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application specification 114--16017 loc b 1 of 12 e 2011 tyco electronics corporation, a te connectivity ltd. company all rights reserved te logo is a trademark. *trademark. other product names, logos, or company names might be trademarks of their respective owners. tooling assistance center 1--800--722-- 1111 product information 1--800--522--6752 this controlled document is subject to change. for latest revision and regional customer service, visit our website at www.te.com mini- universal mate- n- lok* connectors 17 mar 11 rev l all numerical values are in metric units [with u.s. customary units in brackets]. dimensions are in millimeters [and inches]. unless otherwise specif ied, dimensions have a tolerance of + 0.13 [+ .005] and angles have a tolerance of + 2 _ . figures and illustrations are for i dentification only and are not drawn to scale. 1. introduction this specification covers the requirements for application of mini--universal mate--n--lok connectors for free--hanging, panel--mount, and printed circuit (pc) board applications. these connectors provide a reliable and economic means of grouping multiple--lead connections in computers, computer/peripheral equipment, business machines, entertainment centers, and appliances. the connectors are available in hermaphroditic housing and positively polarized: plug housing, vertical pin header, right--angle pin header, and cap housing. the housings accept socket contacts and pin contacts. each contact features a contact stop to ensure proper insertion depth of the contact in the contact cavity of the housing. the contacts are available in strip form for machine application and loose piece for manual tooling application. the hermaphroditic housing is available with 2, 3, or 4 circuits for free--hanging applications. the cap housing is available in 1, 2, or 3 circuits for free--hanging application and 2, 3, 4, 6, 9, 12, or 15 circuits for panel mounting or free--hanging application. the plug housing and vertical pin header is available with 2, 3, 4, 6, 8, 9, 10, 12, 14, 15, 16, 18, 20, 22, or 24 circuits; the vertical blind--mate pin header is available in 4, 6, 8, 9, 10, 12, or 15 circuits for panel mounting or free--hanging application. the right--angle pin header is available in 2, 3, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, or 24 circuits for pc board application. to avoid personal injury, these connectors are not to be used for interrupting current. when corresponding with personnel, use the terminology provided in this specification to fac ilitate your inquiries for information. basic terms and features of this product are provided in figure 1. figure 1 locking latch locking tab mounting ear right- angle pin header cap housing plug housing vertical pin header boardlock solder tine standoff pin contact socket contact insulation barrel wire barrel locking lance contact stop solder tine hermaphroditic housing locking latch locking tab note i danger
114--16017 rev l 2 of 12 2. reference material 2.1. revision summary revisions to this application specification include: s updated application specification to corporate requirements s added danger to section 1 and caution to paragraph 3.3 s added hermaphroditic housing to figure 1 and contact stop to section 1, figures 1 and 10, and paragraph 3.2,c s replaced superceded hand crimping tools in section 5, and added note to paragraph 5.1 2.2. customer assistance reference product base part number 770166 and product code 1311 are representative of mini--universal mate--n--lok connectors. use of these numbers will i dentify the product line and expedite your inquiries through a service network established to help you obtain product and tooling information. such information can be obtained through a local representative or, after purchase, by calling product information at the number at the bottom of page 1. 2.3. drawings customer drawings for product part numbers are available from the service network. if there is a conflict between the information contained in the customer drawings and this specification or with any other technical documentation supplied, the information contained in the customer drawings takes priority. 2.4. specifications design objective 108--5138 provides expected product performance and test information for connectors (94v--o), and 108--5151 provides expected performance and test information for connectors (94v--2). 2.5. instructional material instruction sheets (408--series) provide product assembly instructions or tooling setup and operation procedures and customer manuals (409--series) provide machine setup and operating procedures. instruction material available that pertains to this product are: 408--3234 mini--universal mate--n--lok connectors 408--4118 extraction tool 189727--1 408--4148 straight action hand tool 90710--2 408--4443 straight action hand tool 90717--2 408--7347 insertion tool 91002--1 408--8040 heavy duty miniature quick--change applicators (side--feed) 408--8547 certi--crimp* ii straight action hand tools 91522--1 and 91536--1 408--9965 pro--crimper* iii hand crimping tool 90870--1 409--5128 amp--o--lectric* model ?k? terminating machine 565435--5 409--5842 amp--o--lectric model ?g? terminating machines 354500--[ ] 409--5852 ampomator* cls iii--g lead--making machines 122500--[ ] 409--5878 ampomator cls iv+ lead--making machines 356500--[ ] 2.6. manual manual 402--40 is available upon request and can be used as a guide in soldering. this manual provides information on various flux types and characteristics along with the commercial designation and flux removal procedures. a checklist is attached to the manual as a guide for information on soldering problems. 3. requirements 3.1. wire selection and preparation the contacts accept stranded wire sizes 30 to 16 awg within the insulation diameter range listed in figure 2. the wire insulation shall be stripped to a length from 3.20 to 3.71 [.126 to .146] for one--wire crimping and 3.50 to 3.99 [.138 to .157] for two--wire crimping. reasonable care shall be taken not to nick, scrape, or cut any strands during the stripping operation.
