• Stamping, electroplating • Molding and assembly

Features

• Wire bondable surfaces • Inlay-molded components• 8 different variations



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

Processes

• Stamping, electroplating• Reel-to-reel inlay molding

Features

• High accuracy in flatness• Wire bondable surfaces

Packaging for Acceleration Sensor in ESP

Processes

• Stamping, electroplating• Reel-to-reel inlay molding• Trim and form of solder shape

Features

• Sealed for potting• Wire bondable surfaces• 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• Reel-to-reel inlay molding• Final molding

Features

• High accuracy in flatness

Housing for Crash Sensor

Processes

• Stamping• Electroplating• Pre-molding• Final molding

Features

• PressFit “Multispring”

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.

S E N S O R S


T E C H N O L O G Y

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.



PLCD 15

ApplicationTransmission, chassis, body, steering, engine

FunctionMeasuring linear travel or angle

TechnologyActive 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




Features



S E N S O R S


PLCD 50




Features




L40MC1Contact-less Travel Sensor

ApplicationEngine, Gearbox and Chassis

FunctionLinear Travel Sensor for measurement range up to 40 mm

TechnologyHall with external Magnet

Features

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

R180M1 Contact-less 180° Rotary Sensor

ApplicationThrottle, exhaust recirculation valve, air intakemanifold, variable turbocharger geometry, drive modefor automatic transmission

FunctionHigh precision rotary sensor up to 180°C measurementrange

TechnologyMR with external Magnet

Features

• High measurement performance• Contact-less measurement principle• Programmable measurement range• Shock and vibration robust• Redundancy available• Measurement through non-ferromagnetic materials

R360MC1Contact-less 360° Rotary Sensor

ApplicationEngine, gearbox and chassis

FunctionRotary sensor for angles up to 360°

TechnologyHall with external magnet

Features

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

S E N S O R S


Cylinder Hall Switch

ApplicationHydraulic cylinder for convertible roofs

FunctionDigital position detection

TechnologyHall (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

ApplicationConvertible roofs



Features

• Triggered kinematics of convertible tops• No moving magnet• Current interface• Diagnostics ability due to two-wire interface• Pigtail with flexible connector interface


Powertrain Hall Switch

ApplicationPowertrain



Features

• Triggered by ferromagnetic part (no moving magnet)

• Current interface• Sealed connector interface• Diagnostics ability due to two-wire interface

S E N S O R S


Chassis Hall Switch

ApplicationBody and Chassis



Features

• Triggered kinematics of convertible tops• No moving magnet• Current interface• Diagnostics ability due to two-wire interface

Hall SensorCable Assemblies

ApplicationConvertible roof systems



Features

• Triggered by ferromagnetic parts in retractable hard or soft tops

• Current interface• Pigtail with customized interface• Diagnostics ability due to two-wire interface

Steering Height Position Sensor

ApplicationSteering column

FunctionMeasuring front-aft and height position of steering column

TechnologyHall (turning multipoled ring magnet)

Features

• Adapted to actuator motor• Contact-less measurement• Customized geometry


Seat Position Sensor

ApplicationDual staged airbag

FunctionMeasuring seat track position


Features

• Triggered by seat track = no moving magnet• Current interface• Small geometry• Diagnostics ability due to two-wire interface





Features

• Triggered by seat track = no moving magnet• Current interface• Small geometry• Diagnostics ability due to two-wire interface

S E N S O R S






Features

• Triggered seat track = no moving magnet• Current interface• Small geometry• Diagnostics ability due to two-wire interface

Buckle Switch

ApplicationAirbag

FunctionDetecting buckle up status

TechnologyHall (moving magnet)

Features

• Triggered latch in the buckle• Contact-less measurement• Customized geometry


Brake Light Switch

ApplicationBrake light switch

FunctionDetection of brake pedal position


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

ApplicationPedal box

FunctionDual digital position detection

TechnologyHall

Features

• Moving magnet triggered by brake pedal• Current interface• Self adjusting features• Full redundancy due to two independent

signal channels

S E N S O R S


Brake Master Cylinder Sensor

ApplicationRegenerative brake system for hybrid vehicles

FunctionLinear position of brake master cylinder


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

ApplicationAnti-lock brake system

FunctionWheel speed detection

TechnologyHall

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


Wheel Speed Sensor

ApplicationAnti-lock brake system (in-bearing type)

