38-00-1337

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 KK 254 WEB PAGE REVISION: T3 ECM INFORMATION: TABLE OF CONTENTS TITLE: DATE: 2019/05/24201 9/05/24 DOCUMENT NUMBER: PS-10-07 SHEET No. PRODUCT SPECIFICATION .100 CENTER KK CONNECTORS EC No: 617830617830 DOC TYPE: DOC PART: CREATED / REVISED BY: PS 001 SS06 CHECKED BY: 1 of 13 APPROVED BY: ISHWARGISHWARG ISHWARGISHWAR G TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.3).DOC 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 KK 254 WEB PAGE REVISION: T3 ECM INFORMATION: TABLE OF CONTENTS TITLE: DATE: 2019/05/24201 9/05/24 DOCUMENT NUMBER: PS-10-07 SHEET No. PRODUCT SPECIFICATION .100 CENTER KK CONNECTORS EC No: 617830617830 DOC TYPE: DOC PART: CREATED / REVISED BY: PS 001 SS06 CHECKED BY: 2 of 13 APPROVED BY: ISHWARGISHWARG ISHWARGISHWAR G TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.3).DOC 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 KK 254 WEB PAGE REVISION: T3 ECM INFORMATION: TABLE OF CONTENTS TITLE: DATE: 2019/05/24201 9/05/24 DOCUMENT NUMBER: PS-10-07 SHEET No. PRODUCT SPECIFICATION .100 CENTER KK CONNECTORS EC No: 617830617830 DOC TYPE: DOC PART: CREATED / REVISED BY: PS 001 SS06 CHECKED BY: 3 of 13 APPROVED BY: ISHWARGISHWARG ISHWARGISHWAR G TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.3).DOC PRODUCT SPECIFICATION Header, Vertical, Breakaway Header, RA, Breakaway Series: 42375 Series: 42376 Header, Right-Angle, Breakaway, Surface Mount Compatible Series: 42377 KK 254 WEB PAGE REVISION: T3 ECM INFORMATION: TABLE OF CONTENTS TITLE: DATE: 2019/05/24201 9/05/24 DOCUMENT NUMBER: PS-10-07 SHEET No. PRODUCT SPECIFICATION .100 CENTER KK CONNECTORS EC No: 617830617830 DOC TYPE: DOC PART: CREATED / REVISED BY: PS 001 SS06 CHECKED BY: 4 of 13 APPROVED BY: ISHWARGISHWARG ISHWARGISHWAR G TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.3).DOC 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 KK 254 WEB PAGE REVISION: T3 ECM INFORMATION: TABLE OF CONTENTS TITLE: DATE: 2019/05/24201 9/05/24 DOCUMENT NUMBER: PS-10-07 SHEET No. PRODUCT SPECIFICATION .100 CENTER KK CONNECTORS EC No: 617830617830 DOC TYPE: DOC PART: CREATED / REVISED BY: PS 001 SS06 CHECKED BY: 5 of 13 APPROVED BY: ISHWARGISHWARG ISHWARGISHWAR G TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.3).DOC 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 KK 254 WEB PAGE REVISION: T3 ECM INFORMATION: TABLE OF CONTENTS TITLE: DATE: 2019/05/24201 9/05/24 DOCUMENT NUMBER: PS-10-07 SHEET No. PRODUCT SPECIFICATION .100 CENTER KK CONNECTORS EC No: 617830617830 DOC TYPE: DOC PART: CREATED / REVISED BY: PS 001 SS06 CHECKED BY: 6 of 13 APPROVED BY: ISHWARGISHWARG ISHWARGISHWAR G TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.3).DOC 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 KK 254 WEB PAGE REVISION: T3 ECM INFORMATION: TABLE OF CONTENTS TITLE: DATE: 2019/05/24201 9/05/24 DOCUMENT NUMBER: PS-10-07 SHEET No. PRODUCT SPECIFICATION .100 CENTER KK CONNECTORS EC No: 617830617830 DOC TYPE: DOC PART: CREATED / REVISED BY: PS 001 SS06 CHECKED BY: 7 of 13 APPROVED BY: ISHWARGISHWARG ISHWARGISHWAR G TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.3).DOC 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 KK 254 WEB PAGE REVISION: T3 ECM INFORMATION: TABLE OF CONTENTS TITLE: DATE: 2019/05/24201 9/05/24 DOCUMENT NUMBER: PS-10-07 SHEET No. PRODUCT SPECIFICATION .100 CENTER KK CONNECTORS EC No: 617830617830 DOC TYPE: DOC PART: CREATED / REVISED BY: PS 001 SS06 CHECKED BY: 8 of 13 APPROVED BY: ISHWARGISHWARG ISHWARGISHWAR G TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.3).DOC 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) KK 254 WEB PAGE REVISION: T3 ECM INFORMATION: PS-10-07 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 9/05/24 2 milliohms MAXIMUM [initial] TITLE: EC No: 617830617830 DOCUMENT NUMBER: 10 milliohms MAXIMUM [initial] DOC TYPE: DOC PART: CREATED / REVISED BY: PS 001 SS06 CHECKED BY: 9 of 13 APPROVED BY: ISHWARGISHWARG ISHWARGISHWAR G TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.3).DOC 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 KK 254 WEB PAGE REVISION: T3 ECM INFORMATION: TABLE OF CONTENTS TITLE: DATE: 2019/05/24201 9/05/24 PS-10-07 SHEET No. PRODUCT SPECIFICATION .100 CENTER KK CONNECTORS EC No: 617830617830 DOCUMENT NUMBER: Wire pullout force depends on crimp tooling. See relevant Molex Application Tooling Specification for requirements. DOC TYPE: DOC PART: CREATED / REVISED BY: PS 001 SS06 CHECKED BY: 10 of 13 APPROVED BY: ISHWARGISHWARG ISHWARGISHWAR G TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.3).DOC 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. KK 254 WEB PAGE T3 44.0 N (9.9 lbf) ENVIRONMENTAL PERFORMANCE DESCRIPTION REVISION: 2 ECM INFORMATION: TABLE OF CONTENTS TITLE: DATE: 2019/05/24201 9/05/24 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 DOC TYPE: DOC PART: CREATED / REVISED BY: PS 001 SS06 CHECKED BY: 11 of 13 APPROVED BY: ISHWARGISHWARG ISHWARGISHWAR G TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.3).DOC 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) KK 254 WEB PAGE REVISION: T3 ECM INFORMATION: TABLE OF CONTENTS TITLE: DATE: 2019/05/24201 9/05/24 DOCUMENT NUMBER: PS-10-07 SHEET No. PRODUCT SPECIFICATION .100 CENTER KK CONNECTORS EC No: 617830617830 DOC TYPE: DOC PART: CREATED / REVISED BY: PS 001 SS06 CHECKED BY: 12 of 13 APPROVED BY: ISHWARGISHWARG ISHWARGISHWAR G TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.3).DOC 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. KK 254 WEB PAGE REVISION: T3 ECM INFORMATION: TABLE OF CONTENTS TITLE: DATE: 2019/05/24201 9/05/24 DOCUMENT NUMBER: PS-10-07 SHEET No. PRODUCT SPECIFICATION .100 CENTER KK CONNECTORS EC No: 617830617830 DOC TYPE: DOC PART: CREATED / REVISED BY: PS 001 SS06 CHECKED BY: 13 of 13 APPROVED BY: ISHWARGISHWARG ISHWARGISHWAR G TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.3).DOC