114--16017 rev l 3 of 12 3.2. contact crimp requirements a. carrier cutoff there shall be no burrs on the cutoff tab. the carrier cutoff tab length shall not exceed the dimension giveninfigure2. b. crimp height the insulation barrel shall be formed around but not cut into the wire insulation. the wire barrel and insulation barrel crimp height and width is given in figure 2. the applied crimp dimension (within the function range of the product) is dependent on the termination tooling being used. refer to the documentation (applicator logs and instruction sheets) supplied with the termination tooling for the applied crimp height. c. contact stop the contact stop must not be crimped. any deformation to the contact stop will compromise the insertion depth of the contact in the contact cavity of the housing. d. front and rear bellmouths the front bellmouth shall be visible. the rear bellmouth shall conform to the dimensions given in figure 2. e. wire location the end of the wire shall be flush with the end of the wire barrel or protrude no more than the dimension giveninfigure2. f. locking lances the locking lances shall not be deformed. stack wires as shown for 2--wire crimping wire barrel contact requirements insulation barrel formed around but not cutting into wire insulation wire barrel seam closed with no strands protruding or showing 0.50 [.020] cutoff tab l en g th no burrs on cutoff tab wire strands and insulation both visible in this area endofwireflushwith endofwirebarrelor 0.88 [.035] (max) wire length 0.10--0.51 [.004--.020] (applicator) 0.10 [.004] min (hand tool) rear bellmouth front bellmouth visible 0.25 [.010] max flash locking lances not deformed note: all requirements apply to both pin and socket contact. contact stop not crimped or deformed locking lances not deformed contact stop not crimped or deformed figure 2 (cont?d) note i
114--16017 rev l 4 of 12 automatic machine wire (stranded only) wire barrel crimp insul a tion b a rrel size (awg) insulation diameter height + 0.05 [+ .002] width i n s u l a t i o n b a r r e l crimp width (ref) 30 0.50 [.020] 28 0.88--1.27 [ 0 3 5 - - 0 5 0 ] 0.55 [.022] 1.06 [ 0 4 2 ] 1.78 [ 0 7 0 ] 26 [ . 0 3 5 -- . 0 5 0 ] 0.60 [.024] [ . 0 4 2 ] [ . 0 7 0 ] 26 d 0.63 [.025] d 24 1.20--1.75 [ 0 4 7 -- 0 6 9 ] 0.69 [.027] 1.22 [ 0 4 8 ] 2.03 [ 0 8 0 ] 22 [ . 0 4 7 -- . 0 6 9 ] 0.78 [.031] [ . 0 4 8 ] [ . 0 8 0 ] 22 0.81 [.032] 20 1.50--2.79 [ 0 5 9 -- 1 1 0 ] 0.91 [.036] 1.57 2.79 18 [ . 0 5 9 -- . 1 1 0 ] 1.07 [.042] 1 . 5 7 [.062] 2 . 7 9 [.110] 22 (2 wires) 1.70 [.067] max (2 wires) 0.91 [.036] 20 1.07 [.042] 18 2.0--3.20 [ 0 7 9 -- 1 2 6 ] 1.21 [.048] 1.78 3.56 16 [ . 0 7 9 -- . 1 2 6 ] 1.30 [.051] 1 . 7 8 [.070] 3 . 