FunctionWheel speed detection

TechnologyHall

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

ApplicationCruise control, engine management, interlock, EPB

FunctionMeasuring piston position at clutch master cylinder


Features

• Contact-less measurement through cylinder wall• Up to three switching points or linear PWM output

over 32 mm available

S E N S O R S



ApplicationAutomated manual transmission

FunctionMeasuring piston position at concentric slave cylinderinside the gearbox

TechnologyPassive PLCD (moving magnet)

Features

• Passive PLCD sensor due to high temperatures insidethe gearbox (up to 180°C)

• Measurement range: 22 mm absolute


ApplicationCruise control, engine management, interlock



Features

• Contact-less measurement through cylinder wall• Up to three switching points • Small, flat design




FunctionMeasuring piston position at clutch slave cylinder


Features

• Contact-less measurement through cylinder wall• Measurement range: 44 mm absolute



FunctionMeasuring piston position at concentric slave cylinderinside the gearbox


Features

• Passive PLCD Sensor due to high temperaturesinside the gearbox (up to 180°C)

• Measurement range: 22 mm absolute• Complete overmolded and sealed design

S E N S O R S



ApplicationElectrical park brake



Features

• Contact-less measurement through cylinder wall• Measurement range: 28 mm absolute


ApplicationTruck automated transmission

FunctionMeasuring clutch position at clutch slave cylinder


Features

• Contact-less measurement through cylinder wall• Measurement range: 76 mm absolute• Robust design for truck applications




FunctionMeasuring piston position at clutch slave cylinder


Features

• Contact-less measurement through cylinder wall• Measurement range: 44 mm absolute• Integrated cable assembly for temperature and

pressure connection


ApplicationTruck automated transmission

FunctionMeasuring the clutch position on the concentric slavecylinder (CSC)


Features

• Contact-less measurement• 44 mm measurement range• Highly insensitive against vibration and temperature

(up to 150°C)• Pigtail interface with truck compatible DIN connector

S E N S O R S


Dual Clutch Position Sensor

ApplicationDual clutch transmission

FunctionMeasuring the position of the clutch actuators


Features

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

Drive Mode Sensor

ApplicationAutomatic transmission

FunctionMeasuring drive mode status (PRND) insidetransmission


Features

• Measurement range: 40 mm absolute• Oil sealed packaging and high temperature

(max. 150°C)• High measurement accuracy


Gear and Shift Sensor


FunctionMeasuring gear and shift position


Features

• Angular and travel measurement integrated in one housing

• Measurement range: 26 mm (gear) and 22° (shift)each absolute

Gear and Shift Sensor


FunctionMeasuring gear and shift position

TechnologPLCD (moving magnet)

Features

• Angular and travel measurement integrated in one housing

• Measurement range: 24 mm (gear) and 22° (shift)each absolute

S E N S O R S


Neutral Position Sensor

ApplicationStart-Stop application (mild hybrid)

FunctionMeasuring neutral position of the transmission


Features

• Contact-less measurement through transmission wall• Measurement range: 28 mm absolute• Neutral position ±1% over temperature, life time, etc.

Transmission Controller Housing withintegrated Sensors

ApplicationTransmission controller

FunctionElectronic housing with integrated position and speedsensors


Features

• Sensors, connectors and solenoid interfaceintegrated in one housing concept

• Bondable interface to transmission electronic• Oil sealed interconnection• Highly robust design


Transmission Sensor Module

ApplicationDual clutch transmission

FunctionMeasuring drive mode position / parking lock / inputand output speed

TechnologyActive PLCD sensor (redundant)Hall (turning multipol ring magnet)

Features

• Sensor module with aluminium carrier mountedinside transmission housing

• Oil sealed 8 pin connector system (between ATF andMTF area)

• Highly insensitive against vibration, temperature andpollution inside the transmission

• Complete redundancy of drive mode detection dueto safety requirements

Turbo Charger Sensor

ApplicationTurbo charger

FunctionMeasuring pneumatic actuator position


Features

• High temperature resistance due to externalelectronics

• Measurement range: 16 mm absolute• High measuring and lifetime accuracy

S E N S O R S


Turbo Charger Sensor

ApplicationTurbo charger

FunctionMeasuring pneumatic actuator position


Features

• Sensor integrated in actuator cove• Measurement range: 19 mm absolute• High measuring and lifetime accuracy• Temperature up to 150°C

EGR Actuator Sensor

ApplicationExhaust gas recirculation

FunctionMeasuring position of the piston in the pneumaticcylinder for Truck EGR

TechnologyActive PLCD

Features

• Contact-less measuring through cylinder wall• Measuring range max. 50 mm• Integrated cylinder fixation• Temperature up to 150°C


Rotational Sensor for Engine Actuator

ApplicationAir control valve, turbo actuator, EGR

FunctionMeasuring actuator position

TechnologyAMR (moving magnet)

Features

• Contact-less measurement up to 180°• High vibration resistance• Temperature up to 150°C• Integrated connector and motor interface• Sensor integrated in actuator cover

Truck Rear Axle Steering Sensor

ApplicationTruck rear axle steering

FunctionRear axle steering wheel position


Features

• Contact-less measurement through cylinder wall• Measurement range: 180 mm absolute• Truck specific DIN connector interface

S E N S O R S


Water Detection Sensor

ApplicationFuel filter

FunctionWater detection

TechnologyResistance 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


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.

