0022031101

PRODUCT SPECIFICATION 1.0 SCOPE This Product Specification covers 2.54 mm centerline (pitch) 0.64 mm square pin headers when mated with either printed circuit board (PCB) connectors or connectors terminated with 22 to 28 AWG wire using crimp technology. 2.0 PRODUCT DESCRIPTION 2.1 PRODUCT NAME AND SERIES NUMBERS Crimp Terminals: 4809, 2759, 41572, 6459, 8088 Crimp Housings: 2695, 6471 PCB Connectors: 4455 Headers: 6410, 7395 Other products conforming to this specification are noted on the individual drawings. 2.2 DIMENSIONS, MATERIALS, PLATINGS AND MARKINGS Terminal Material: Brass or Phos. Bronze (for Max performance use phos bronze material.) Housing: Nylon or Polyester Pins: Brass or Phos. Bronze For more information on dimensions, materials, and plating see the individual drawings. 2.3 SAFETY AGENCY APPROVALS UL File Number @@.. E29179 CSA @@@@@@@....LR19980 SERIES 2695 6471 4455 6410 7395 Agency Voltage Rating (AC RMS or DC) UL CSA 250 250 250 250 250 Agency Current Rating (Single Circuit) (Amps) UL CSA 2.5 2.5 2.5 2.5 4 Agency Temperature Rating (°C) UL 105°C 105°C 105°C 105°C 105°C 3.0 APPLICABLE DOCUMENTS AND SPECIFICATIONS None 4.0 RATINGS 4.1 VOLTAGE 250 Volts REVISION: F ECR/ECN INFORMATION: EC No: UCP2014-1506 DATE: 12/6/2013 DOCUMENT NUMBER: PS-99020-0088 TITLE: PRODUCT SPECIFICATION 2.54mm CENTER KK CONNECTORS SHEET No. 1 of 6 CREATED / REVISED BY: CHECKED BY: APPROVED BY: MKIPPER JBELL FSMITH-ROEMER TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC PRODUCT SPECIFICATION 4.2 CURRENT AND APPLICABLE WIRES (Current is dependent on connector size, contact material, plating, ambient temperature, printed circuit board characteristics and related factors. Actual current rating is application dependent and should be evaluated for each application.) AWG 22 24 26 28 Amps (Max) 4.00 3.75 3.50 3.00 Outside Insulation Diameter See Drawings See Drawings See Drawings See Drawings Note: current ratings are for a single circuit, based on not exceeding 30°C temperature rise. 4.3 TEMPERATURE Operating Temperature Non-Operating Temperature *including terminal temperature rise. **parts not mated REVISION: F ECR/ECN INFORMATION: EC No: UCP2014-1506 DATE: 12/6/2013 DOCUMENT NUMBER: PS-99020-0088 TITLE: Brass Terminals -40°C to +80°C* -40°C to +105°C** Phos Bronze Terminals -40°C to +105°C* -40°C to +105°C PRODUCT SPECIFICATION 2.54mm CENTER KK CONNECTORS SHEET No. 2 of 6 CREATED / REVISED BY: CHECKED BY: APPROVED BY: MKIPPER JBELL FSMITH-ROEMER TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC PRODUCT SPECIFICATION 5.0 PERFORMANCE 5.1 ELECTRICAL REQUIREMENTS DESCRIPTION REQUIREMENT Contact Resistance (Low Level) Mate connectors: apply a maximum voltage of 20 mV and a current of 100 mA. Contact Resistance of Wire Termination (Low Level) Terminate the applicable wire to the terminal and measure wire using a voltage of 20 mV and a current of 100 mA. Insulation Resistance Unmate & unmount connectors: apply a voltage of 500 VDC between adjacent terminals and between terminals to ground. Dielectric Withstanding Voltage Unmate connectors: apply a voltage of {two times the rated voltage plus 1000 volts} VAC for 1 minute between adjacent terminals and between terminals to ground. Capacitance Measure between adjacent terminals at 1 MHz. Temperature Rise (via Current Cycling) REVISION: F TEST CONDITION EC No: UCP2014-1506 DOCUMENT NUMBER: PS-99020-0088 2 milliohms MAXIMUM [initial] 1000 Megaohms MINIMUM No breakdown 2 picofarads MAXIMUM Mate connectors: measure the temperature rise at the rated current after: 1) 96 hours (steady state) 2) 240 hours (45 minutes ON and 15 minutes OFF per hour) 3) 96 hours (steady state) ECR/ECN INFORMATION: DATE: 12/6/2013 10 milliohms MAXIMUM [initial] TITLE: Temperature rise: +30°C MAXIMUM PRODUCT SPECIFICATION 2.54mm CENTER KK CONNECTORS SHEET No. 3 of 6 CREATED / REVISED BY: CHECKED BY: APPROVED BY: MKIPPER JBELL FSMITH-ROEMER TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC PRODUCT SPECIFICATION 5.2 MECHANICAL REQUIREMENTS DESCRIPTION REQUIREMENT Connector Mate and Unmate Forces Per circuit when mated to a 0.635mm Sq. pin header without friction lock. Mate and unmate connector (male to female) at a rate of 25 ± 6 mm per minute. Terminal Retention Force (in Housing) Axial