5 6 [.140] 20 (2 wires) 1.91 [.075] max (2 wires) 1.30 [.051] d for tin-- coated 7-- strand wire size 26 awg with 0.15 [.006] insulation diameter, crimp height must be controlled to +0.03/-- 0.05 [+.001/-- .002]. hand tool wire (stranded only) wire barrel crimp i n s u l a t i o n b a r r e l size (awg) insulation diameter anvil die letter height + 0.05 [+ .002] width insul a tion b a rrel crimp width (ref) 30 0.58 [ .023 ] 28 1.52 [.060] max ? 0 . 5 8 [ . 0 2 3 ] 1.07 [ 0 4 2 ] 1.78 [ 0 7 0 ] 26 [ ] 0.64 [.025] [ . 0 4 2 ] [ . 0 7 0 ] 26 a 0.69 [.027] 24 1.20--1.75 [ 0 4 7 - - 0 6 9 ] a 0.69 [.027] 1.07 [ 0 4 2 ] 2.03 [ 0 8 0 ] 22 [ . 0 4 7 -- . 0 6 9 ] b 0.78 [.031] [ . 0 4 2 ] [ . 0 8 0 ] 22 a 0.79 [.031] 20 1.50--2.79 [ 0 5 9 -- 1 1 0 ] a 0.79 [.031] 1.58 2.79 18 [ . 0 5 9 -- . 1 1 0 ] b 1.04 [.041] 1 . 5 8 [.062] 2 . 7 9 [.110] 22 (2 wires) 1.70 [.067] max (2 wires) b 1.04 [.041] 20 2.00--3.20 a 1.07 [.042] 18 2 . 0 0 - - 3 . 2 0 [.079--.126] a 1.07 [.042] 1 7 8 3 5 6 20 (2 wires) 1.91 [.075] max (2 wires) b 1.27 [.050] 1.78 [ .070] 3.56 [ .140] 16 2.48--3.20 [.098--.126] b 1.27 [.050] [ . 0 7 0 ] [ . 1 4 0 ] figure 2 (end)
114--16017 rev l 5 of 12 g. wire barrel seam the wire barrel seam shall be closed adequately to confine all strands of the wire. there shall be no loose strands. wire strands should not be embedded in the outside of the wire barrel. h. straightness the contact, including the cutoff tab, shall not be bent above or below the datum line more than the amount shown in figure 3. i. twist and roll there shall be no twist or roll in crimped portion that will impair usage of the contact. see figure 3. figure 3 datum line 4 _ max 4 _ max 10 _ max twist and roll straightness datum line 4 _ max datum line note: not to scale 10 _ max up--and--down s i d e -- t o -- s i d e 3.3. assembly a crimped contact (pin or socket) must be inserted into the housing by aligning it with the desired contact cavity in the back (wire side) of the housing. the wire must be grasped directly behind the insulation barrel and the contact pushed straight into the contact cavity until the contact bottoms (there will be an audible click). excessive force must not be used when inserting the contac t into the contact cavity. the contact stop of the contact is designed to ensure proper insertion depth of the contact. ov er--insertion will cause damage to the contact or contact cavity of the housing and prevent the contact from floatin g in the contact cavity, which is necessary for optimum performance of the connector. the wire must be pulled back lightly to ensure that the contact is locked in place. 3.4. panel mounting (cap housing) a. thickness the panel thickness range shall be 0.79 through 2.01 [.031 through .079]. b. cutout the dimensions of the panel cutout for panel mounting is provided in figure 4. caution !