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


T E C H N O L O G Y

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:

Downscaling:

Monostable Power K

vs. Latching Micro K

Overmolded Magnetic System:

Nano Relay

Wiper Module Mounted on

Leadframe



O V E R M O L D I N G T E C H N O L O G Y

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

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:

• 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.



Complete Range of ElectromechanicalDevices

Producing more than 350 million automotive relays ayear, Tyco Electronics is the market leader andsupplies all major vehicle manufacturers worldwide.Our products cover virtually any application, rangingfrom lamps and electric sunroofs to batterydisconnection over to energy management.

Evolution of Relay Size andPerformance

In the past few years relay engineers realizedtremendous improvements in several areas. The size ofa relay has been reduced to 1/4 compared to previoustypes without performance loss. On top, the powerconsumption of relays has been reduced by 50 %.

More and more individual switching solutions are requested by the automotivemarket. Especially the continuously increasing number of conveniencefeatures requires intelligent solutions. Tyco Electronics offers a completerange of electromechanical components designed to switch a fewmilliamps to several thousand amps. They are grouped in four categories:

1. PCB Relays2. Plug-In Relays3. Application Specific Switching Solutions4. High Current Solutions



PCB Relays

To meet the increasing quality requirements of theautomotive industry and in response to the growingdemand for comfort and higher packaging density inmodern vehicles, Tyco Electronics offers extremelyperforming and miniaturized PCB Relays.

The most recent developments are:

• The Nano Relay as the benchmark for successfulminiaturization. Developed as Twin and Single Relaythey are both the smallest PCB relays in theirrespective classes and are deemed to be marvels ofminiaturization.

• The innovative PK2 that represents the newgeneration of Automotive Power Relays for PCBmounting. 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 andMaxi Plug-In Relays with ISO or 280 footprint for 12 and24 V applications.

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

The Micro Class comprises the standard Micro Relay Aavailable with different features and special types suchas High Current, Low Noise and Latching Relays. All Plug-In relays are available with different contactarrangements, cover colors, mounting brackets/notchesand release features. They combine highest quality andreliability standards with a good price/performance ratiofor cross carline applications.



Application Specific SwitchingSolutions

Application specific switching solutions are smartproducts designed for your very specific needs.

The Power Module F available in the current classes40 A and 70 A combines up to 3 separate relays inone housing, together with an optional electroniccircuitry on a PCB or leadframe. In combination with aleadframe this is a clever alternative for various smartswitching 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 applicationsdemanding relays with high current capability.

The Star Point Relay has particularly been developedto operate EPS motors in the automobile. In the eventof a system failure the relay will reliably shut down the EPS system.

A further high current device is our Battery DisconnectSwitch A suitable for extreme high current loads. It isdesigned to be easily adapted to various battery andharness system requirements and may additionally becombined with electronics.

It has a wide range of applications, ranging from thedisconnection of starter, generator, fuel pump andvarious loads in case of vehicle accident to preventfire, battery explosion and discharge. Other applicationsare to disconnect the battery in case of short circuit,over current or reverse polarity jump-start. Alsoseasonal shut down, service disconnection andtransport deactivation as well as energy managementfunctions are typical applications.


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.

P O W E R D I S T R I B U T I O N S Y S T E M S

T E C H N O L O G Y

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.

L E A D F R A M E T E C H N O L O G Y

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.

P O W E R P C B T E C H N O L O G Y

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.

D I R E C T W I R E D T E C H N O L O G Y

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.



P O W E R D I S T R I B U T I O N S Y S T E M S


General Central Electric Units

These products covering specifically the powerdistribution, carrying fuses and relays and providingpass through connections from one harness toanother. According to customer requirements themodules are designed in sealed or unsealed conditionsto fit in the specified environment. For optimizedspace usage Tyco Electronics often realizes solutionswith integrated bolted fuse interfaces to cover theprefuse functionality.

Showed ApplicationCentral Electric Unit in leadframe technology forengine compartment applications with integrated prefuse functionality. Integrated optional relay carrierfor additional equipment.

