Application Specification 114-- 13089 Mini- Universal MATE- N- LOK* Splash- Proof Sealed Connectors NOTE 15 OCT 09 Rev B All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2_. Figures and illustrations are for identification only and are not drawn to scale. i 1. INTRODUCTION This specification covers the requirements for application of mini--universal MATE--N--LOK splash--proof sealed connectors. These connectors are designed to be used with splash--proof seals that will ensure a water and dust resistant assembly. The connectors are available in plug housings and cap housings for wire--to--wire free--hanging and panel mount applications, and vertical pin headers and right--angle pin headers for wire--to-printed circuit (pc) board applications. Each connector consists of a housing and contacts. The connectors have dual rows available in 2, 4, 6, 8, or 10 positions with a contact centerline spacing of 4.14 mm [.163 in.]. The housings accept crimp type contacts. End contact cavities of the cap housing are marked to provide circuit identification. A raised alignment rib along the side of the plug housing indicates Position 1. The cap housing features mounting ears and panel stops to aid in mounting to a panel. The contacts are available in loose--piece form for terminating with manual hand--held tools, and in strip form for terminating with semi--automatic or automatic machines. The pin headers contain through--hole solder type contacts. The pin headers feature integral boardlocks to provide stability for placement on the pc board and standoffs to facilitate pc board cleaning after the soldering operation. The pin headers are placed on the pc board by hand. When corresponding with Tyco Electronics Personnel, use the terminology provided in this specification to facilitate your inquiries for information. Basic terms and features of this product are provided in Figure 1. Plug Housing Locking Latch Alignment Rib Cap Housing Circuit Identifier Contact Cavity Housing Contact Cavity Silo Mounting Ear (2 Places) Panel Stop (4 Places) Vertical Pin Header Keying Plug Right- Angle Pin Header Chamfered Edge Housing Locking Tab Housing Boardlock Through-- Hole Contacts Wire Seal Pin Contact Socket Contact Locking Tab Cavity Plug Seal Locking Tab Housing Chamfered Edges Interface Seal Through-- Hole Contacts Standoff (4 Places) Figure 1 TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111 E2009 Tyco Electronics Corporation, Harrisburg, PA PRODUCT INFORMATION 1-- 800-- 522-- 6752 All International Rights Reserved TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. Boardlock Standoff (4 Places) This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 20 LOC B Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 1.1. Seals The seals are available to be installed onto the connectors to ensure a sealed assembly. The interface seal protects the connecting point between mating connectors, the cavity plug seal protects the opening of an unused contact cavity, and the wire seal protects the opening around the contact cavity containing a contact or keying plug. 1.2. Polarization and Keying Plugs The connectors are polarized for proper mating. The contact cavities with chamfered edges (each forming a "D" shaped opening) at the mating face of the connector provide proper connector alignment, and the location of the these cavities ensure proper connector orientation. Because mating connectors must have identical number of positions, the location of these cavities is specific to the connector positions. Keying plugs are available for further assurance of proper mating. 1.3. Mating When the connectors are properly mated, positive locking mechanisms (locking latch on plug housing and locking tab on cap housing and pin headers) prevent accidental disengagement of mated connectors. 2. REFERENCE MATERIAL 2.1. Revision Summary S Update document to corporate requirements S Added clarifying information to table in Figure 5 2.2. Customer Assistance Reference Product Part Number 794895 and Product Code 7167 are representative of mini--universal MATE--N--LOK splash--proof sealed connectors. Use of these numbers will identify 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 Tyco Electronics 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, call Product Information at the number at the bottom of page 1. 