PRODUCT SPECIFICATION
KK 254 / .100
WIRE-TO-BOARD
BOARD-TO-BOARD
CONNECTOR SYSTEM
Crimp Terminal
Crimp Terminal
Series: 2759, 6459
Series: 41572
Crimp Terminal
Crimp Terminal
Series: 4089
Series: 8088
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PRODUCT SPECIFICATION
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PRODUCT SPECIFICATION
Crimp Housing
PCB Connector
Series: 2695
Series: 4455
Vertical Header
RA Header
Series: 4030
Series: 4094
Vertical Header with Friction Lock
Right Angle Header with Friction Lock
Series: 6373
Series: 7478
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PRODUCT SPECIFICATION
Vertical Header with Friction Lock
Right Angle Header with Friction Lock
Series: 6410
Series: 7395
Header, Vertical, Breakaway with
Friction Lock
Header, RA, Breakaway with Friction
Lock
Series: 42227
Series: 42228
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PRODUCT SPECIFICATION
Header, Vertical, Breakaway
Header, RA, Breakaway
Series: 42375
Series: 42376
Header, Right-Angle, Breakaway,
Surface Mount Compatible
Series: 42377
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PRODUCT SPECIFICATION
Table of Contents
1.0
2.0
2.1
2.2
2.3
3.0
3.1
3.2
4.0
4.1
4.2
4.3
4.4
5.0
6.0
6.1
6.2
6.3
7.0
7.1
8.0
9.0
SCOPE .................................................................................................................................................. 6
PRODUCT DESCRIPTION .................................................................................................................... 6
PRODUCT NAME AND SERIES NUMBER (S).................................................................................. 6
DIMENSIONS, MATERIALS, PLATING AND MARKINGS ................................................................. 6
SAFETY AGENCY APPROVALS....................................................................................................... 6
APPLICABLE DOCUMENTS AND SPECIFICATION ............................................................................. 7
MOLEX DOCUMENTS ...................................................................................................................... 7
INDUSTRY DOCUMENTS ................................................................................................................. 7
ELECTRICAL PERFORMANCE RATINGS ........................................................................................... 8
VOLTAGE .......................................................................................................................................... 8
CURRENT AND APPLICABLE WIRES .............................................................................................. 8
TEMPERATURE (AMBIENT +30°C TEMP) ....................................................................................... 8
DURABILITY ...................................................................................................................................... 8
QUALIFICATION ................................................................................................................................... 8
PERFORMANCE ................................................................................................................................... 9
ELECTRICAL PERFORMANCE ........................................................................................................ 9
MECHANICAL PERFORMANCE ..................................................................................................... 10
ENVIRONMENTAL PERFORMANCE .............................................................................................. 11
SOLDER INFORMATION .................................................................................................................... 12
SOLDER PROCESS TEMPERATURES .......................................................................................... 12
PACKAGING ....................................................................................................................................... 13
CABLE TIE AND/ OR TWIST LOCATION............................................................................................ 13
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PRODUCT SPECIFICATION
1.0
SCOPE
This Product Specification covers the 2.54 mm (.100 inch) centerline (pitch) 0.64 mm (.025) square pin headers
when mated with either printed circuit board (PCB) connectors or connectors terminated with 22 to 30 AWG
wire using crimp technology.
2.0
PRODUCT DESCRIPTION
2.1
PRODUCT NAME AND SERIES NUMBER (S)
Description
Crimp Terminals
Crimp Housings
PCB Connectors
Headers
Series
2759, 6459, 41572, 4809, 8088
2695
4455
4030, 4094, 6373, 7478, 6410, 7395, 42225, 42226, 42227, 42228,
42375, 42376, 42377, 4380, 42009, 43009, 46607
Other products conforming to this specification are noted on the individual drawings
2.2
DIMENSIONS, MATERIALS, PLATING 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.
RoHS compliant materials*.