Integrated Body Control Modules

On these modules Tyco Electronics is working veryclose together with the First Tier customers to createsolutions with smart interfaces for optimized integrationof customers electronic control units in the powerdistribution module. The result will be an optimizedmodule in space, weight and cost because of thesaving of the different harness connectors betweenthe CE box and the ECU.

Showed ApplicationCentral Electric Unit with integrated Electronic ControlModule.


Prefuse Modules

The development of prefuse modules, former simpleboxes with some bolted fuses on a busbar is movingmore and more to power management units withhigher content of functionality then only protect somebig wires in the harness. Power switch-off componentsin case of an accident or for an intelligent powermanagement to increase battery lifetime or to preventbreak down situations are integrated in these modules.

Showed ApplicationPrefuse module without power managementfunctionality.

Switching Modules

The switching modules are mostly an application ofpower pcb’s equipped with solder relays andadditional electrical components. These small andcompact modules give the customer the possibility todecentralize functionalities in unaccessable areas. Theadvantage of these modules are significant savings inweight, size and number of components as good asthe improved thermal performance and resistanceagainst vibrations.

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.

I N D U C T I V E S Y S T E M S


T E C H N O L O G Y

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.



Immobilizer Antenna

ApplicationPassive anti theft system

FunctionTransponder read-write function

TechnologyLF antenna coil with electronic controller

Features

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

Keyless Entry Antenna

ApplicationPassive entry system

FunctionData acquisition from keyless entry card

TechnologyLF resonator ferrite antenna

Features

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





Brake and Stability Module

ApplicationBrake and stability system

FunctionInterface between hydraulic valves and electroniccontrol unit, pressure sensor housing, pump motorpower supply

TechnologyInductive actuator coils

Features

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

Actuator Assembly

ApplicationGear box axle shifting

FunctionAutomate shifting of gears in tractor gearbox

TechnologySelf 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




Injector Coils

ApplicationDiesel, gasoline and compressed natural gas injectors

FunctionActuator coils for fuel injector needles

TechnologyHigh precision molding and thin thermoplastovermolding

Features

• Standardized coil bobbin• High speed actuator

ABS Coil Family

Application:Wheel speed sensor & actuator

FunctionMeasuring the wheel speed in high temperatureenvironments next to the brake disk and powertransfer for actuators

TechnologyUltra thin wire winding process (>0.06 mm diameter),magnet integration

Features

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




Heavy Duty Brake Module

ApplicationBrake and stability system

FunctionInterface between hydraulic valves and electroniccontrol unit, pressure sensor housing, pump motorpower supply

TechnologyHousing molding, coil winding, assembly

Features

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


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.

A LT E R N AT I V E P O W E R S Y S T E M S COMPONENTS FOR HYBRID, ELECTRIC AND FUEL CELL TECHNOLOGY


T E C H N O L O G Y

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)

A LT E R N AT I V E P O W E R S Y S T E M S


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 • 360° EMC shielding

Performance

• Rated Voltage:500 V DC

• Current Carrying Capacity: 25 A continuous @ +85 °C on2.5 mm2 wire

• Operating Temperature:–40 °C to +85 °C

• Degree of Protection:IP6K9K, IPX7 mated, IP2XB unmated

HVC 70 Connector

Application

• Accessory interconnect

Description

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


Performance

• Rated Voltage:500 V DC

• Current Carrying Capacity: 70 A continuous @ +85 °C on16.0 mm2 wire

• Operating Temperature:–40 °C to +85 °C



Shielded Connector HVC 25 (AMP MCP 2.8 Contact System)

Joint development with Ballard

Shielded Connector HVC 70 (AMP MCP 9.5 Contact System)

With Shielded Tab Header, 2 Positions, HVC 70

(Tab 9.5 3 1.2 mm)

Shielded Tab Header,2 Positions HVC 25 (Tab 2.8 3 0.8 mm)


HVC 230 Connector

Application

• Main interconnect

Description

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


Performance


• Current Carrying Capacity:260 A continuous @ +85 °C on 70.0 mm2 wire



LV Connector (2 Positions)

Application

• Accessory/main interconnect

Description

• 2 Positions • Sealed • 8.0 mm Socket contact system • Wire range 25.0–50.0 mm2

• Wire-to-Device

Performance


• Current Carrying Capacity: 170 A continuous @ +105 °C on 35.0 mm2 wire


• Degree of Protection: IP6K9K, IPX7 mated



Shielded Connector HVC 230 (B 16.0 mm Socket Contact System)


HV Connector (2 Positions)

