Mechanical Assembly Drawing

FIG.1
FIG.3
FIG.2
POS1
POS2
POS3
Red wire
FIG.4
POS4
TRACOPOWER Order Code: TSP-JC
Remote link cable for current sharing: 2 cables 0.5 m included with REM module
Remote link cable for battery control: 1 cable 0.5 m included with BCM module
Remot control input cable: not included
DC3
Assembly Instructions:
1.Remove 20mm of the outer insulation from one end of cable POS3.
2.Remove 4mm insulation from each of the two wires as shown in Fig.1.
3.Now insert the ends of the wires into the crimps POS2 (including approximately
2mm of the insulation) and crimp securely using ONLY the correct crimping tool.
5.Insert the crimps into the connector housing POS1 as shown in Fig.3.
6. Repeat steps 1 to 5 for the other end of the cable POS3.
7. Now carefully roll the cable assembly into a loop and place inside plastic bag POS4.
QC instructions.
Only use the crimping tool designed for the crimps POS2.
Make sure that the insulation on each wire is firmly held by the crimp.
Use the red wire as a reference to check polarity.
30.08.04
30.08.04
0
30.08.04 J.Kelly
J.Kelly
K.Burke
Mechanical Assembly
Drawing
MAD-CA-240BCM144.01
1
1
FEATURES AND SPECIFICATIONS
Features and Benefits
■ Sizes 1 to 25 circuits
■ 6471 is end-to-end stackable (2 housings only)
■ 2695 version with or without locking ramp and
PCB and Wire Connectors
polarizing ribs
Reference Information
Product Specification: PS-10-07
Packaging: Bag
UL File No.: E29179
CSA File No.: LR19980
Mates With: Molex KK 2.54mm (.100") pitch headers and
0.04mm (.025") pins
Use With: 2695—2759, 6459 or 41572 terminals
6471—4809 terminals
Designed In: Inches
Electrical*
Voltage: 250V
Current: Phosphor Bronze—4.0A max.
Brass—2.5A max.
Contact Resistance: 20mΩ max.
Dielectric Withstanding Voltage: 1500V AC
Insulation Resistance: 50K MΩ min.
2.54mm (.100") Pitch
KK®
Crimp Terminal Housing
2695/6471
Mechanical*
Contact Insertion Force: 681g (1.5 lb) max.
Contact Retention to Housing: 3.63kg (8 lb) min.
Mating Force: 199g max.
Unmating Force: 57g min.
Normal Force: 200g min.
Physical
Housing: 2695—Red nylon, UL 94V-0
6471—White nylon, UL 94V-0
Temperature: 0 to +75˚C
J
Order No.
15-04-9209
15-04-9210
Polarizing Key
Polarizing Peg
Note: 2695 shown
ORDERING INFORMATION AND DIMENSIONS
Order No.
2695
6471
With Locking
Without
With Locking
Circuits
With Locking Ramp and
Locking
Ramp and
Ramp
Polarizing
Ramp or
Polarizing
Ribs
Ribs
Ribs†
01
• 22-01-2011
02
• 22-01-2027 • 22-01-3027 • 22-01-2021 22-01-2025
03
• 22-01-2037 • 22-01-3037 • 22-01-2031 22-01-2035
04
• 22-01-2047 • 22-01-3047 • 22-01-2041 22-01-2045
05
• 22-01-2057 • 22-01-3057 • 22-01-2051 22-01-2055
06
• 22-01-2067 • 22-01-3067 • 22-01-2061 22-01-2065
07
• 22-01-2077 • 22-01-3077 • 22-01-2071 22-01-2075
08
• 22-01-2087 • 22-01-3087 • 22-01-2081 22-01-2085
09
• 22-01-2097 • 22-01-3097 • 22-01-2091 22-01-2095
10
• 22-01-2107 • 22-01-3107 • 22-01-2101 22-01-2105
11
• 22-01-2117 • 22-01-3117 • 22-01-2111 22-01-2115
12
• 22-01-2127 • 22-01-3127 • 22-01-2121 22-01-2125
13
• 22-01-2137 • 22-01-3137 • 22-01-2131 22-01-2135
• US Standard Product, available through Molex franchised distributors
* When mated with Molex product only
† For circuits 19-28, contact factory
J-34
990
Dimension
Circuits
A
3.10
5.60
8.10
10.70
13.20
15.80
18.30
20.90
23.40
25.90
28.50
31.00
33.50
(.122)
(.220)
(.320)
(.420)
(.520)
(.620)
(.720)
(.820)
(.920)
(1.020)
(1.120)
(1.220)
(1.320)
B
2.54
5.08
7.62
10.16
12.70
15.24
17.78
20.32
22.86
25.40
27.94
30.48
(.100)
(.200)
(.300)
(.400)
(.500)
(.600)
(.700)
(.800)
(.900)
(1.000)
(1.100)
(1.200)
14
15
16
17
18
19
20
21
22
23
24
25
With Locking
Ramp
• 22-01-2147
• 22-01-2157
• 22-01-2167
• 22-01-2177
• 22-01-2187
• 22-01-2197
• 22-01-2207
• 22-01-2217
• 22-01-2227
• 22-01-2237
• 22-01-2247
• 22-01-2257
Order No.