2.4. Specifications Application Specification 114--16017 provides product description and application requirements for mini--universal MATE--N--LOK connectors. Product Specification 108--1543 provides product performance and test information for the header assembly, and 108--1542--2 provides product performance and test information for the splash--proof seals (interface seal, wire seal, and cavity plug seal). Product Specification 108--1542 provides product performance and test information for the plug housing. 2.5. Instructional Material Instruction Sheets (408--series) provide assembly instructions and Customer Manuals (409--series) provide machine setup and operation procedures. Documents available which pertain to this product are: Document Number 408--4118 408--7347 408--8040 408--8547 409--5128 409--5842 409--5852 409--5878 2 of 20 Document Title Extraction Tool 189727--1 Insertion Tool 91002--1 HDM Quick--Change Applicators (Side--Feed Type) with Mechanical Feed System CERTI--CRIMP* II Straight Action Hand Tools 91522--1 and 91529--1 AMP--O--LECTRIC* Model "K" Terminator Machine 565435--5 AMP--O--LECTRIC Model "G" Terminating Machines 354500--[ ] AMPOMATOR* CLS III--G Lead--Making Machine 122500--[ ] AMPOMATOR CLS IV+ Lead--Making Machine 356500--[ ] Tyco Electronics Corporation Rev B Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 2.6. Manuals Manual 402--40 can be used as a guide to soldering. This manual provides information on various flux types and characteristics with the commercial designation and flux removal procedures. A checklist is included in the manual as a guide for information on soldering problems. 2.7. Standards and Publications Standards and publications developed by the International Electrotechnical Commission (IEC) provide industry test and performance requirements. Documents available which pertain to this product are: IEC 60529, "Degrees of Protection Provided by Enclosures (IP Code)" 3. REQUIREMENTS 3.1. Special Assembly Considerations The following information must be considered when designing the system into which these connectors are installed: -- These connectors are interchangeable with mini--universal MATE--N--LOK connectors; however, applications using any unsealed product (connector, contact, or keying plug) will not perform as a sealed assembly -- The pin headers described in this document do not have drain holes. Pin headers with drain holes MUST NOT be used in sealed applications 3.2. Safety Do not stack product shipping containers so high that the containers buckle or deform. 3.3. Storage A. Ultraviolet Light Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the connector material. B. Shelf Life The connectors should remain in the shipping containers until ready for use to prevent deformation to components. The connectors should be used on a first in, first out basis to avoid storage contamination that could adversely affect performance. The seals must be stored in sealed plastic bags to prevent seals from drying and cracking. C. Chemical Exposure Do not store connectors near any chemical listed below as they may cause stress corrosion cracking in the components. Alkalies Amines Rev B Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Tyco Electronics Corporation Sulfur Compounds Tartrates 3 of 20 Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 3.4. Component Selection A. Connectors and Seals Each connector must be used with specific seals to ensure a sealed assembly for the required application. Mating connectors must have identical number of positions. A cross--reference of connector--to--seal and connector--to--connector is listed in Figure 2. Wire- to- Wire Application Cavity Plug Seal Wire Seal Contact (Ref) Interface Seal Plug Housing Cavity Plug Seal Cap Housing Contact (Ref) Wire Seal Wire- to- Board Application Wire Seal Contact (Ref) Cavity Plug Seal Wire Seal Cavity Plug Seal Contact (Ref) Interface Seal Plug Housing Plug Housing Right-- Angle Pin Header Vertical Pin Header CONNECTOR Number of Positions CAP HOUSING PLUG HOUSING Interface Wire 2 794896--1 794894--1 0--794772--2 4 794939--1 794805--1 6 794940--1 8 10 SEAL Cavity Plug VERTICAL PIN HEADER RIGHT-- ANGLE PIN HEADER 794758--1 794995--1 770872--[ ] 770966--[ ] 0--794772--4 794758--1 794995--1 770874--[ ] 770968--[ ] 794895--1 0--794772--6 794758--1 794995--1 770875--[ ] 770969--[ ] 794941--1 794821--1 0--794772--8 794758--1 794995--1 794073--[ ] 770970--[ ] 794942--1 794781--1 1--794772--0 794758--1 794995--1 770858--[ ] 770971--[ ] Figure 2 4 of 20 Tyco Electronics Corporation Rev B Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 B. Contact and Wire The contacts accept stranded copper or tin--coated wire sizes 26 through 18 AWG with an insulation diameter range of 1.02 through 2.11 mm [.040 through .083 in.]