Application


Description

• 2 Positions • Sealed • Touch-Safe • 8.0 mm Socket contact system • Wire range 25.0–50.0 mm2


Performance





HV Connector (3 Positions)

Application


Description

• 3 Positions • Sealed • Touch-Safe • 8.0 mm Socket contact system • Wire range 25.0–50.0 mm2


Performance






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

Application


Description

• 1 Position • Sealed • Ring tongue • Wire Range 25.0–50.0 mm2

• Wire-to-Device • 360° EMC shielding

Performance





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

Application


Description

• 1 Position • Sealed • Ring tongue • Wire Range 70.0–120.0 mm2

• Wire-to-Device • 360° EMC shielding

Performance







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 • Hermetically sealed

Performance

• 400 A DC continuous carry • .500 A DC 10 second carry • 2500 A, 320 V DC emergency interrupt • 1800 V DC contact maximum • Capacitive Make Switching


• 12 V DC, 24 V DC coil voltage• 8.7 Watts coil power


Kilovac EV200

Application

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

Description

• Form A, H • Hermetically sealed

Performance

• 200 A DC continuous carry • 500 A DC 10 second carry • 2000 A, 320 V DC emergency interrupt • 900 V DC contact maximum • Capacitive Make Switching


• 9 to 95 V DC coil voltage • 1.6 Watts coil power

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 • Hermetically sealed

Performance

• 100 A DC continuous carry • 200 A DC 3 minute carry • 1000 A, 400 V DC emergency interrupt • 900 V DC contact maximum • 12, 24, and 48 V DC coil voltage • 3.5 Watts coil power



Kilovac PD5

Application

• Pre-Charge relay

Description

• Form X, B • Hermetically sealed

Performance

• 15 A DC continuous carry • 5 A DC, 320 V DC resistive load switching • 1800 V DC contact maximum • 12 V DC, 24 V DC, 125 V DC coil voltage • 2 Watts coil power

Kilovac PD10

Application

• Pre-Charge relay

Description

• Form A, B, P (latching) • Hermetically sealed

Performance

• 15 A DC continuous carry • 200 A DC 10 second carry • 10 A DC, 320 V DC resistive switching • 1800 V DC contact maximum • 12 V DC, 24 V DC, 125 V DC coil voltage • 2 Watts coil power


Typical Make / Break

Application



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

Motor Controller

Pre-Charge Relay and Resistor

Filter CapsFrom Source

(Fuel Cell Batteries, Generator etc.)

To LoadMain Relay

Capacitive Switching Test Protocols

Test Protocol 1 Make/Break Life Capacitive and Resistive Loads at 320 V DC 1), 2)

Cycles@ 90% capacitive pre-charge (make only) see charts below 50,000@ 80% capacitive pre-charge (make only) see charts below 50@ 200 A make/break 2 consecutive, reverse polarity 1) 12@ 2000 A break only (1700 A for auxiliary contact model 1) 1*

Test Protocol 2 Make/Break Life Capacitive and Resistive Loads at 320 V DC 1), 2)

Cycles@ 90% capacitive pre-charge (make only) see charts below 50,000@ 70% capacitive pre-charge (make only) see charts below 50@ 250 A, 320 V make/break 2 consecutive, reverse polarity 1) 10@ Interrupt Current Maximum, 320 V break only 4*

(1700 A for auxiliary contact model) 1)

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.

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

Cu

rre

nt

(Am

ps)

Cu

rre

nt

(Am

ps)

Time (ms) Time (ms)

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

80% Pre-Charge

90% Pre-Charge

80% Pre-Charge

90% Pre-Charge

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 multivalentapplications, 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

• 200 A DC continuous carry • 300 A DC emergency interrupt • To 200 V DC contact maximum • 12 V DC, 24 V DC coil voltage• 3.3 Watts coil power


Application

• Alternative powertrain solutions

Function

• Measuring piston position at concentric slavecylinder

Technology

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

Product Features

• Small design in • Measurement range: 22 mm absolute • Highly temperature stable (up to +180 °C)• Redundancy possible



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 • Measurement range: 28 mm absolute • Neutral position <2% over travel, temperature,

life time, etc. • Optional redundancy possible


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



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 forover-temperature (OT) signaling. They provide “silicon-like” performance (in a passive component), reducefootprint needs and support simple distributedmonitoring. In contrast to ceramic PTC devices, RTI devicesprovide clear, “near digital”, OT signals due to a steepresistance change with temperature (~10 x resistancechange per 2 °C).