114--16017 rev l 6 of 12 cap housing panel cutout b a d c 3.4 [.132] 1.6 [.063] 5.4 [.211] c a phousing panel dimension c a p h o u s i n g number of circuits a b c d 0 2 10.69 [.421] 0 6.15 [.242] 2.49 [.098] 10.34 [.407] 0 3 10.69 [.421] 0 6.15 [.242] 4.60 [.181] 14.55 [.573] 0 4 14.91 [.587] 10.34 [.407] 2.49 [.098] 10.34 [.407] 0 6 19.10 [.752] 14.55 [.573] 2.49 [.098] 10.34 [.407] 0 9 19.10 [.752] 14.55 [.573] 12 23.29 [.917] 18.74 [.738] 4.60 [.181] 14.55 [.573] 15 27.43 [1.080] 0 22.96 [.904] [ ] [ ] figure 4 3.5. pc board (vertical and right--angle pin headers) a. thickness the pc board thickness shall be 1.57 [.062]. pc board thickness of 2.36 [.093] can also be used, but the plastic boardlock will function only as a press fit. b. layout the pc board holes must be precisely located to ensure proper placement and optimum performance. recommended pc board layouts are shown in figure 5. figure 5 (cont?d) recommended pc board layout 2-- and 3--circuit, inline 4--, 6--, 8--,10--, and 12--circuit, dual row 4.44 [.175] 3.18 [.125] dia 4.14 [.163] typ 1.40 | 0.08 dia [.055 | .003] dia typ 1.40 | 0.08 dia [.055 | .003] dia typ 4.44 [.175] 4.14 [.163] typ 4.14 [.163] typ 3.18 [.125] dia vertical pin header
114--16017 rev l 7 of 12 figure 5 (cont?d) 2--circuit 3--circuit right- angle pin header 2.070 [.081] 0 7.34 [.289] 7.34 [.289] 5.33 [.210] ? 1.40 | 0.08 [.055 | .003] ? 0.13 [.005] m ? 3.86 | 0.05 [.152 | .002] 0 4.14 [.163] 4.14 [.163] ? 1.40 | 0.08 [.055 | .003] ? 0.13 [.005] m ? 3.86 | 0.05 [.152 | .002] 5.33 [.210] 2.070 [.081] 3plc 2plc vertical pin header 9--, 12--, and 15--circuit, matrix 14--, 16--, 18--, 20--, 22--, and 24--circuit, dual row 4.44 [.175] 3.18 [.125] dia 4.14 [.163] typ 4.14 [.163] typ 3.18 [.125] dia typ 1.40 | 0.08 dia [.055 | .003] dia typ 4.44 [.175] 1.40 | 0.08 dia [.055 | .003] dia typ 4.14 [.163] typ 4.14 [.163] typ 4.14 [.163] typ 4--, 8--, and 12--circuit 6-- and 10--circuit 2.070 [.081] ? 1.40 | 0.08 [.055 | .003] ? 0.13 [.005] m ? 3.86 | 0.05 [.152 | .002] 5.33 [.210] 0 4.14 [.163] 8.28 [.326] 8.28 [.326] 4.14 [.163] ? 3.86 | 0.05 [.152 | .002] 5.33 [.210] 7.34 [.289] 4.14 [.163] 0 2.070 [.081] 6.210 [.244] 6.210 [.244] 10.351 [.408] ? 1.40 | 0.08 [.055 | .003] ? 0.13 [.005] m 10 plc 12 plc 4.14 [.163] 7.34 [.289] 10.351 [.408]
114--16017 rev l 8 of 12 14-- and 18--circuit 7.34 [.289] 4.14 [.163] ? 3.86 | 0.05 [.152 | .002] 2 plc ? 1.40 | 0.08 [.055 | .003] ? 0.13 [.005] m 5.33 [.210] 18 plc 0 8.280 | 0.064 [.326 | .003] 2 plc 4.14 [.163] 8.28 [.326] 12.42 [.489] 16.56 [.652] 4.14 [.163] 8.28 [.326] 12.42 [.489] 12.42 [.489] 16.56 [.652] 4.14 [.163] 5.33 [.210] ? 1.40 | 0.08 [.055 | .003] ? 0.13 [.005] m 22 plc 22--circuit ? 3.86 | 0.05 [.152 | .002] 7.34 [.289] 12.418 | 0.064 [.489 | .003] 2 plc 0 4.14 [.163] 8.28 [.326] 16.56 [.652] 12.42 [.489] 20.70 [.815] 4.14 [.163] 8.28 [.326] 12.42 [.489] 16.56 [.652] 20.70 [.815] figure 5 (end) 16--, 20--, and 24--circuit 7.34 [.289] 10.351 | .064 [.408 | .003] 2 plc ? 3.86 | 0.05 [.152 | .002] 0 2.070 [.081] 22.771 [.896] 18.631 [.734] 14.491 [.570] 10.351 [.408] 6.210 [.244] 2.070 [.081] 22.771 [.896] 18.631 [.734] 14.491 [.570] 10.351 [.408] 6.210 [.244] ? 1.40 | 0.08 [.055 | .003] ? 0.13 [.005] m 24 plc 4.14 [.163] 5.33 [.210]
