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Subject: Making power cables

From: "Paul Schreiber" <synth1@...>
Date: 2008-06-09

(resending, having some email issues)


a) first you need the correct wire:

http://stevenengineering.com/tech_support/PDFs/37PCBMTACN.pdf
which for 18ga. is UL 1007.

b) MTA = Mass Termination Assembly = IDC = Insulation Displacement
Connector.
That means: a special tool is needed to "cram" the ∗stranded∗ wire into the
connector so that little blades slice through the insulation
and make contact with the wire. Same thing that ribbon cables do, but on a
larger scale

c) There is a low-cost AMP tool, Mouser (www.mouser.com) part #571-598041
(for MTA-156) and also #571-598031 (for MTA-100). This is used to 'cram'
the wire into the contact, assuming that the connector is somehow secured
beforehand (I've use a PanaVise). These are $22.00ea. I use a pneumatic
machine with a "feedthrough" tool that cost $430. But I've made over 8,000
cables so big deal
>
d) note that MTA-156 is designed for 18ga wire with PVC insulation rate
300V or less (this is to control the thickness of the wire versus the
thickness of the insulation).
>
e) also note there are "dust covers" that slide over the female IDC
connectors. The Mouser part number for the 4-pin MTA-156 is a #571-6405514
and these run $0.18ea.

> Paul S.
>