. Selection of the contact depends upon the wire size as listed in Figure 3. CONTACT WIRE SIZE ((AWG)) PIN SOCKET Strip Loose Piece Strip Loose Piece 26--22 770901 770985 770902 770986 22--18 770903 770987 770904 770988 Figure 3 3.5. Wire Preparation A. Wire Stripping Proper strip length is necessary to properly insert the wire into the contact. Reasonable care must be taken not to nick, scrape, or cut any part of the wire during the stripping operation. The strip length of the wire is shown in Figure 4. There must be no loose wire strands and the conductors must not be cut. The wire insulation must be round and there must be no flaws, dents, or other damage. B. Wire Seal The wire seal must be installed onto the wire before or after stripping the wire. It is recommended to install the wire seal after stripping the wire; however, if installing before stripping the wire, the wire seal must be protected from being damaged during the stripping operation. The wire seal must be installed onto the wire, flanged end (end opposite the throat) first. The wire seal must be located on the wire so that the wire insulation is flush with or extends beyond the wire seal to the dimension stated in Figure 4. After installation, there must be no flaws or other damage to the wire seal, and the shape of the wire seal must be maintained. Insulation 3.20-- 3.71 [.126-- .146] Strip Length Note: Not to Scale Conductors Wire Seal Flanges Wire Insulation Flush With or Extends Beyond Wire Seal to 0.4 [.015] (Max) Wire Seal Location Wire Seal Throat Figure 4 3.6. Crimp Requirements NOTE i A single wire per contact is recommended for use with these connectors. Dual wire crimps are not compatible with the wire seals. The contact must be crimped to the wire according to instructions packaged with applicable tooling. Rev B Tyco Electronics Corporation 5 of 20 Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 A. Cutoff Tab and Burr The cutoff tab is the remaining portion of the carrier strip after the contact is cut from the strip. The following dimensional requirements will ensure proper application for these contacts. 1. The cutoff tab must not exceed the dimension shown in Figure 5. 2. There must be no burr resulting from the cutoff tab shearing. B. Flash The flash is the formation that may appear on both sides of the wire barrel as the result of crimping. Flash must not exceed the dimension shown in Figure 5. C. Wire Barrel Seam The seam between the two sides of the wire barrel must be completely closed. There must be no loose wire strands or wire strands visible in the seam. Wire strands must not be embedded in the outside of the wire barrel. D. Wire Barrel Crimp The crimp applied to the wire barrel is the most compressed area and is critical in ensuring optimum electrical and mechanical performance of the crimped contact. No strands can be folded back over the wire insulation. The wire barrel crimp height and width must be within the dimensions provided in Figure 5. E. Insulation Barrel Crimp The insulation barrel must be crimped in the "F" crimp where the tips of the insulation barrel turn inward and capture the throat of the wire seal and the wire insulation. The insulation barrel crimp width must be within the dimensions provided in Figure 5. F. Bellmouths The front bellmouth and rear bellmouth shall be evident and conform to the dimensions shown in Figure 5. G. Effective Crimp Length Effective crimp length is defined as that portion of the wire barrel, excluding bellmouths, fully formed by the tooling. For optimum crimp effectiveness, the crimp must be within the area shown in Figure 5. H. Wire Location The wire conductors must be visible within the transition area (between the wire barrel and insulation barrel). The wire insulation may be visible within the transition area. Wire strands must not extend beyond the height of the wire barrel. The conductor ends must be flush with, or extend beyond, the end of the wire barrel to the dimension shown in Figure 5. I. Locking Lances The locking lances shall not be deformed in any way. The position of each locking lance, measured from the body of the contact to the tip of the locking lance, must be within the specified limit in Figure 5. J. Wire Seal Location and Workmanship The wire seal shall not enter the wire barrel. The throat of the wire seal must protrude into the transition area (between the wire barrel and insulation barrel) to the minimum stated in Figure 5. There shall be no cuts, flaws, or other damage to the wire seal. The tips of the insulation barrel may partially pierce the throat of the wire seal; however, the throat must not be split. The insulation barrel crimp must maintain an even grip on the throat of the wire seal without tilting. The wire seal shall not slant beyond the limit provided in Figure 5. 