Application Specification
Box Header Assemblies and Receptacle
Connectors with Contacts on 1.90 mm
[.075 in.] and 2.54 mm [.100-in.] Centerlines
114-9013
18 MAY 15 Rev B
NOTE
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and inches].
Unless otherwise specified, dimensions have a tolerance of ±0.13 [±.005] and angles have a tolerance of ±2°. Figures and
illustrations are for identification only and are not drawn to scale.
1. INTRODUCTION
This specification covers the requirements for application of .075 and .100 Box Pin Header Assembly and
Receptacle Connector Components which are designed for printed circuit (pc) board and panel-mount
applications. Headers and receptacles are available with various contact positions and pc board mounting
patterns. All are designed to be installed by hand.
Each header and receptacle has mounting holes that will accept commercially available hardware such as
rivets, screws, bolts and nuts, or specially designed TE Connectivity (TE) hardware. See Figure 1 for typical
product features that will be referred to throughout this text. The illustrations present a composite of available
mounting options and typical headers and receptacles. They do not depict actual applications or all header and
receptacle styles.
Pin header assemblies and receptacle connectors are available with a variety of contact tail arrangements to
meet various application requirements. Each is available with one of four types of contact tails: (1) solder tines,
(2) wrap-type posts, (3) solder eyelets, and (4) crimp wire barrels (2.54 mm [.100 in.] headers and receptacles
only). Wrap-type posts are available as 0.25 x 0.51 mm [.010 x .020 in.] posts for solder or single wire
application, and 0.64 x 0.64 mm [.025 x .025 in.] posts for up to 3 wire applications. The crimp-type pin and
receptacle contacts are designed for crimping of individual wires.
Straight-through contacts can be removed and replaced from unsealed connectors. Right-angle contacts are
permanently retained in the housing and damage to these contacts will require replacement of the header or
receptacle. To avoid damage or any contact tails, TE recommends that the headers and receptacles remain in
their packaging container until ready for use. See Figure 2 for available contact styles.
When corresponding with TE Personnel, use the terminology provided in this specification to facilitate inquiries
for information. Basic terms and features of this product are provided in Figures 1 and 2.
Solder Tine
Type Contact
Mounting
Flange
PC Board
Mounting Hole
Polarizing Slot
Wrap-Type
Post Contact
Marking for
External Keying
Receptacle Connectors
Pin Header Connectors
Polarizing Rib
Polarizing Groove
Jackscrew
Polarizing
Groove
Polarizing
Rib
Mounting Hole
Figure 1
© 2015 TE Connectivity family of companies
All Rights Reserved
*Trademark
PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com.
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
1 of 14
114-9013
Pin (Ref)
Socket (Ref)
Locking
Lance
Solder
Eyelet
Wire
Barrel
Locking
Lance
Insulation Barrel
Crimp-Type
Contact
Solder 0.25 x 0.51
[.010 x .020]
Solder-Type
Contact
Locking
Lances
Locking
Lance
Post 0.64 x 0.64
[.025 x .025]
Wrap-Type
Contact
Solder
Eyelet-Type
Contact
Figure 2
2. REFERENCE MATERIAL
2.1. Revision Summary
Updated document to corporate requirements
Updated complete document
Added new information to tables in Figures 9 and 13 and Paragraph 3.7.C
2.2. Customer Assistance
Reference Product Base Part Number 531838 and Product Code 5365 are representative of Box Header
Assemblies and Receptacle Connectors with Contacts on 1.90 x 2.54 mm [.075 and .100-in.] Centerlines. Use
of these numbers will identify the product line and help you to obtain product and tooling information. Such
information can be obtained through a local TE Representative, by visiting our website at www.te.com, or by
calling PRODUCT INFORMATION or the TOOLING ASSISTANCE CENTER at the numbers at the bottom of
page 1.
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. If there is a conflict
between the information contained in the Customer Drawings and this specification or with any other technical
documentation supplied, the information contained in the Customer Drawings takes priority.
2.4. Manuals
Manual 402-40 can be used as a guide to soldering. This manual provides information on various flux types
and characteristics with the commercial designation and flux removal procedures. A checklist is included in the
manual as a guide for information on soldering problems.
2.5. Specifications
Product Specification 108-9003 provides product performance and test results.
