Application Specification
114--2153
Series 250 Positive Lock MK I
LOC B
1of 11
E2009 Tyco Electronics Corporation, Harrisburg, PA
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.
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.tycoelectronics.com
Receptacle Connectors 10 DEC 09 Rev A
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.
1. INTRODUCTION
This specification covers the requirements for the application of Series 250 Positive Lock MK I Receptacle
Connectors. These receptacle contacts are designed to accept a wire size range of 20 to 10 AWG.
One-- and two position housings are available for your production requirements. The contacts are designed to
be mated with tabs containing holes for proper locking. These receptacle contacts are terminated by automatic
or semi--automatic machines.
When corresponding with Tyco Electronics Personnel, use the terminology provided on this specification to
help facilitate your inquiry for information. Basic terms and features of components are provided in Figure 1.
Figure 1
Single Circuit
Housing (Typ)
One Position
Flag Housing
Multiple Circuit
Housing (Typ)
Insulation
Barrel
Wire Barrel
Release Latch
Release Latch
Secondary
Lock
Retention
Nib
Retention
Nib
Series 250
Positive Lock
Contact
Series 250
Positive Lock
Flag Contact
Receptacle
Contact
Insertion End
Mating End
of Housing
Release
Latch
2. REFERENCE MATERIAL
2.1. Revision Summary
SUpdated document to corporate requirements
SNew logo and format
NOTE
i
114- 2153Series 250 Positive Lock MK I Receptacle Connectors
Rev A2 of 11 Tyco Electronics Corporation
2.2. Customer Assistance
Reference Part Number 154717 and Product Code 1113 are representative of Series 250 Positive Lock MK I
Receptacle Connectors. These numbers are used in the network of customer service to access tooling and
product application information. This service is provided by your local Tyco Electronics Representative or, after
purchase, by calling the Tooling Assistance Center or the Product Information number at the bottom of page 1.
2.3. Drawings
Customer Drawings for specific products are available from the responsible Tyco Electronics Engineering
Department via the service network. The information contained in the Customer Drawing takes priority if there
is a conflict with this specification or any other technical documentation supplied by Tyco Electronics.
2.4. Specifications
Product Specification 108--3017 provides product performance requirements and test information.
2.5. Instructional Material
The following list includes available instruction sheets (408--series) that provide assembly procedures for
product, operation, maintenance and repair of tooling, and customer manuals (409--series) that provide setup,
operation, and maintenance of machines.
Document Number Document Title
408--3295 Preparing Reel of Contacts for Application Tooling
408--7424 Checking Terminal Crimp Height or Gaging Die Closure
408--8040 Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type)
408--8053 Conversion Guide for Miniature Quick--Change Applicators
408--9816 Handling of Reeled Products
409--5128 Basic AMP--O--LECTRIC* Model âKâ Terminating Machines, and Accessories
409--5842 AMP--O--LECTRIC Model âGâ Terminating Machine 354500--1
3. REQUIREMENTS
3.1. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housing
material.
B. Reel Storage
When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically.
C. Shelf Life
The contacts and housings should remain in the shipping containers until ready for use to prevent
deformation to those components. The components should be used on a first in, first out basis to avoid
storage contamination that could adversely affect signal transmissions.
D. Chemical Exposure
Do not store contacts near any chemicals listed below as they may cause stress corrosion cracking in the
contacts.
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfides Nitrites Tartrates
Where the above environmental conditions exist, phosphor--bronze contacts are recommended instead of brass if
available.
3.2. Special Characteristics
Positive Lock Receptacles are designed with reduced mating forces and a flexible locking dimple. This unique
locking feature acknowledges proper mating with an audible mechanical âsnapâ of the dimple into the hole in
the mating tab. The locking feature enhances safety and reliability of the mated circuit for isolated and hard to
reach areas.
NOTE
i
114- 2153
Series 250 Positive Lock MK I Receptacle Connectors
Rev A 3 of 11Tyco Electronics Corporation
3.3. Wire and Receptacle Selection
A. Receptacle Selection
The basic criteria for choosing a receptacle is the width and the thickness of the mating tab. Series 250
Positive Lock MK I will mate with 6.35 x 0.81 mm [.250 x .032 in.] tabs.