6 of 20 Tyco Electronics Corporation Rev B Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 Note: Socket Contact Shown, Requirements Apply Equally to Pin Contact 0.13 [.005] Max Burr 0.38 [.015] Max Cutoff Tab Transition Area (Wire Conductors Must Be Visible Here, Wire Insulation May Be Visible Here) Flush With or Extend from End of Wire Barrel to 0.89 [.035] (Max) Wire Conductor Location 0.4 [.015] Min Wire Seal Protrudes into Transition Area Wire Barrel Closed with No Wire Strands Showing in Seam 0.51-- 0.71 [.020-- .028] Locking Lance Position Tips of Insulation Barrel Turn Inward 1.63-- 1.93 [.064-- .076] Effective Crimp Length 0.00-- 0.25 [.000-- .010] Front Bellmouth 0.10-- 0.51 [.004-- .020] Rear Bellmouth Wire Strands Do Not Extend Beyond Height of Wire Barrel Y X X Y Section X- X (Wire Barrel) Section Y- Y (Insulation Barrel) "F" Crimp Crimp Width (See Table) 0.25 [.010] Max Flash 8_ Max Tilt of Wire Seal Crimp Width (See Table) Crimp Height (See Table) No Flash Figure 5 (cont'd) Rev B Tyco Electronics Corporation 7 of 20 Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors WIRE INSULATION DIAMETER SIZE (AWG) 24 22 22 20 STRIP FORM CONTACT (Using Automatic Machine) WIRE BARREL CRIMP INSULATION BARREL WIDTH (Ref) HEIGHT WIDTH 1.02--1.52 1.02 1.52 [.040 [.040--.060] .060] 0.63+0.05 [.025+.002] 0.63+0.03/--0.05 [.025+.001/--.002]G 1.27--2.11 1.27 2.11 [.050--.083] [.050 .083] 0.91+0.05 [.036+.002] 26 18 114- 13089 0.69+0.05 [.027+.002] 0.78+0.05 [.031+.002] 0.81+0.05 [.032+.002] 1.22 [.048] 2.03 [.080] 1.57 [.062] 2.79 [.110]z 1.07+0.05 [.042+.002] GFor 7--strand, tin--coated wire with insulation diameter of 0.15 mm [.006 in.]. z2.54 mm [.100 in.] max when using wire seal. WIRE LOOSE-- PIECE CONTACT (Using Hand Tool) WIRE BARREL CRIMP INSULATION INSULATION BARREL SIZE (AWG) DIAMETER WIDTH (Ref) HEIGHT WIDTH 26 24 22 22 20 0.69+0.05 [.027+.002] 1.02--1.52 0 5 [.040--.060] [ 0 0 060] 1.27--2.11 [.050--.083] [ 050 083] 18 0.69+0.05 [.027+.002] 0.78+0.05 [.031+.002] 0.79+0.05 [.031+.002] 0.79+0.05 [.031+.002] 2.03 03 [.080] [ 080] 1.57 5 [.062] [ 06 ] 2.79 [.110]z 1.04+0.05 [.041+.002] z2.54 mm [.100 in.] max when using wire seal. NOTE 1.07 0 [.042] [0 ] Figure 5 (end) The developed crimp configurations result from using the specific tooling described in Section 5, TOOLING. i K. Twist and Roll There should be no twist or roll of the crimped portions or mating portion of the contact that would cause overstress or impair usage. Twist and roll is allowed within the limits specified in Figure 6. Allowable Twist and Roll Crimped Portion 10_ Max Datum Line 10_ Max Figure 6 L. Bend Allowance The force applied during crimping may cause some bending between the crimped portion and wire. Such deformation is acceptable within the following limits. 1. Up and Down The crimped portion, including the cutoff tab, must not be bent beyond the limits shown in Figure 7. 2. Side--to--Side The crimped portion must not be bent from one side to the other beyond the limits shown in Figure 7. 8 of 20 Tyco Electronics Corporation Rev B Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 Note: Socket Contact Shown, Requirements Apply Equally to Pin Contact Up and Down Alignment 4_ Max Datum Line Side- to- Side Alignment 4_ Max 4_ Max Datum Line 4_ Max Figure 7 3.7. Interface Seal The interface seal must be installed onto the plug housing. The installed interface seal must fit inside the channel at the base of the silos of the plug housing. The interface seal must remain flat against the back of the channel and shall not be twisted. There shall be no tears, rips, or other damage to the interface seal. Refer to Figure 8. NOTE i A method to prevent damage to the interface seal is to use the mating cap housing (without contacts) or pin header (not installed onto pc board) to slide the interface seal along the silos and against the back of the channel. 