2.6. Instructional Material
Instruction sheets (408-series) and customer manuals (409-series) provide product assembly instructions or
tool setup and operation procedures. Documents available that pertain to this product are:
Document Number
408-6623
408-6624
408-6626
408-6627
408-6660
408-7328
408-7335
408-7424
Rev B
Document Title
1001 Series Box Connectors (Using Crimp, Snap-In Contacts)
Box Connector Jackscrew Assemblies
Clinching Tool 91117-3
Clinching Tool for 3-Row Box Connectors
Extraction Tools
750, 751, 1000, and 1001 Series In-Line Box Connectors
1000 Staggered Series Box Connectors
Checking the Terminal Crimp Height or Gaging the Die Closure
2 of 14
114-9013
Document Number
408-7803
408-8040
408-9344
408-9506
409-5128
Document Title
Clinching Tool 91117-1
Heavy Duty Miniature Quick-Change Applicators (Side-Feed Type)
Alignment Ring
Insertion Tool 446167-1 For 1001 Series Box Pin Connectors
Basic AMP-O-LECTRIC* Model ''K'' Terminating Machine
3. REQUIREMENTS
3.1. Safety
Do not stack product shipping containers so high that the containers buckle or deform.
3.2. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the product
material.
B. Shelf Life
The product should remain in the shipping containers until ready for use to prevent deformation to
components. The product should be used on a first in, first out basis to avoid storage contamination that
could adversely affect performance.
C. Chemical Exposure
Do not store product near any chemical listed below as they may cause stress corrosion cracking in the
material.
Alkalies
Amines
Ammonia
Carbonates
Citrates
Nitrites
Phosphates Citrates
Sulfur Nitrites
Sulfur Compounds
Tartrates
3.3. PC Board Mounting
A. Thickness
Header designs are available to accommodate pc board thicknesses of 2.44 mm [.096 in.] maximum.
Receptacle designs are available to accommodate greater pc board thicknesses. For additional
information, contact TE Engineering by one of the phone numbers listed at the bottom of page 1.
B. Layout
The 1.90 mm [.075 in.] centerline headers and receptacles are available with two and four rows of contact
tails. The 2.54 mm [.100 in.] centerline headers and receptacles are available with two, three, or four
contact tails. All solder tail contacts require precisely located holes. See Figure 3 for 1.90 mm [.075 in.]
contact centerline spacing, and Figures 4 and 5 for 2.54 mm [.100 in.] centerline spacing.
NOTE
The letters used in the layouts coincide with our customer drawing layouts to avoid confusion when working with both layouts.
The letter “A”, representing overall length on the customer drawing was not used on this document.
Rev B
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114-9013
NOTE: All layouts shown are the component side of the pc board.
Receptacle Connectors
[.014 x .019 in.] Solder Tine Contacts
Pin Header Connectors
[.016 x .018 in.] Right-Angle Contact Posts
(Staggered Rows)
[.010 x .020 in.] Posted Contacts
[.016 x .018 in.] Contact Posts
(Two In-Line Rows)
Refer to specific layout above and the following formulas for dimensions B and D.
B = Dimension “D” plus two times Dimension “C” [.332 in.].
C = Dimension from end position to mounting hole.
D = The number of in-row positions, minus one position, times [.075 in.].
Figure 3
Rev B
4 of 14
114-9013
NOTE: All layouts shown are the component side of the pc board.
Receptacle Connectors
[.025 x .025 in.] Straight Post Contacts
(In-Line Rows)
[.010 x .020 in.] Posted Contacts
(Staggered Rows)
Right-Angle [.025 x .025 in.] Posted Contacts
(In-Line Rows)
Solder Channel Contacts
(In-Line Rows)
[.014 x .019 in.] Channel Contacts
(Staggered Rows)
Wrap-Type Posted Contacts
(In-Line Rows)
Refer to specific layout above and the following formulas for dimensions B and D.
B = Dimension “D” plus two times Dimension “C”.
C = Dimension from end position to mounting hole.
D = The number of in-row positions, minus one position, times [.100 in.].
Figure 4
Rev B
5 of 14
114-9013
NOTE: All layouts shown are the component side of the pc board.
Pin Header Connectors
Right-Angle Flow Solder Contacts
(Two In-Line Rows)
Right-Angle Flow Solder Contacts
(Three In-Line Rows)
Refer to specific layout above and the following formulas for dimensions B and D.
B = Dimension “D” plus two times Dimension “C”.
C = Dimension from end position to mounting hole.
D = The number of in-row positions, minus one position, times [.100 in.].
Figure 5
3.4. Panel-Mounting
Front panel-mounting is recommended to provide mating and unmating. Figure 6 provides panel cutout
dimensions.
Refer to specific connector pc board (Figure 3, 4, or 5) for dimensions B and D.
Figure 6
3.5. Limitations
Refer to Product Specification 108-9003 for testing procedures and any limitations that may apply to these
headers and receptacles.