114--16017 rev l 9 of 12 3.6. soldering a. flux selection the solder tines must be fluxed prior to soldering with a mildly active, rosin base flux. selection of the flux will depend on the type of pc board and other components mounted on the board. additionally, the flux must be compatible with the wave solder line, manufacturing, health, and safety requirements. call the product information at the number at the bottom of page 1 for consideration of other types of flux. fluxes that are compatible with these connectors are provided in figure 6. f l u x t y p e a c t i v i t y r e s i d u e commercial designation flu x t y pe a ctivit y residue kester alpha rma mild non--corrosive 186 611 figure 6 b. cleaning after soldering, removal of fluxes, residues, and activators is necessary. consult with the supplier of the solder and flux for recommended cleaning solvents. a list of common cleaning solvents and specified time and temperature that will not affect the c onnectors is given in figure 7. consideration must be given to toxicity and other safety requirements recommended by the solvent manufacturer. refer to the manufacturer?s material safety data sheet (msds) for characteristics and handling of cleaners. trichloroethylene and methylene chloride can be used with no harmful affect to the connectors; however tyco electronics does not recommend them because of the harmful occupational and environmental effects. both are carcinogenic (cancer--causing) and trichloroet hylene is harmful to the earth?s ozone layer. for solvents not listed, contact the product information at the number at the bottom of page 1. cleaner time temper a ture name type t i m e (minutes) t e m p e r a t u r e (maximum) alpha 2110 aqueous 1 132 _ c [270 _ f] bioact ec-- 7 solvent 5 100 _ c [212 _ f] butyl carbitol solvent solvent 1 ambient room isopropyl alcohol solvent 5 kester 5778 aqueous 5 kester 5779 aqueous 5 1 0 0 _ c [ 2 1 2 _ f ] loncoterge 520 aqueous 5 100 _ c [ 212 _ f] loncoterge 530 aqueous 5 terpene solvent solvent 5 figure 7 c. drying when drying cleaned assemblies and pc boards, make certain that temperature limitations of --55 to 105 _ c [ --67 to 222 _ f] are not exceeded. excessive temperatures may cause connector degradation and/or plating deterioration. d. process the connectors and pc boards can be soldered using wave soldering techniques. the temperatures and exposure time shall be within the ranges specified in figure 8. alpha, bioact, carbitol, kester, and loncoterge are tr ademarks of their respective owners. danger note i
114--16017 rev l 10 of 12 s o l d e r i n g p r o c e s s maximum wave temperature time soldering process celsius fahrenheit t i m e (at max temperature) wave soldering 260 500 5 seconds figure 8 3.7. mating and unmating a. polarization the connectors (excluding hermaphroditic) are fully polarized (ribs and slots) to provide proper mating using a positive locking mechanism to prevent accidental disengagement of mated connectors. b. keying keying plugs provide additional polarization for mating connectors. the keying plug may be inserted into the front of the plug housing or cap housing. c. engagement the mating connectors must have an identical number of circuit positions. polarizing features must be properly oriented. the connectors must be inserted straight toward each other until they bottom and the positive locking latch and locking tab engage. d. disengagement for panel--mounted and free--hanging connectors, the lock on the plug housing must be pinched and the plug housing must be pulled straight out. 3.8. strain relief and wire dress if required, wires can be bundled together and supported with cable ties. wires must not be stretched or confined in any way that would restrict the floating action of the contacts. therefore, the wires must remain perpendicular to the connector and avoid an excessively sharp bend radius. the minimum distance for the cable tie, measured from the wire end of the connector to the cable tie, must be 76.2 [3.00]. 3.9. replacement and repair damaged, worn, or improperly crimped contacts and damaged connectors must not be used. such components should be removed, discarded, and replaced with new components. 