They also feature a temperature hysteresis responsethat can minimize signal oscillation traditionallyachieved using active components. The steep resistance response and hysteresis alsoallow for a reduction in support com-ponents. RTI devices require only one ballasting resistor todirectly control power FET’s and BJT’s. Solutions usingceramic PTC’s might require a resistor network andcomparator to offer similar functionality. This reduction in support components translatesdirectly to lower system cost and reduced board arearequirements.

Finally, the “near digital” resistance response allows formultiple devices to be placed in series on the samecircuit without significant dilution in systemmeasurement accuracy. This allows for a simple, lowcost implementation of multi-point distributedmonitoring.


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 routingof power cables

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

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


Basis of optical datatransmission point topoint

Device: Sender Device: Receiver

Transmitter

Header Header

Receiver

Harness

Harness

LEDTechnology

POF (PMMA)Technology

PhotodiodeTechnology


The benefits of Optical Networking:• Wide bandwidth• Electromagnetic immunity

• Light weight • Small packaging requirements

Because MOST is a ring bus structure of single optical fibers which arebetter to handle in a harness. At the end of each lead a ferrule is attachedwhich can easily be put into a header. The fixation of the optical fiber tothe ferrule must fulfil a pullout force of >60 N. Tyco Electronicsinvestigated various different methods to fix the ferrules. Tyco Electronicsresearched the brass crimp, the ultrasonic welding and the laser weldingtechnology.In mass production the laser welding technology is usedbecause of the best process performance. The brass crimp will serve as afixing method in the field and for service.

T E C H N O L O G Y

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.

Current optical networking has been achieved based on the current designbuilding blocks:

When these features are coupled with the Tyco Electronics connectorsystems then the following system features are available:

• LED: Light Emitting Diode• Polymer Optical Fibers (POF):

Multi-Mode Step Index Plastic Optical Fibers

• Data transmission up to 50 MBit/s• Band width 200 MHz * 10 m• Temperature range from -40°C to

+85°C (95°C)

• Optical Loss of 0.25 dB/m (with 650 nm)

• Bending radius of 25 mm

• Laser welded optical contacts (Ferrules),a Tyco Electronics creation whichcombines the optimal between pull outforce of the contact with optical loss ofthe light power


Fakra RF Coax Products

Tyco Electronics offers a full product range ofconnections compatible to the Fakra II RF Automotiverequirements. The Fakra II product range wasdeveloped for automotive applications for AM/FM,GSM and GPS signal distribution.

Features

• Ergonomically designed for ease of assembly anddisassembly

• Full keying/coding range for all automotiveapplications

• Connector offerings in 1 and 2 Way housing for 90°and 180° cable exists

• Full product range of header componentscompatible to reflow soldering requirements

• RF Contacts compatible to the RG174 and RTK031which offer ease of processing on reeled terminationprocess

• Product offering can also include cable assemblies

MOST Micro Pigtail Range

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

Features

• Product according to MOST Physical Layer, MOST2+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

MOST (Media Orientation System Transportation) is an optical Bus system for data communication forinfotainment and telematics systems in the car. TycoElectronics offers the complete physical layer productportfolio and was a prominent design partner in thedevelopment of the MOST Physical Layer specification.The MOST 2+4 connection is based on the MOST 2+4Interface.

Features

• Product according to MOST Physical Layer MOST2+4 Interface which includes two MOST connectionsand 4 MQS positions

• 2+4 connection compatible with the Tyco Electronicsflexible or integrated pigtail system

• Flexible and integrated pigtail system available in avariety of FOT’s options

• Option of separate delivery of FOT optical moduleavailable

• Harness connection based on Tyco Electronicswelding contact system

• Tyco Electronics also offers products based on theMOST interface 2+12, 2+20

MOST 4+40 Connection

MOST (Media Orientation System Transportation) is an optical Bus system for data communication forinfotainment and telematics systems in the car. TycoElectronics offers the complete physical layer productportfolio and was a prominent design partner in thedevelopment of the MOST Physical Layer specification.The MOST 4+40 connection is based on the MOST4+40 Interface.

Features

• Product according to MOST Physical Layer MOST4+40 Interface and the Fakra Radio Interface

• 4+40 connection compatible with the Tyco Electronicsflexible pigtail system

• Flexible pigtail system available in a variety of FOT’soptions

• Option of separate delivery of FOT optical moduleavailable

• Harness connection based on Tyco Electronicswelding contact system

• Tyco Electronics offers three versions of the two 8-Way connectors based on the Tyco ElectronicsMPQ, JPT or MCP contact system

• Header available with or without fibre optic opening



MOST Inline Connections

MOST (Media Orientation System Transportation) is an optical Bus system for data communication forinfotainment and telematics systems in the car. TycoElectronics offers the complete physical layer productportfolio and was a prominent design partner in thedevelopment of the MOST Physical Layer specification.MOST inline connections form the MOST cable tocable connections.