Rev B
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114-9013
3.6. Polarization and Keying
Each header and receptacle has a polarizing design that ensures proper orientation for mating. When more
than one header and receptacle of the same configuration is used in an area, they can be keyed to prevent
mis-mating. Keying sleeves are available for internal keying of 2.54 mm [.100 in.] headers and receptacles with
staggered contact positions. Keying kits are available for external keying of headers and receptacles with
octagonal keying cavities. See Figure 7.
NOTE
Pin headers are designed for rivet-type keying and receptacles are designed for screw-type keying.
Key
Cavity
Tool Jaw
(Ref)
Keying
Number
Code
Rivet-Type
Keying
Insert
Rivet
(Typ)
Punch Tip
(Ref)
Receptacle
Connector
Inset A
Split (Ref)
Connector
Mating Face
Mounting
Screw
Housing
Threaded
Keying Insert
Rivet
Head
Rivet
Formation
Parallel
Flats (Typ)
Housing
0.38 [.015]
(Max)
Connector Flange
Key Hole
Figure 7
Keys must be installed properly to ensure mating of the headers and receptacles. See Insert A, Figure 7.
1. The rivet formation may have a maximum of four splits. None of the split lengths should exceed 50%
of the formation length.
2. The flat sides of the key must be parallel to the flat sides in the housing.
3. The space between the rivet head and housing may not exceed 0.38 mm [.015 in.].
3.7. Hardware (See Figure 8)
A. Commercially Available Hardware
Commercially available 2-56 screws, lockwashers, and nuts are recommended for securing headers and
receptacles to the pc boards.
Rev B
7 of 14
114-9013
B. Jackscrew Assemblies
A variety of TE Fixed and Turnable Jackscrew Assemblies have been designed to accommodate the
various styles of headers and receptacles. These assemblies provide a means of locking mated freehanging and panel-mount headers and receptacles. Some typical components are shown in Figure 8.
Refer to the instruction sheets packaged with the jackscrews for assembly procedure.
NOTE
Jackscrews cannot be used when external keying is used.
Turnable
Jackscrew
Bodies
Turnable
Jackscrew
Bodies
NOTE: All bodies and tips are available
with either internal or external threads.
Fixed Jackscrew Tips
Figure 8
3.8. Contact Extraction
Headers and receptacles with damaged straight-through contacts can be repaired by removing the damaged
contact and replacing it with a new one. Right-angle contacts are permanently retained in the housing. Damage
to a contact will necessitate the replacement of the header or receptacle.
A. Solder and Wrap-Type Contacts
Socket contacts are released from the back of the contact cavity and pin contacts are released from the
front of the contact cavity. Refer to Section 5, TOOLING for tooling information.
B. Crimp-Type Contacts
Pin and socket contacts are released and removed through the back of the connector.
3.9. Crimp-Type Contacts (For 2.54 mm [.100 in.] Centerline Receptacle Connectors Only)
A. Selection
Crimp contacts are designed for stranded wires of the sizes and insulation ranges provided in Figure 9.
The table provides the wire strip length, and the crimp height and crimp width ranges for hand tool and
heady-duty applicator automatic machine application.
B. Contact Locking Lance and Cavity Stop
The highest point of the contact locking lance should be as indicated in Figure 9 to ensure that it will
engage the recess inside the contact cavity. The cavity stop should also be level with the sides to prevent
over-insertion into the contact cavity. Inspection of several uncrimped contacts will provide the required
visual appearance before and after crimping.
Rev B
8 of 14
114-9013
Locking Lance Should be 1.27/1.02 mm
[.050/.040 in.] Above Terminal Sides
Wire Barrel
Cavity Stop
Wire Strip
Length
Insulation Barrel
Cutoff Tab
CONTACT
AND WIRE
RANGE
(AWG)
530750
22-26
WIRE
WIRE BARREL CRIMP HEIGHT AND WIDTH
SIZE (AWG)
DIAMETER
(MAX)
STRIP
LENGTH
22
1.17-1.37
[.046-.054]
24
26
APPLICATOR 466625-3
HAND TOOL 2217745-1
CRIMPED
WIRE
TENSILE
STRENGTH
HEIGHT
WIDTH
HEIGHT
±0.05 [.002]
WIDTH
(REF)
3.56
[.140]
0.91
[.036]
1.07
[.042]
0.76
[.030]
1.07
[.042]
49 N
[11lb-in.]