*Refer to the “Product Environmental Compliance” section in Molex.com to know the individual PN RoHS
compliance status
2.3
SAFETY AGENCY APPROVALS
2.3.1
UL File Number: E29179
2.3.2
File Number*: LR19980
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PRODUCT SPECIFICATION
SERIES
2695
4455
4030
4094
6373
7478
6410
7395
42225
42226
42227
42228
42375
42376
42377
3.0
Agency Voltage
Rating (AC RMS or
DC)
UL
CSA
500 V AC
250
600 V DC
600
250
600
250
600
250
600
250
600
250
600
250
600
250
600
250
600
250
600
250
600
250
600
250
600
250
600
250
Agency Current
Rating (Single
Circuit) (Amps)
UL
CSA
2.5
-
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
Agency
Temperature
Rating (°C)
UL
105°C
105°C
105°C
105°C
105°C
105°C
105°C
105°C
105°C
105°C
105°C
105°C
120°C
120°C
120°C
APPLICABLE DOCUMENTS AND SPECIFICATION
3.1
MOLEX DOCUMENTS
See series specific sales drawings and the other sections of this specifications for the necessary
referenced documents and specifications.
Cosmetic Specification PS-45499-002
Molex Quality Crimping Handbook Order No. 63800-0029
Molex Solderability Specification SMES-152
Molex Heat Resistance Specification AS-40000-5013
Molex Moisture Technical Advisory AS-45499-001
Molex Package Handling Specification 454990100-PK
ATS – Application Tooling Specification*
*Application Tooling Specification for terminals is not provided in this document. ATS for terminals can be available
from respective terminal part number page in Molex.com
3.2
INDUSTRY DOCUMENTS
EIA-364-1000.01
UL-1977
CSA STD. C22.2 NO. 182.3-M1987
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PRODUCT SPECIFICATION
4.0
ELECTRICAL PERFORMANCE RATINGS
4.1
VOLTAGE
500 Volts AC (or 600 Volts DC)
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
Amps (Max.)
Outside Insulation Diameter
22
4.00
See Drawings
24
3.75
See Drawings
26
3.50
See Drawings
28
3.00
See Drawings
30
2.50
See Drawings
Note: current ratings are for a single circuit, based on not exceeding 30°C temperature rise
4.3
TEMPERATURE (AMBIENT +30°C TEMP)
Brass Terminals
-40°C to +80°C*
-40°C to +105°C**
Operating Temperature
Non-Operating Temperature
Phos Bronze Terminals
-40°C to +105°C*
-40°C to +105°C
*including terminal temperature rise.
**parts not mated
4.4
DURABILITY
Tin / Gold plated: 25 mating cycles
As tested in accordance with EIA-364-1000.01 test method (see Sec. 6.2 of this specification).
5.0
QUALIFICATION
Laboratory conditions and sample selection are in accordance with EIA-364-1000.01
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PRODUCT SPECIFICATION
6.0
PERFORMANCE
6.1
ELECTRICAL PERFORMANCE
DESCRIPTION
TEST CONDITION
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)
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)
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1000 Megohms
MINIMUM
No breakdown
2 picofarads
MAXIMUM
Temperature rise:
+30°C MAXIMUM
TABLE OF CONTENTS
SHEET No.
PRODUCT SPECIFICATION
.100 CENTER KK CONNECTORS
DATE: 2019/05/24201
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2 milliohms
MAXIMUM
[initial]
TITLE:
EC No: 617830617830
DOCUMENT NUMBER:
10 milliohms
MAXIMUM
[initial]
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PRODUCT SPECIFICATION
6.2
MECHANICAL PERFORMANCE
DESCRIPTION
TEST CONDITION
REQUIREMENT
Connector Mate
and
Unmate Forces
Per circuit when mated to an .025 Sq. pin
header without friction lock.
Mate and unmate connector (male to female)
at a rate of 25 ± 6 mm (1 ± ¼ inch) per
minute.
4.9 N (1.1 lbf)
MAXIMUM insertion force
&
0.56 N (0.125 lbf)
MINIMUM withdrawal force
Connector Mate
and
Unmate Forces
46856 series only
Per circuit when mated to a .093 thick PCB
Mate and unmate connector at a rate of 25 ±
6 mm (1 ± ¼ inch) per minute.
6.67 N (1.5 lbf)
MAXIMUM insertion force
&
0.56 N (0.125 lbf)
MINIMUM withdrawal force
Terminal
Retention Force
(in Housing)
Axial pullout force on the terminal in the
housing at a rate of 25 ± 6 mm (1 ± ¼ inch)
per minute. (Forces will change with platings
and materials.)