3.8. Installing Contacts into Housing The contacts must be installed into the plug housing and cap housing. Each contact must be inserted into a contact cavity at the wire end of the housing until it bottoms (there should be an audible "click"). For optimum sealing performance, the wire seal on the contact must have at least two of the three flanges fully inserted into the contact cavity. Each contact must be locked into place. Refer to Figure 8. NOTE Because of the wire seal, these contacts require more insertion force than unsealed contacts (without a wire seal). i 3.9. Cavity Plug Seal The cavity plug seal must be installed into any unused contact cavities of the plug housing and cap housing. The cavity plug seal must be inserted (short tab end first) into the contact cavity at the wire end of the housing. For optimum sealing performance, the cavity plug seal must have at least two of the three flanges fully inserted into the contact cavity. See Figure 8. A cavity plug seal must also be installed in any mating contact cavity containing a keying plug. See Figure 8. NOTE i The cavity plug seals can be installed manually or by using Insertion Tool 91002--1. Instruction for using the tool is provided on Instruction Sheet 408--7347. 3.10. Keying Plug The keying plug must be installed into an empty contact cavity in the plug housing or cap housing. The keying plug must be inserted (tapered end first) into the contact cavity at the mating face of the housing until it bottoms (there should be an audible "click"). Rev B Tyco Electronics Corporation 9 of 20 Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 The contact cavity containing the keying plug must be sealed using a wire seal. The wire seal must be installed into the contact cavity at the wire end of the housing after the keying plug is installed. The wire seal must be inserted flanged end (end opposite the throat) first, over the keying plug and into the contact cavity. For optimum sealing performance, the wire seal must have at least two of the three flanges fully inserted into the contact cavity. See Figure 8. NOTE i The wire seal can be installed over the keying plug and into the contact cavity manually or by using Insertion Tool 91002--1. Instruction for using the tool is provided on Instruction Sheet 408--7347. If a keying plug is installed into a housing, the corresponding contact cavity of the mating connector must contain a cavity plug seal. Note: Cap Housing Shown, Requirements Equally Apply to Pin Header Wire End of Plug Housing Keying Plug Mating Face of Cap Housing Cavity Plug Seal Wire Seal (For Keying Plug) Mating Face of Plug Housing Wire End of Cap Housing Interface Seal Contact with Wire Seal Cavity Plug Seal Installed into Contact Cavity Plug Housing Silo (6 Places Shown, Ref) Cavity Plug Seal Installed into Contact Cavity Cap Housing Cavity Plug Seal Installed into Contact Cavity Interface Seal Installed onto Plug Housing Keying Plug with Wire Seal Installed into Contact Cavity Contact with Wire Seal Installed into Contact Cavity Figure 8 10 of 20 Tyco Electronics Corporation Rev B Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 3.11. PC Board A. Material and Thickness The pc board material shall be glass epoxy (FR--4 or G--10). The pc board thickness range shall be 1.57 to 2.36 mm [.062 to .093 in.]. B. Pads The pc board circuit pads must be solderable in accordance with Test Specification 109--11. C. Hole Dimensions The contact holes must be drilled and plated through to specific dimensions to prevent stubbing during placement of the pin headers on the pc board. The drilled hole size, plating types, and plating thickness are dependent on the application requirements. The boardlock hole may be used with or without plated holes. The finished hole size must be as stated to provide unrestricted insertion. See Figure 9. Contact Hole Boardlock Hole Trace Width (As Required) Drilled Hole Diameter (Ref) 1.40+0.08 [.055+.003] Finished Hole Diameter After Plating "A" (Refer to Table) Drilled Hole Diameter .051+.025 [.002+.001] Copper Plating (Max Hardness 150 Knoop) 0.008 [.0003] (Min) Tin-- Lead Plating DIMENSION A Vertical Pin Header Right-- Angle Pin Header 3.18+0.05 [.125+.002] 3.86+0.05 [.152+.002] Figure 9 Rev B Tyco Electronics Corporation 11 of 20 Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 D. Layout The holes in the pc board must be precisely located to ensure proper placement and optimum performance of the pin header. The pc board layout must be designed using the dimensions provided on the customer drawing for the specific pin header. Reference