1.02-1.22
[.040-.048]
3.56
[.140]
0.86
[.034]
1.07
[.042]
0.76
[.030]
1.07
[.042]
31 N
[7 lb-in.]7
0.89-1.24
[.035-.049]
3.56
[.140]
0.76
[.030]
1.07
[.042]
0.76
[.030]
1.07
[.042]
20 N
[4 lb-in.]4
Figure 9
C. Contact Crimp and Tensile Strength
The crimp applied to the wire barrel portion of a contact is the most compressed area and is the most
critical to ensure optimum performance and tensile strength of a termination. The effective length shall be
2.16 mm [.085 in.] minimum (excluding bellmouths) over the length of the wire barrel. See Figure 9.
The wire barrel will be crimped in the “F” crimp configuration where the ends of the wire barrel are turned
inward and the insulation barrel will be crimped to the “O” crimp configuration where the ends of the
insulation barrel will butt against each other. See Figure 9 for crimp dimensions.
D. Contact Cutoff Tab
Cutoff tab length shall not exceed 0.25 mm [.010 in.] and cutoff burr shall not exceed 0.08 mm [.003 in.].
E. Bellmouth
A rear bellmouth will appear due to extrusion of the contact metal during termination. It may be 0.13 mm
[.005 in.] minimum with a height of 0.38 mm [.015 in.] maximum.
F. Wire Barrel Seam
The wire barrel shall be completely closed with no protruding wire strands. Crimp flash along the sides of
the wire barrel that are caused by the crimp pressure and allowable tolerances in the tool shall not exceed
0.13 mm [.005 in.].
G. Conductor Location
The conductor of the wire may be flush to 0.38 mm [.015 in.] protrusion from the front of the wire barrel.
Both insulation and conductor should be visible in the transition area between the insulation and the wire
barrel. No insulation may be crimped in the wire barrel.
H. Vertical and Horizontal Straightness
Contacts must be straight and aligned within tolerances shown in Figure 10.
Rev B
9 of 14
114-9013
1.52 [.060]
0.25 [.010] (Max)
A
A
0.25 [.010] (Min)
0.25 [.010] (Max)
1.78 [.070]
0.89 [.035]
0.25 [.010] (Max)
Figure 10
I. Twist or Roll
The vertical center of the crimp barrels should be in alignment with the vertical center of the mating end of
the contact and the horizontal center should be 0.89 mm [.035 in.] above the contact base line. See
Figure 10.
3.10. Soldering
A. Solder Eyelet Contacts
The contacts are designed for single wire or multiple wire terminations with soldering of each wire being
done by a hand soldering technique. When only a single wire is used in a single contact, the wire
conductor should be placed lengthwise in the contact channel and soldered into position. When multiple
wires are to be attached to a single contact, the wires should be bent to the correct position BEFORE
placing the conductors in the solder eyelet. See Figure 11.
Single Wire Termination in a Single Eyelet Contact
(Conductor In-Line with Eyelet Channel)
Multiple Wire Terminations in One Eyelet Contact
(Conductors 90° to Eyelet)
NOTE: Dress Wires BEFORE Soldering.
Figure 11
B. Solder Tine Contacts
Headers and receptacles with solder tine contacts can be mounted and secured to a pc board by hand,
wave, or flow soldering techniques.
NOTE
Right-angle pin headers with three rows of contacts have a shroud that extends beyond the board edge as indicated in
Figure 12. The exposed portion must be protected from the solder when wave soldering is used. TE recommends one of two
methods that utilizes fluoropolymer based material.
Rev B
10 of 14
114-9013
1. Application of fluoropolymer backed adhesive tape (KAPTON No. 54123) over the mating ace and the
exposed area of the housing prior to soldering.
2. Use of the cover 445207-1 will protect surfaces exposed to infrared preheat and solder wave
elements. Advantages of this method are: (1) ease of installation, and (2) repeated use.
Cover Shown in Place
Full Length of Connector
Figure 12
C. Flux Selection (Figure 13)
Contact solder tails must be fluxed prior to soldering with a mildly active, rosin base flux. Selection of the
flux will depend on the type of pc board and other components mounted on the board. Additionally, the
flux must be compatible with the wave solder line, manufacturing, health, and safety requirements.
TYPE
ACTIVITY
RESIDUE
RMA
Mild
Noncorrosive
COMMERCIAL DESIGNATION
ALPHA
KESTER
611
186
Figure 13
D. Process
The connectors can be soldered using wave soldering or equivalent soldering techniques. Manual 402-40
provides guidelines for establishing soldering practices. The temperature and exposure time shall be as
specified in Figure 14.
SOLDERING PROCESS
TEMPERATURE
TIME (At Max Temperature)
Wave
260°C [500°F] (Wave Temperature)
5 Seconds
Figure 14
E. Cleaning
After soldering, removal of fluxes, residues, an activators is necessary. Consult with the supplier of the
solder and flux for recommended cleaning solvents. Cleaners must be free of dissolved flux and other
contaminants. Common cleaning solvents with times and temperatures that will not affect these
connectors is specified in Figure 15.
