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 NUMBERS
Crimp Terminals: 2759, 6459, 41572, 4809, 8088
Crimp Housings: 2695
PCB Connectors: 4455
Headers: 4030, 4094, 6373, 7478, 6410, 7395, 42225, 42226, 42227, 42228, 42375, 42376,
42377
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
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
TITLE:
SERIES
2695
4455
4030
4094
6373
7478
6410
7395
42225
42226
42227
42228
42375
42376
42377
REVISION:
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
SHEET No.
ECM INFORMATION:
ECM No:
604532
DATE:
17/09/2018
T2
PRODUCT SPECIFICATION
.100 CENTER KK CONNECTORS
CHECKED BY:
1
of
6
DOCUMENT NUMBER:
CREATED / REVISED BY:
APPROVED BY:
PS-10-07
SS06
SS06
ISHWARG
TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC
PRODUCT SPECIFICATION
3.0 APPLICABLE DOCUMENTS AND SPECIFICATIONS
None
4.0 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
22
24
26
28
30
Amps (Max)
4.00
3.75
3.50
3.00
2.50
Outside Insulation Diameter
See Drawings
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 (ambient +30°C temp)
Brass Terminals
Operating Temperature
-40°C to +80°C*
Non-Operating Temperature
-40°C to +105°C**
*including terminal temperature rise.
**parts not mated
Phos Bronze Terminals
-40°C to +105°C*
-40°C to +105°C
REVISION:
ECM INFORMATION:
ECM No:
604532
DATE:
17/09/2018
TITLE:
T2
PRODUCT SPECIFICATION
.100 CENTER KK CONNECTORS
CHECKED BY:
SHEET No.
2
of
6
DOCUMENT NUMBER:
CREATED / REVISED BY:
APPROVED BY:
PS-10-07
SS06
SS06
ISHWARG
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 Megohms
MINIMUM
No breakdown
2 picofarads
MAXIMUM
Temperature
Rise
(via Current Cycling)
Temperature rise:
+30°C MAXIMUM
REVISION:
ECM INFORMATION:
ECM No:
604532
DATE:
17/09/2018
TITLE:
T2
PRODUCT SPECIFICATION
.100 CENTER KK CONNECTORS
CHECKED BY:
SHEET No.
3
of
6
DOCUMENT NUMBER:
CREATED / REVISED BY:
APPROVED BY:
PS-10-07
SS06
SS06
ISHWARG
TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC
PRODUCT SPECIFICATION
5.2 MECHANICAL REQUIREMENTS
DESCRIPTION
Connector Mate
and
Unmate Forces
TEST CONDITION
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.
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.
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.)
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.)
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
I.
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 (1 ± ¼ inch) per
minute. (For maximum performance use
Molex application tooling with stranded
tinned copper wire)
Apply a perpendicular force.
REQUIREMENT
4.9 N (1.1 lbf)
MAXIMUM insertion force
&
0.56 N (0.125 lbf)
MINIMUM withdrawal force
6.67 N (1.5 lbf)
MAXIMUM insertion force
&
0.56 N (0.125 lbf)
MINIMUM withdrawal force
17.8 N (4.0 lbf)
MINIMUM withdrawal force
Connector Mate
and
Unmate Forces
46856 series only
Terminal
Retention Force
(in Housing)
Terminal
Insertion Force
(into Housing)
11.12 N (2.5 lbf)
MAXIMUM insertion force
Durability
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.
Vibration
(Sine)
Shock
(Mechanical)
Wire
Pullout Force
(Axial)
Normal
Force
2.94 N (300 grams) average
Number
Maximum
Average
of kinked Insertion force Insertion force
pins
(per pin)
(per pin)
2
4
6
44.0 N (9.9 lbf) 15.1N (3.4 lbf)
21.4 N (4.8 lbf) 9.8 N (2.2 lbf)
18.2 N (4.1 lbf) 4.9 N (1.1 lbf)
SHEET No.
Kinked PC Pin
Insertion Force
(into PCB Hole)
Apply an axial insertion force on pins at a
rate of 25 ± 6 mm (1 ± ¼ inch) per minute.
REVISION:
ECM INFORMATION:
ECM No:
604532
DATE:
17/09/2018
TITLE:
T2
PRODUCT SPECIFICATION
.100 CENTER KK CONNECTORS
CHECKED BY:
4
of
6
DOCUMENT NUMBER:
CREATED / REVISED BY:
APPROVED BY:
PS-10-07
SS06
SS06
ISHWARG
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 Megohms MINIMUM
&
Visual: No Damage
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)
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:
ECM INFORMATION:
ECM No:
604532
DATE:
17/09/2018
TITLE:
T2
PRODUCT SPECIFICATION
.100 CENTER KK CONNECTORS
CHECKED BY:
SHEET No.
5
of
6
DOCUMENT NUMBER:
CREATED / REVISED BY:
APPROVED BY:
PS-10-07
SS06
SS06
ISHWARG
TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC
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