samples of the recommended pc board layouts are shown in Figure 10. Sample Recommended PC Board Layout 6--Position Vertical Pin Header 1.40+0.08 [.055+.003] Typ 4.45 [.175] 3.18 [.125] 4.14 [.163] 4.14 [.163] Typ Recommended Mounting Hole Pattern for 1.57-- Thick PC Board Tolerances Non-- Accumulative 6--Position Right--Angle Pin Header 4.14 [.163] 4.14 [.163] 1.40+0.08 [.055+.003] 0.13 [.005] M 4.14 [.163] 6 Plc 3 7.34 [.289] 5.33 [.210] 4 3.86+0.05 [.152+.002] Recommended Mounting Hole Pattern for 1.57-- Thick PC Board 3 Coordinate Dimension Applies from Center of Actual Feature 4 Recommended for Edge Mounting Figure 10 E. Pin Header Spacing Care must be used to avoid interference between adjacent pin headers and other components. The minimum allowable distance between pin headers to ensure proper mating is provided in Figure 11. 12 of 20 Tyco Electronics Corporation Rev B Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 Right--Angle Pin Header Vertical Pin Header 3.30 [.130] Min Allowable Distance Contact Cavities (Ref) 3.30 [.130] Min Allowable Distance Contact Cavities (Ref) Figure 11 3.12. Pin Header Placement CAUTION ! Pin headers should be handled only by the housing to avoid deformation, contamination, or damage to the contact solder tails. The pin header number one position must be aligned with the number one position pc board hole. When placing pin headers on the pc board, the contact solder tails and boardlock must be aligned and started into their matching holes before seating the pin header onto the pc board. After seating, the shoulder of the boardlock must be through the pc board, and the standoffs must be seated on the pc board. See Figure 12. Right--Angle Pin Header Vertical Pin Header Standoffs Seated on PC Board Standoffs Seated on PC Board Shoulder of Boardlock Through PC Board Shoulder of Boardlock Through PC Board Figure 12 3.13. Soldering Observe guidelines and procedures when soldering header assembly contacts. All solder joints should conform to those specified in Workmanship Specification 101--21 and all other requirements specified in this document. Solder, clean, and dry all wire leads to contacts according to the following: A. Flux Selection Contacts 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 PRODUCT INFO at the number at the bottom of page 1 for consideration of other types of flux. Flux that is compatible with these connectors is provided in Figure 13. FLUX TYPE ACTIVITY RESIDUE RMA Mild Noncorrosive COMMERCIAL DESIGNATION KESTER ALPHA 186 611 Figure 13 Rev B Tyco Electronics Corporation 13 of 20 Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 B. Process The connectors can be soldered using wave soldering or equivalent soldering techniques. The temperatures and exposure time shall be as specified in Figure 14. SOLDERING PROCESS WAVE TEMPERATURE TIME (At Max Temperature) Wave 260_C [500_F] 5 Seconds Figure 14 C. Cleaning After soldering, removal of fluxes, residues, and activators is necessary. Consult with the supplier of the solder and flux for recommended cleaning solvents. The following is a list of common cleaning solvents that will not affect the connectors for the time and temperature specified. See Figure 15. CLEANER NAME TYPE TIME (Minutes) TEMPERATURE (Maximum) CELSIUS FAHRENHEIT ALPHA 2110 Aqueous 1 132 270 BIOACT EC--7 Solvent 5 100 212 Butyl CARBITOL Solvent 1 Isopropyl Alcohol Solvent 5 100 212 KESTER 5778 Aqueous 5 100 212 KESTER 5779 Aqueous 5 100 212 LONCOTERGE 520 Aqueous 5 100 212 LONCOTERGE 530 Aqueous 5 100 212 Terpene Solvent Solvent 5 100 212 Ambient Room Figure 15 DANGER 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 is not recommended because of harmful occupational and environmental effects. Both are carcinogenic (cancer--causing). NOTE If you have a particular solvent that is not listed, contact Product Information at the number at the bottom of page 1. i D. Drying When drying cleaned assemblies and pc boards, make certain that temperature limitations are not exceeded: --55_ to 105_C [--68_ to 221_F]. Excessive temperatures may cause degradation or deterioration. 3.14. Checking Installed Pin Header All solder joints should conform to those specified in Workmanship Specification 101--21 and all other requirements specified in this document. The installed pin header must have solder fillets evenly formed around each contact with no skips or voids. There should be no solder on the boardlocks. Refer to Figure 16. 