It is recommended that cleaning takes place with the pc board on its edge. If using an aqueous cleaner, it
is recommended using standard equipment such as a soak-tank or an automatic in-line machine.
DANGER
Consideration must be given to toxicity and other safety requirements recommended by the solvent manufacturer. Refer to the
manufacturer’s Material Safety Data Sheet (MSDS) for characteristics and handling of cleaners. Trichloroethylene and
Methylene Chloride is not recommended because of harmful occupational and environmental effects. Both are carcinogenic
(cancer-causing).
KAPTON, ALPHA, and KESTER are trademarks of their respective owners.
Rev B
11 of 14
114-9013
CLEANER
NAME
TYPE
TIME
(Minutes)
TEMPERATURE
(Max)
ALPHA 2110
Aqueous
1
132°C [270°F]
BIOACT EC-7
Solvent
5
100°C [212°F]
Butyl CARBITOL
Solvent
1
Ambient Room
Isopropyl Alcohol
Solvent
KESTER 5778
Aqueous
KESTER 5779
Aqueous
LONCOTERGE 520
Aqueous
5
100°C [212°F]
LONCOTERGE 530
Aqueous
Terpene
Solvent
Figure 15
NOTE
If a particular cleaning solvent is not listed, contact PRODUCT INFORMATION at the number at the bottom of page 1.
F. Drying
When drying cleaned assemblies, temperature limitations must not be exceeded: -55° to 125°C [-67° to
257°].
4. QUALIFICATION
Box Header Assemblies and Receptacle Connectors that are marked with the number M55302 are qualified to
Military Specification M55302.
5. TOOLING
Hand crimping tools and mini-applicators are available for applying crimp-type contacts. Keying tools are
available for applying rivet keys, and extraction tools are available for removing straight-through contacts.
Instruction sheets describing tool operation are packaged with the tool. See Figure 16
Mini-Applicator
Hand Tool
Keying Tool
Receptacle
Extraction
Tool
Pin Extraction
Tool
Figure 16 (cont’d)
ALPHA, BIOACT, CARBITOL, LONCOTERGE, and KESTER are trademarks of their respective owners.
Rev B
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114-9013
HAND TOOL AND APPLICATOR
CONTACT WIRE SIZE (AWG)
HAND TOOL
APPLICATOR (DOCUMENT)
26-22
2217745-1
466625-3 (408-8040)
RIVET KEYING TOOLS
CONNECTOR CONFIGURATION
TOOL
DOCUMENT
3-Row 2.54 mm [.100 in.]●
91117-4
408-6627
2-Row 1.90 mm [.075 in.] & 2.54 mm [.100 in.]
91117-1
408-7803
3-Row 1.90 mm [.075 in.] & 2.54 mm [.100 in.]
91117-3
408-6626
EXTRACTION TOOLS
CONTACT TYPE
TOOL
DOCUMENT
Pin
91156-1
408-6660
Receptacle
91035-1
408-7328
●For guide pin keying inserts only.
Figure 16 (end)
Rev B
13 of 14
114-9013
6. VISUAL AID
The illustration below shows a typical application of this product. This illustration should be used by production
personnel to ensure a correctly applied product. Applications which do not appear correct should be inspected
using the information in the preceding pages of this specification and in the instructional material shipped with
the product or tooling.
WIRE MUST BE FLUSH WITH
END OF WIRE BARREL, OR
PROTRUDE SLIGHTLY
WIRE AND INSULATION
MUST BE VISIBLE IN
THIS AREA
LOCKING LANCE MUST
NOT BE DEFORMED
SOLDER FILLET MUST BE
EVENLY FORMED
AROUND BASE OF POSTS
METALLIC ATTACHING
HARDWEAR SHOULD BE
COATED WITH SOLDER
RIVET AND HOUSING
FLATS SHOULD BE
PARALLEL
EXTERNAL KEYING INSERT
MUST MATCH MATING
CONNECTOR, AND IT MUST
BE SECURED
ATTACHING
HARDWARE MUST
BE SECURED
SOLDER EYELET WIRES SHOULD BE DRESSED AND AN EVEN COAT OF SOLDER
SHOULD COVER THE PART OF THE CONDUCTOR THAT IS IN CONTACT WITH THE
SOLDER EYELET
EACH WIRE
SHOULD HAVE
THREE WRAPS
HARDWARE MUST BE
COMPATIBLE WITH HARDWARE
OF MATING CONNECTOR
FIGURE 17. VISUAL AID
Rev B
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