Features

• Product according to MOST Physical Layer MOSTperformance 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 automobilefor high speed electrical networking, Tyco Electronicshas developed a product range which fulfils therequirements for video link, camera and USBconnections.

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


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.

A U T O M O T I V E P R O T E C T I O N P R O D U C T S

T E C H N O L O G Y

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.

A U T O M O T I V E S E A L I N G A N D P R O T E C T I O N P R O D U C T S

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.



RBK-ILS-125

RBK-ILS-125 is an adhesive-lined, heat-shrinkabletubing which provides excellent moisture proof sealingof ring terminals in automobile applications, particularlyin wet areas of the vehicle. This product also provideseffective electrical insulation as well as strain relief andmechanical protection against flexing, abrasion andcut-through. RBK-ILS-125 is available in six sizes tocover a wide range of ring terminals – depending onterminal design. For multiple wire configurations itmay be necessary to consider additional adhesiveinserts.

Features

• Continuous operating temperature from -40°C up to +125°C (3000 hrs)

• Mechanically tough, dual-wall polyolefin-basedmaterial

• Adhesive-lined to environ-mentally seal ringterminals – depending on terminal design

• High shrink ratio, allowing one size to fit a widerange 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 superiormechanical strength, RNF-100 is ideal for wire andcable heat protection where abrasion and cut-throughcould also occur.

Features

• A complete range of heat insulation solutions up to200°C – including tubings and flexible conduits,heat-shrinkable fluoro-elastomer tubings and wovenfabric tubings

• High temperature protection – without the cost ofPTFE

• 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

A U T O M O T I V E P R O T E C T I O N P R O D U C T S



RBK-ILS Processor

The RBK-ILS-Processor MkII is a semi-automatic unitdesigned specifically to install splice sealing productsonto ultrasonically welded or crimped splice jointsused in automotive harnesses. The tool can operate inseveral modes:• Stand-alone-operator sets time and temperature. • Sequenced-preset times and temperature can be

sequenced automatically (and can also be randomlyselected from sequence stored).

• Automatic-communication with upstream ultrasonicwelder can allow time and temperature to beautomatically set without operator intervention.

Raychem HFT 5000

HFT is a highly flexible heat-shrinkable fabric tubingdesigned to provide excellent mechanical abrasionprotection for rubber hoses. HFT is woven from heat-shrinkable circumferential cross-linked filaments andnon-shrinking longitudinal polyester fibres and iscompletely halogen-free. HFT generally offers thelowest installed cost per metre protected due to lowshrinkage compared to braids.

Features

• Provides outstanding abrasion protection – even attemperatures as high as 150°C

• Highly flexible woven fabric construction for easyinstallation onto awkward substrates such as benthoses

• 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

The Model 19 conveyor heater is the latest generationof reliable and versatile process heaters for a widevariety of heat-shrinkable products. Two sets of timingbelts grip the individual assemblies and carry themthrough a closed-loop infrared heating zone, thenthrough a cooling zone, and deposit the completedassemblies in a collection bin. The processor wasdesigned to meet the requirements of the EuropeanSafety Directives and is CE approved, allowing forworldwide use. The processor is designed to operateon the following line voltages: 210 to 240 V ac, 20 A, 1Ø, 50/60 Hz.

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.


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


www.tycoelectronics.com

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

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Philippines – Makati City Phone: +632-848-0171 Fax: +632-867-8661

People’s Republic of China Hong Kong Phone: +852-2735-1628 Fax: +852-2735-0243

Shanghai Phone: +86-21-2407-1588 Fax: +86-21-2407-1599

Singapore – Singapore Phone: +65-6482-0311 Fax: +65-6482-1012

Taiwan – Taipei Phone: +886-2-8768-2788Fax: +886-2-8768-2268

Thailand – Bangkok Phone: +66-2-955-0500Fax: +66-2-955-0505

Vietnam – Ho Chi Minh CityPhone: +84-8-930-5546 Fax: +84-8-930-3443

United StatesHarrisburg, PA Phone: +1-717-564-0100 Fax: +1-717-986-7575 Product Information Center: Phone: +1-800-522-6752 Fax: +1-717-986-7575

Troy, MI Phone: +1-248-273-3359 Fax: +1-248-273-3322

Europe/Middle East/Africa Austria – Vienna Phone: +43-1-905-60-0 Fax: +43-1-905-60-1333 Product Information Center: Phone: +43-1-905-60-1249 Fax: +43-1-905-60-1251