14 of 20 Tyco Electronics Corporation Rev B Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors Right--Angle Pin Header 114- 13089 Vertical Pin Header Solder Fillet Evenly Formed Around Each Contact with No Skips or Voids (No Solder on Boardlocks) Figure 16 3.15. Panel Cutout The cap housings are designed to be panel mounted. The panel thickness range must be 0.8 through 2.0 mm [.031 through .079 in.]. The panel cutout must conform to the dimensions provided in Figure 17. Panel Cutout A (See Table) B (See Table) 3.35 [.132] 2.49 [.098] 5.36 [.211] 10.34 [.407] 1.60 [.063] B (See Table) PANEL DIMENSION CAP HOUSING No. of Positions A B 2 10.69 [.421] 6.15 [.242] 4 14.91 [.587] 10.34 [.407] 6 19.10 [.752] 14.55 [.573] 8 23.29 [.917] 18.72 [.737] 10 27.50 [1.083] 22.96 [.904] Figure 17 3.16. Mounting Cap Housing in Panel The cap housing must be inserted (mating face first) through the panel cutout in the same direction as the punch. The panel stops must be flush with the panel, and the mounting ears must be against the panel. The serrations on the mounting ears are designed to ensure a tight fit between the connector and panel by accommodating any of the panel thicknesses within range. See Figure 18. Before removing the cap housing from the panel, the mounting ears must be deflected until clear of the panel. The cap housing can be removed from either the front or back of the panel. Rev B Tyco Electronics Corporation 15 of 20 Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 Side View Panel Stop (4 Places) Flush with Panel Mounting Ear (See Also Top View) Mating Face of Cap Housing Wires Install Punch Side of Panel (Ref) Top View Mounting Ear Against Panel Cutout Deflect to Remove Wires Deflect to Remove Mounting Ear Against Panel Cutout Figure 18 3.17. Mating and Unmating Mating connectors must have identical number of positions. When mating, the housing must be pushed straight into the housing or header. The locking latch of the plug housing must engage and be fully seated on the locking tab of the cap housing or pin header after mating. The interface seal must be flat and compressed against the back of the channel at the base of the silos of the plug housing. Refer to Figure 19. The locking latch of the plug housing must be depressed to release the locking tab of the cap housing or pin header. The plug housing must be pulled straight out of the mating connector. After unmating the connectors, the interface seal must be inspected for damage or twisting. If damaged or twisted, the interface seal must be replaced before re--mating the connectors. Note: Cap Housing Shown, Requirements Equally Apply to Pin Header Locking Latch Cap Housing Plug Housing Locking Tab Figure 19 16 of 20 Tyco Electronics Corporation Rev B Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 3.18. Strain Relief and Wire Dress If necessary, wires can be bundled together and supported with cable ties or similar device. Wires must not be stretched or confined in any way. 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 housing at the wire end of the connector to the cable tie is shown in Figure 20. 76.2 [3.0] Min Distance Housing Cable Tie (Ref) Figure 20 3.19. Repair and Removal Connectors, contacts, interface seals, wire seals, and cavity plug seals are not repairable. Any damaged or defective components MUST NOT be used. Terminated contacts or wire seals MUST NOT be re--used by removing the wire. Standard de--soldering methods must be used to remove pin headers from the pc board. Removed pin headers MUST NOT be re--used. Keying plugs must be removed from the mating face of the connector using pliers. 4. QUALIFICATION No qualifying support for mini--universal MATE--N--LOK splash--proof sealed connectors was defined at the time of publication of this document. 5. TOOLING Tooling part numbers and instructional material packaged with the tooling are shown in Figure 21. 5.1. Hand Tools Hand tools for manual application of loose--piece contacts are available to cover the full wire size range. CAUTION ! Only CERTI--CRIMP II hand tools (or similar type of tools) can be used to crimp these contacts with wire seals. The wire seals are not compatible with other types of hand tools. 5.2. Extraction Tool The extraction tool is used to remove the contacts from the plug housing or the cap housing by releasing the contact locking lance from the housing without overstressing the contact. 5.3. Insertion Tool The insertion tool is available for inserting contacts crimped onto small wire sizes or when the wire bundle is too large for hand insertion. 