pullout force on the terminal in the housing at a rate of 25 ± 6 mm per minute. (Forces will change with platings and materials.) Terminal Insertion Force (into Housing) Apply an axial insertion force on the terminal at a rate of 25 ± 6 mm. (Forces will change with platings and materials.) REVISION: 4.9 N MAXIMUM insertion force & 0.56 N MINIMUM withdrawal force 17.8 N MINIMUM withdrawal force 6.67 N MAXIMUM insertion force Durability Mate connectors up to 25 cycles at a maximum rate of 10 cycles per minute prior to Environmental Tests. Vibration (Random) Mate connectors and vibrate per EIA 364-28, test condition VII. 10 milliohms MAXIMUM (change from initial) & Discontinuity < 1 microsecond Shock (Mechanical) Mate connectors and shock at 50 g's with ½ sine wave (11 milliseconds) shocks in the ±X,±Y,±Z axes (18 shocks total). 10 milliohms MAXIMUM (change from initial]) & Discontinuity < 1 microsecond Wire Pullout Force (Axial) Apply an axial pullout force on the wire at a rate of 25 ± 6 mm. (For maximum performance use Molex application tooling with stranded tinned copper wire) Wire pullout force depends on crimp tooling. See relevant Molex Application Tooling Specification for requirements. Normal Force F TEST CONDITION Apply a perpendicular force. ECR/ECN INFORMATION: EC No: UCP2014-1506 DATE: 12/6/2013 DOCUMENT NUMBER: PS-99020-0088 TITLE: 10 milliohms MAXIMUM (change from initial) 2.94 N (300 grams) average PRODUCT SPECIFICATION 2.54mm CENTER KK CONNECTORS SHEET No. 4 of 6 CREATED / REVISED BY: CHECKED BY: APPROVED BY: MKIPPER JBELL FSMITH-ROEMER TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC PRODUCT SPECIFICATION 5.3 ENVIRONMENTAL REQUIREMENTS DESCRIPTION Shock (Thermal) Thermal Aging Humidity (Steady State) TEST CONDITION REQUIREMENT Mate connectors; expose to 5 cycles of: Temperature °C Duration (Minutes) -40 +0/-3 30 +25 ±10 5 MAXIMUM +105 +3/-0 30 +25 ±10 5 MAXIMUM 10 milliohms MAXIMUM (change from initial) & Visual: No Damage Mate connectors; expose to: 96 hours at 105 ± 2°C 10 milliohms MAXIMUM (change from initial]) & Visual: No Damage Mate connectors: expose to a temperature of 40 ± 2°C with a relative humidity of 90-95% for 96 hours. Note: Remove surface moisture and air dry for 1 hour prior to measurements. Humidity (Cyclic) Mate connectors: cycle per EIA-364-31: 24 cycles at temperature 25 ± 3°C at 80 ± 5% relative humidity and 65 ± 3°C at 50 ± 5% relative humidity; dwell time of 1.0 hour; ramp time of 0.5 hours. {Note: Remove surface moisture and air dry for 1 hour prior to measurements.} Solderability REVISION: F EC No: UCP2014-1506 DATE: 12/6/2013 DOCUMENT NUMBER: PS-99020-0088 TITLE: 10 milliohms MAXIMUM (change from initial) & Dielectric Withstanding Voltage: No Breakdown at 500 VAC & Insulation Resistance: 1000 Megaohms MINIMUM & Visual: No Damage Solder coverage: 95% MINIMUM (per SMES-152) Per SMES-152 ECR/ECN INFORMATION: 10 milliohms MAXIMUM (change from initial) & Dielectric Withstanding Voltage: No Breakdown at 500 VAC & Insulation Resistance: 1000 Megaohms MINIMUM & Visual: No Damage PRODUCT SPECIFICATION 2.54mm CENTER KK CONNECTORS SHEET No. 5 of 6 CREATED / REVISED BY: CHECKED BY: APPROVED BY: MKIPPER JBELL FSMITH-ROEMER TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC PRODUCT SPECIFICATION 5.3 ENVIRONMENTAL REQUIREMENTS DESCRIPTION Solder Resistance Cold Resistance Corrosive Atmosphere: Flowing Mixed Gas (FMG) TEST CONDITION REQUIREMENT Dip connector terminal tails in solder: Solder Duration: 5 ± 0.5 seconds; Solder Temperature: 230 ± 5°C Visual: No Damage to insulator material Mate connectors: Duration: 96 hours; Temperature: -40 ± 3°C 10 milliohms MAXIMUM (change from initial) & Visual: No Damage Test per EIA-364-65, Class II, Exposure to gasses for 4 days, unmated. 10 milliohms MAXIMUM (change from initial) & Visual: No Damage 6.0 PACKAGING Parts shall be packaged to protect against damage during handling, transit and storage. 7.0 GAGES AND FIXTURES 8.0 OTHER REVISION: F ECR/ECN INFORMATION: EC No: UCP2014-1506 DATE: 12/6/2013 DOCUMENT NUMBER: PS-99020-0088 TITLE: PRODUCT SPECIFICATION 2.54mm CENTER KK CONNECTORS SHEET No. 6 of 6 CREATED / REVISED BY: CHECKED BY: APPROVED BY: MKIPPER JBELL FSMITH-ROEMER TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC