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
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
SERIES
2695
6471
4455
6410
7395
3.0 APPLICABLE DOCUMENTS AND SPECIFICATIONS
None
4.0 RATINGS
4.1 VOLTAGE
250 Volts
REVISION:
ECR/ECN INFORMATION:
EC No:
UCP2014-1506
DATE:
12/6/2013
TITLE:
F
PRODUCT SPECIFICATION
2.54mm CENTER KK CONNECTORS
CHECKED BY:
SHEET No.
1
of
6
DOCUMENT NUMBER:
CREATED / REVISED BY:
APPROVED BY:
PS-99020-0088
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
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
REVISION:
ECR/ECN INFORMATION:
EC No:
UCP2014-1506
DATE:
12/6/2013
TITLE:
F
PRODUCT SPECIFICATION
2.54mm CENTER KK CONNECTORS
CHECKED BY:
SHEET No.
2
of
6
DOCUMENT NUMBER:
CREATED / REVISED BY:
APPROVED BY:
PS-99020-0088
MKIPPER
JBELL
FSMITH-ROEMER
TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC
PRODUCT SPECIFICATION
5.0 PERFORMANCE
5.1 ELECTRICAL REQUIREMENTS
DESCRIPTION
Contact
Resistance
(Low Level)
Contact
Resistance of
Wire Termination
(Low Level)
Insulation
Resistance
Dielectric
Withstanding
Voltage
Capacitance
TEST CONDITION
Mate connectors: apply a maximum voltage
of 20 mV and a current of 100 mA.
Terminate the applicable wire to the terminal
and measure wire using a voltage of 20 mV
and a current of 100 mA.
Unmate & unmount connectors: apply a
voltage of 500 VDC between adjacent
terminals and between terminals to ground.
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.
Measure between adjacent terminals at 1
MHz.
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)
REQUIREMENT
10 milliohms
MAXIMUM
[initial]
2 milliohms
MAXIMUM
[initial]
1000 Megaohms
MINIMUM
No breakdown
2 picofarads
MAXIMUM
Temperature
Rise
(via Current Cycling)
Temperature rise:
+30°C MAXIMUM
REVISION:
ECR/ECN INFORMATION:
EC No:
UCP2014-1506
DATE:
12/6/2013
TITLE:
F
PRODUCT SPECIFICATION
2.54mm CENTER KK CONNECTORS
CHECKED BY:
SHEET No.
3
of
6
DOCUMENT NUMBER:
CREATED / REVISED BY:
APPROVED BY:
PS-99020-0088
MKIPPER
JBELL
FSMITH-ROEMER
TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC
PRODUCT SPECIFICATION
5.2 MECHANICAL REQUIREMENTS
DESCRIPTION
Connector Mate
and
Unmate Forces
Terminal
Retention Force
(in Housing)
Terminal
Insertion Force
(into Housing)
Durability
TEST CONDITION
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.
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.)
Apply an axial insertion force on the terminal
at a rate of 25 ± 6 mm. (Forces will change
with platings and materials.)
Mate connectors up to 25 cycles at a
maximum rate of 10 cycles per minute prior
to Environmental Tests.
Mate connectors and vibrate per EIA 364-28,
test condition
VII.
REQUIREMENT
4.9 N MAXIMUM insertion
force &
0.56 N MINIMUM withdrawal
force
17.8 N
MINIMUM withdrawal force
6.67 N
MAXIMUM insertion force
10 milliohms MAXIMUM
(change from initial)
10 milliohms MAXIMUM
(change from initial)
&
Discontinuity < 1 microsecond
10 milliohms MAXIMUM
(change from initial])
&
Discontinuity < 1 microsecond
Wire pullout force depends on
crimp tooling. See relevant
Molex Application Tooling
Specification for requirements.
2.94 N (300 grams) average
Vibration
(Random)
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).
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)
Apply a perpendicular force.
Wire
Pullout Force
(Axial)
Normal
Force
REVISION:
ECR/ECN INFORMATION:
EC No:
UCP2014-1506
DATE:
12/6/2013
TITLE:
F
PRODUCT SPECIFICATION
2.54mm CENTER KK CONNECTORS
CHECKED BY:
SHEET No.
4
of
6
DOCUMENT NUMBER:
CREATED / REVISED BY:
APPROVED BY:
PS-99020-0088
MKIPPER
JBELL
FSMITH-ROEMER
TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC
PRODUCT SPECIFICATION
5.3 ENVIRONMENTAL REQUIREMENTS
DESCRIPTION
TEST CONDITION
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
Mate connectors; expose to:
96 hours at 105 ± 2°C
REQUIREMENT
10 milliohms MAXIMUM
(change from initial)
&
Visual: No Damage
10 milliohms MAXIMUM
(change from initial])
&
Visual: No Damage
10 milliohms MAXIMUM
(change from initial)
&
Dielectric Withstanding
Voltage:
No Breakdown at 500 VAC
&
Insulation Resistance:
1000 Megaohms MINIMUM
&
Visual: No Damage
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)
Shock
(Thermal)
Thermal Aging
Humidity
(Steady State)
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
Per SMES-152
REVISION:
ECR/ECN INFORMATION:
EC No:
UCP2014-1506
DATE:
12/6/2013
TITLE:
F
PRODUCT SPECIFICATION
2.54mm CENTER KK CONNECTORS
CHECKED BY:
SHEET No.
5
of
6
DOCUMENT NUMBER:
CREATED / REVISED BY:
APPROVED BY:
PS-99020-0088
MKIPPER
JBELL
FSMITH-ROEMER
TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC
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