5.4. Applicators Applicators are used to crimp strip form contacts onto pre--stripped wire, and provide for high volume, heavy duty production requirements. The applicator must be installed onto a power unit. Rev B Tyco Electronics Corporation 17 of 20 Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 5.5. Power Units Automatic and semi--automatic machines for power assisted application of strip form contacts are available to cover the full wire size range. These power units provide the force required to drive the applicator for crimping the contacts. Automatic power units are single--wire lead--making machines that do all the work necessary to automatically turn the reels of wire and contacts into finished leads while maintaining high production rates. The machines are designed to be floor--standing. The semi--automatic power unit terminates pre--stripped wires onto the contacts. It is designed to be bench mounted and provides for medium--volume applications. CERTI-- CRIMP II Straight Action Hand Tools 91522-- 1 and 91529-- 1 (408-- 8547) Extraction Tool 189727-- 1 (408-- 4118) Insertion Tool 91002-- 1 (408-- 7347) AMP-- O-- LECTRIC Model "K" Terminator Machine 565435-- 5 (409-- 5128) AMP-- O-- LECTRIC Model "G" Terminating Machine 354500-- 1 (409-- 5842) No Longer Manufactured New AMPOMATOR CLS IV+ Lead-- Making Machine 356500-- [ ] (409-- 5878) AMPOMATOR CLS III-- G Lead-- Making Machine 122500-- 2, or - 3 (409-- 5852) Heavy Duty Miniature Quick-- Change Applicators, Side-- Feed Type with Mechanical Feed System (408-- 8040, Refer to Table for Part Numbers) WIRE SIZE (AWG) INSULATION DIAMETER 26 APPLICATOR POWER UNIT 567066--3 AMPOMATOR CLS IV+ or CLS III--G 24 22 22 1.02--1.52 0 5 [.040--.060] [ 0 0 060] 567066--4 567066--4 567067--1 20 18 1.27--2.11 [.050--.083] [ 050 083] 567067--1 567067--2 AMP O LECTRIC Model "G" or Model "K" AMP--O--LECTRIC AMPOMATOR CLS IV+ or CLS III--G III G HAND TOOL 991529--1 5 9 991522--1 5 AMP--O--LECTRIC Model "G" or Model "K" Figure 21 18 of 20 Tyco Electronics Corporation Rev B Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 6. VISUAL AID Figure 22 shows a typical application of mini--universal MATE--N--LOK splash--proof sealed 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. Note: Socket Contact Shown, Requirements Apply Equally to Pin Contact WIRE BARREL MUST BE CLOSED WITH NO WIRE STRANDS SHOWING IN SEAM INSULATION BARREL MUST BE FOLDED INWARD AND GRIP, BUT NOT CUT INTO, WIRE INSULATION AND WIRE SEAL WIRE STRANDS MUST NOT EXTEND BEYOND HEIGHT OF WIRE BARREL WIRE SEAL MUST NOT SLANT OR BE DAMAGED IN ANY WAY WIRE CONDUCTORS AND WIRE SEAL MUST BE VISIBLE BETWEEN WIRE BARREL AND INSULATION BARREL WIRE CONDUCTORS MUST BE FLUSH WITH, OR EXTEND SLIGHTLY BEYOND, WIRE BARREL WIRE SEAL AND WIRE INSULATION MUST NOT ENTER WIRE BARREL LOCKING LANCES MUST NOT BE DEFORMED WIRE SEAL MUST PROTRUDE SLIGHTLY FROM INSULATION BARREL CONTACT MUST NOT BE DAMAGED IN ANY WAY WIRE- TO- WIRE FREE- HANGING APPLICATION PLUG HOUSING LOCKING LATCH BE ENGAGED WITH AND FULLY SEATED ON CAP HOUSING LOCKING TAB WIRES MUST REMAIN PERPENDICULAR TO CONNECTOR WITH NO EXCESSIVELY SHARP BEND RADIUS KEYING PLUG (IF USED) MUST BE FULLY INSERTED INTO EMPTY CONTACT CAVITY AND SEALED WITH A WIRE SEALH CORRESPONDING CONTACT CAVITY WITH KEYING PLUG MUST CONTAIN CAVITY PLUG SEAL UNUSED CONTACT CAVITIES MUST CONTAIN CAVITY PLUG SEAL HOUSINGS MUST NOT BE DAMAGED IN ANY WAY INTERFACE SEAL MUST BE FLAT AGAINST PLUG HOUSING HAT LEAST TWO FLANGES OF WIRE SEAL MUST BE FULLY INSERTED INTO CONTACT CAVITY CONTACTS MUST BE LOCKED INTO CONNECTORH FIGURE 22. Rev B VISUAL AID (Cont'd) Tyco Electronics Corporation 19 of 20 Mini- Universal MATE- N- LOK Splash- Proof Sealed Connectors 114- 13089 WIRE- TO- WIRE PANEL MOUNT APPLICATION CAP HOUSING PANEL STOPS MUST BE FLUSH WITH PANEL SAME REQUIREMENTS OF FREE- HANGING APPLICATION APPLY HERE MOUNTING EARS MUST BE AGAINST PANEL WIRE- TO- BOARD APPLICATION Note: Vertical Pin Header Shown, Requirements Apply Equally to Right-- Angle Pin Header SAME REQUIREMENTS OF FREE- HANGING APPLICATION APPLY HERE SHOULDER OF BOARDLOCK MUST BE THROUGH PC BOARD AND THERE MUST BE NO SOLDER ON BOARDLOCK PLUG HOUSING LOCKING LATCH BE ENGAGED WITH AND FULLY SEATED ON PIN HEADER LOCKING TAB STANDOFFS MUST BE VISUALLY SEATED ON PC BOARD SOLDER FILLETS MUST BE EVENLY FORMED AROUND EACH CONTACT FIGURE 22. 20 of 20 VISUAL AID (End) Tyco Electronics Corporation Rev B