17.8 N (4.0 lbf)
MINIMUM withdrawal force
Terminal
Insertion Force
(into Housing)
Apply an axial insertion force on the terminal
at a rate of 25 ± 6 mm (1 ± ¼ inch) per
minute. (Forces will change with platings and
materials.)
11.12 N (2.5 lbf)
MAXIMUM insertion force
Durability
Mate connectors up to 25 cycles at a
maximum rate of 10 cycles per minute prior to
Environmental Tests.
10 milliohms MAXIMUM
(change from initial)
Vibration
(Sine)
Mate connectors and vibrate per EIA 364-28,
test condition I.
10 milliohms MAXIMUM
(change from initial) &
Discontinuity < 1 microsecond
Shock
(Mechanical)
Mate connectors and shock at 50 g's with ½
10 milliohms MAXIMUM
sine wave (11 milliseconds) shocks in the ±X,
(change from initial]) &
±Y,±Z axes (18 shocks total).
Discontinuity < 1 microsecond
Wire
Pullout Force
(Axial)
Apply an axial pullout force on the wire at a
rate of 25 ± 6 mm (1 ± ¼ inch) per minute.
(For maximum performance use Molex
application tooling with stranded tinned
copper wire)
Normal
Force
Apply a perpendicular force.
2.94 N (300 grams) average
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PRODUCT SPECIFICATION
.100 CENTER KK CONNECTORS
EC No: 617830617830
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Wire pullout force depends on
crimp tooling. See relevant
Molex Application Tooling
Specification for requirements.
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PRODUCT SPECIFICATION
Maximum Average
Number
Insertion Insertion
of kinked
force (per
force
pins
pin)
(per pin)
Kinked PC Pin
Insertion Force
(into PCB Hole)
6.3
Apply an axial insertion force on pins at a rate
of 25 ± 6 mm (1 ± ¼ inch) per minute.
Shock
(Thermal)
Thermal Aging
Humidity
(Steady State)
TEST CONDITION
15.1N
(3.4 lbf)
4
21.4 N
(4.8 lbf)
9.8 N
(2.2 lbf)
6
18.2 N
(4.1 lbf)
4.9 N
(1.1 lbf)
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.
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44.0 N
(9.9 lbf)
ENVIRONMENTAL PERFORMANCE
DESCRIPTION
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PS-10-07
SHEET No.
PRODUCT SPECIFICATION
.100 CENTER KK CONNECTORS
EC No: 617830617830
DOCUMENT NUMBER:
10 milliohms MAXIMUM
(change from initial)
&
Dielectric Withstanding Voltage:
No Breakdown at 500 VAC
&
Insulation Resistance:
1000 Megohms MINIMUM
&
Visual: No Damage
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PRODUCT SPECIFICATION
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
Solder
Resistance
Cold Resistance
Corrosive
Atmosphere:
Flowing Mixed Gas
(FMG)
7.0
10 milliohms MAXIMUM
(change from initial)
&
Dielectric Withstanding Voltage:
No Breakdown at 500 VAC
&
Insulation Resistance:
1000 Megohms MINIMUM
&
Visual: No Damage
Solder coverage:
95% MINIMUM (per
SMES-152)
Per SMES-152
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
SOLDER INFORMATION
7.1
SOLDER PROCESS TEMPERATURES
Wave Solder: 235°C MAX
Molex Solderability Specification SMES-152
(Click Here)
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PRODUCT SPECIFICATION
8.0
PACKAGING
Parts shall be packaged to protect against damage during normal handling, transit and storage. “For specific
part packaging details, refer to the packaging specification called out on the applicable product sales drawing.
9.0
CABLE TIE AND/ OR TWIST LOCATION
Circuit Sizes
2
4
8
10
14
18
22
Dimension T Minimum
0.50” (12.7mm)
0.75” (19.1mm)
1.00” (25.40mm)
1.25” (31.75mm)
1.50” (38.09mm)
1.75” (44.45mm)
6
12
16
20
24
Dim T
The “T” dimension defines a “free” length of wire, or a length of wire that is not subject to significant bias by
external factors such as a wire tie, wire twisting, or other means of bending or deforming of the wires that
repositions them from their natural relaxed state or location where they enter the housing. Wires are to be
dressed in such a manner to allow the terminals to float freely in the pocket. This dimension is general
recommendation and may need to be adjusted for different wire gauges and wire type and insulation thickness
and insulation material.
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