Belarus – Minsk Phone: +375-17-237-47-94 Fax: +375-17-237-47-94

Belgium – Kessel-Lo Phone: +32-16-352-300 Fax: +32-16-352-352

Bulgaria – Sofia Phone: +359-2-971-2152 Fax: +359-2-971-2153

Czech Republic and Slovakia Czech Republic – Kurim Phone: +420-541-162-111 Fax: +420-541-162-223 Product Information Center: Phone: +420-541-162-113 Fax: +420-541-162-132

Denmark – Glostrup Phone: +45-43-48-04-00 Fax: +45-43-44-14-14

Egypt – CairoPhone: +202-419-2334 Fax: +202-417-7647

Estonia – Tartu Phone: +372-5138-274 Fax: +372-7400-779

Finland – Helsinki Phone: +358-95-12-34-20 Fax: +358-95-12-34-250

France – Cergy-Pontoise Cedex Phone: +33-1-3420-8888 Fax: +33-1-3420-8600 Product Information Center: Phone: +33-1-3420-8686 Fax: +33-1-3420-8623

France Export Divisions –Cergy-Pontoise Cedex Phone: +33-1-3420-8866 Fax: +33-1-3420-8300

Germany – Bensheim Phone: +49-6251-133-0 Fax: +49-6251-133-1600 Product Information Center: Phone: +49-6251-133-1999 Fax: +49-6251-133-1988

Greece – Athens Phone: +30-210-9370-396/397 Fax: +30-210-9370-655

Hungary – Budapest Phone: +36-1-289-1000 Fax: +36-1-289-1010 Product Information Center: Phone: +36-1-289-1016 Fax: +36-1-289-1017

Ireland – Dublin Phone: +353-1-866-5612 Fax: +353-1-866-5714

Israel – Petach-Tikva Phone: +972-3-929-0999 Fax: +972-3-919-1088

Italy – Collegno (Torino)Phone: +39-011-4012-111 Fax: +39-011-4031-116Product Information Center: Phone: +39-011-4012-428 Fax: +39-011-40-287-428

Lithuania and Latvia Lithuania – Vilnius Phone: +370-5-213-1402 Fax: +370-5-213-1403 Product Information Center: Phone: +370-5-211-3016 Fax: +370-5-213-1403

Netherlands – ’s-HertogenboschPhone: +31-73-6246-246 Fax: +31-73-6212-365 Product Information Center: Phone: +31-73-6246-999 Fax: +31-73-6246-998

Norway – Nesbru Phone: +47-66-77-88-50 Fax: +47-66-77-88-55

Poland – Warsaw Phone: +48-22-4576-700 Fax: +48-22-4576-720 Product Information Center: Phone: +48-22-4576-704 Fax: +48-22-4576-720

Romania – Bucharest Phone: +40-21-311-3479/3596 Fax: +40-21-312-0574

Russia – Moscow Phone: +7-495-790-7902 Fax: +7-495-721-1893 Product Information Center: Phone: +7-495-790-7902-503 Fax: +7-495-721-1893

Russia – Nizhniy Novgorod Phone: +7-831-220-33-05/-06 Fax: +7-831-220-33-39/-40

Slovenia – Ljubljana Phone: +386-1561-3270 Fax: +386-1561-3240

South Africa – Port Elizabeth Phone: +27-41-503-4500 Fax: +27-41-581-0440

Spain – Barcelona Phone: +34-93-291-0330 Fax: +34-93-201-7879

Sweden – Upplands VäsbyPhone: +46-8-50-72-50-00 Fax: +46-8-50-72-50-01

Switzerland – Steinach Phone: +41-71-447-0447 Fax: +41-71-447-0444

Turkey – Istanbul Phone: +90-212-281-8181-83

+90-212-282-5130/5430 Fax: +90-212-281-8184

Ukraine – Kiev Phone: +380-44-206-2265 Fax: +380-44-206-2264 Product Information Center: Phone: +380-44-206-2265 Fax: +380-44-206-2264

United Kingdom –Stanmore, Middlesex Phone: +44-8706-080208 Fax: +44-208-954-6234 Product Information Center: Freephone (UK only):

+0800-267-666Phone: +44-8706-080208 Fax: +44-208-420-8095

Tyco Electronics AMP GmbH AMPèrestr. 12–1464625 Bensheim / Germany Phone: +49-(0)6251-133-0 Fax: +49-(0)6251-133-1600 www.tycoelectronics.com

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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