4. qualification mini--universal mate--n--lok connectors are recognized by underwriters laboratories inc. (ul) under file e28476 and certified by csa international under file lr 7189. 5. tooling tooling for crimping, inserting, and extracting contacts is given in figure 9. 5.1. crimping contacts strip--form contacts are designed to be crimped with a miniature applicator installed in a semi--automatic or automatic machine. loose--piece contacts are designed to be crimped with a hand crimping tool. amp--o--lectric model ?k? terminating machine 565435--5 can be used for terminating the contacts; however, it is no longer being manufactured new. it has been superseded by amp--o--lectric model ?g? terminating machine 354500--1. 5.2. contact insertion and extraction an insertion tool is not usually required for inserting contacts into housings. however, an insertion tool is available for inserting contacts crimped to small wire or when the wire bundle is too large for hand insertion. an extraction tool is available for removing both pin and socket contacts from the housings. note i
114--16017 rev l 11 of 12 extraction tool 189727--1 (408--4118) insertion tool 91002--1 (408--7347) hand crimping tool (typ) (refer to table) amp--o--lectric model ?k? terminating machine 565435--5 (409--5128) heavy duty miniature quick change applicator (refer to table) (408--8040) amp--o--lectric model ?g? terminating machine 354500--[ ] (409--5842) ampomator cls lead--making machines 122500--[ ] (409--5852) or 356500--[ ] (409--5878) wire a p p l i c a t o r p o w e r u n i t h a nd crimping tool size (awg) insulation diameter a pplic a tor power unit h a n d c r i m p i n g t o o l (instruction sheet) 30 0.88--1.52 [.035--.060] 567418--1 122500--2, --3 or 356500--1, --2 90870--1 ( 408--9965 ) o r 28, 26 0.88--1.52 [.035--.060] 567418--2 354500--1 or 565435--5 9 0 8 7 0 - - 1 ( 4 0 8 - - 9 9 6 5 ) o r 90717--2 (408--4443) or 26 1.20--1.75 [.047--.069] 567066--3 122500--2, --3 or 356500--1, --2 9 1 5 2 9 1 ( 4 0 8 8 5 4 7 ) 24, 22 1.20--1.75 [.047--.069] 567066--4 354500--1 or 565435--5 91529--1 ( 408--8547) 22, 20 1.50--2.79 [.059--.110] 567067--1 122500--2, --3 or 356500--1, --2 18 1.50--2.79 [.059--.110] 5 6 7 0 6 7 2 3 5 4 5 0 0 1 o r 5 6 5 4 3 5 5 91522--1 (408--8547) 22 (2 wires) 1.70 [.067] max (2 wires) 567067--2 354500--1 o r 565435--5 ( ) 20, 18 2.00--3.20 [.079--.126] 567251--2 354500--1 or 565435--5 16 2.00--3.20 [.079--.126] 5 6 7 2 5 1 3 3 5 4 5 0 0 [ ] 91536--1 (408--8547) 20 (2 wires) 1.91 [.075] max (2 wires) 567251--3 354500-- [ ] ( ) figure 9
114--16017 rev l 12 of 12 6. visual aid the illustration below shows a typical application of mini--universal mate--n--lok connectors. this illustration should be used by production personnel to ensure a correctly applied product. applications which do not appear correct should be inspected using the information in the preceding pages of this specification and in the instructional material shipped with the product or tooling. figure 10. visual aid wire strands must be visible anywhere in this area locking lances must not be not deformed wire strands and insulation must both be visible anywhere in this area front and rear bellmouths must be visible cutoff tab must be visible standoffs must be visually seated on pc board solder fillet must be formed evenly around tines cable tie must be minimum distance of 76.2 [3.00] from wire end of housing locking latches and tabs must be securely fastened locking latches and tabs must be securely fastened free- hanging applica tion pc board applica tion crimped cont act contact stop must not be crimped or deformed

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