2695
6471
With Locking
Without
With Locking
Ramp and
Locking
Ramp and
Polarizing
Ramp or
Polarizing
Ribs
Ribs
Ribs†
• 22-01-3147 • 22-01-2141 22-01-2145
• 22-01-3157 • 22-01-2151 22-01-2155
• 22-01-3167 • 22-01-2161 22-01-2165
• 22-01-3177 • 22-01-2171 22-01-2175
• 22-01-3187 • 22-01-2181 22-01-2185
• 22-01-3197 • 22-01-2191
• 22-01-3207 • 22-01-2201
• 22-01-3217 • 22-01-2211
• 22-01-3227 • 22-01-2221
• 22-01-3237 • 22-01-2231
• 22-01-3247 • 22-01-2241
• 22-01-3257 • 22-01-2251
Dimension
A
36.10
38.60
41.20
43.70
46.20
48.80
51.30
53.90
56.40
58.90
61.50
64.00
(1.420)
(1.520)
(1.620)
(1.720)
(1.820)
(1.920)
(2.020)
(2.120)
(2.220)
(2.320)
(2.420)
(2.520)
B
33.02
35.56
38.10
40.64
43.18
45.72
48.26
50.80
53.34
55.88
58.42
60.96
(1.300)
(1.400)
(1.500)
(1.600)
(1.700)
(1.800)
(1.900)
(2.000)
(2.100)
(2.200)
(2.300)
(2.400)
4809
Anti-Fishhooking
Features and Benefits
■ Avoids tangling at pre-assembly
■ Available with cat ears
Electrical
Voltage: 250V
Current: 2.5A
Contact Resistance: 20 milliohms max.
Dielectric Withstanding Voltage: 1500V
Insulation Resistance: 500K Megohms min.
Reference Information
Product Specification: PS-10-07
Packaging: Reel or bag
Tooling Information: See crimp tooling section
UL File No.: E29179
CSA File No.: LR19980
Mates With: 5051-NM and 6471 housings
Designed In: Inches
Mechanical
Contact Insertion Force: 681g max.
Contact Retention to Housing: 27.21g min.
Wire Pull-Out Force: 3 lb min.
Mating Force: 199g max.
Unmating Force: 57g min.
Normal Force: 300g
Durability: 50 cycles Gold and 25 cycles Tin
C
Physical
Contact: Brass
Plating: Gold, select Gold and Tin
Operating Temperature: Storage— -40 to +105˚C Operating— 0 to +75˚C
Wire Accommodation: 22 to 30 AWG
Order No.
Bag
08-50-0032
08-55-0111
Reel
08-50-0031
08-55-0110
08-56-0115
08-56-0120
2.54mm (.100") Pitch
KK®
Crimp Terminal
7879
High Pressure
Plating
Crimp Wire Size
Insulation Diameter
Engineering No.
Lead-free
1.00 to 2.50mm Tin
0.38mm Gold in contact area only
0.38mm Gold in contact area, Gold flash overall
22-30
1.57 (.062) max.
4809
Yes
Features and Benefits
■ Multiple contacting points
■ Patented triple cantilever with box shroud
■ Suitable for high vibration requirements
■ Box shroud prevents contamination to the contact surface
■ Crimping die or hand tool available
Electrical
Voltage: 250V
Current: 2.5A
Contact Resistance: 10 milliohms max.
Dielectric Withstanding Voltage: 1500V
Insulation Resistance: 50K Megohms min.
Mechanical
Wire Pull-Out Force:
Reference Information
Product Specification: PS-7879
Packaging: Reel or bag
Tooling Information: See crimp tooling section
UL File No.: E29179
CSA File No.: LR19980
Use With: 7880 housings
Designed In: Inches
Order No.
Reel
08-50-0004
08-55-0124
Bag
08-50-0005
08-55-0129
Wire Gauge (AWG)
Pull-Out Force (lb)
22
10
24
8
26
6
28
4
30
3
Mating Force: 475g max.
Unmating Force: 100g min.
Normal Force: 430g min.
Physical
Contact: Brass
Plating: See Table
Wire Accommodation: 22 to 30 AWG
Insulation Range: 1.58mm (.062") diameter max.
Plating
Wire Gauge (AWG)
Insulation Diameter
Lead-free
Tin/Copper
Select Gold
22-30
1.57 (.062) max.
Yes
Recommended wire range assumes stranded wire
www.molex.com/product/kk/kk.html
MX07 C-53
2.54mm (.100") Pitch PCB and Wire Connectors
2.54mm (.100") Pitch
KK®
Crimp Terminal