B. Wire Selection
Series 250 Positive Lock MK I Contacts will accept wires with insulation diameters, strip lengths, and
crimp heights and widths as listed in Figure 2.
DO NOT nick, cut, or scrape the wire conductor during the stripping operation.
TERMINAL WIRE
S
I
Z
E
R
A
N
G
E
WIRE
A
P
P
L
I
E
D
INSULATION STRIP INSULATION
C
R
I
M
P
WIRE BARREL CRIMP
S
I
Z
E
R
A
N
G
E
mm2[AWG]
A
P
P
L
I
E
D
mm2[AWG]
I
N
S
U
L
A
T
I
O
N
DIAMETER
S
T
R
I
P
LENGTH
C
R
I
M
P
WIDTH (Ref) HEIGHT +0.05 [.002] WIDTH (Ref)
0.5 [20] 1.45 [.057]
0
5
1
5
[
2
0
1
6
]
0.6 [19]
2
2
9
3
3
0
[
0
9
0
1
3
0
]
3
3
0
[
1
3
0
]
1.50 [.059]
2
2
9
[
0
9
0
]
0.5--1.5
[
20--16
]
0.7 [18] 2.29--3.30
[
.090--.130
]
3.30
[
.130
]
1.60 [.063] 2.29
[
.090
]
1.5 [16] 1.65 [.065]
0.7 [18]
2
4
1
3
9
4
[
0
9
5
1
5
5
]
3
9
4
[
1
5
5
]
1.50 [.059]
0.7--2.0 [18--14] 1.5 [16] 2.41--3.94
[
.095--.155
]
5.46--6.22
3.94
[
.155
]
1.65 [.065] 2.79 [.110]
0
0
[
8
]
2 [14] 3.43--4.95 [.135--.195]
5
.
4
6
6
.
2
2
[.215--.245] 5.33 [.210] 1.88 [.074]
9
[
0
]
2.5 [13.5] 2.03 [.080]
2.5--4.0 [13.5--11] 3 [12] 3.56--4.32 [.140--.170] 5.59 [.220] 2.13 [.084] 3.30 [.130]
5
0
[
3
5
]
4[11]
3
5
6
3
[
0
0
]
5
5
9
[
0
]
2.36 [.093]
3
3
0
[
3
0
]
3
0
5
0
[
1
2
1
0
]
3 [12]
3
4
3
5
0
8
[
1
3
5
2
0
0
]
5
5
9
[
2
2
0
]
2.01 [.079]
4
5
7
[
1
8
0
]
3.0--5.0
[
12--10
]
5 [10] 3.43--5.08
[
.135--.200
]
5.59
[
.220
]
2.39 [.094] 4.57
[
.180
]
Figure 2
Each crimp dimension represents the functional range of a wire/contact combination. There are tool designs available
to meet various application requirements. The developed crimp configuration is unique for each tool design and is
acceptable provided the crimp height is within the functional range. For crimp dimensions of a specific tool, refer to the
applicator log packaged with power tools.
3.4. Crimped Contact Requirements
Locate the contact to be crimped in the appropriate tooling according to the instructions packaged with that
tooling. Detailed instructions covering the placement of contacts in the tooling and the use of such tooling is
packaged with each tool.
Terminate the contact according to the directions shipped with the appropriate tooling. See Section 5,
TOOLING.
Wire insulation shall NOT be cut or broken during the crimping operation, nor shall the insulation be crimped into the
contact wire barrel. Reasonable care should be taken by tooling operators to provide undamaged wire terminations.
Periodic inspections must be made to ensure crimped contact formation is consistent as shown.
A. Crimp Height
The crimp applied to the wire portion of the contact is the most compressed area and is most critical in
ensuring optimum electrical and mechanical performance of the crimped contact. The crimp height must
be within the dimensions provided in Figure 2.
CAUTION
!
NOTE
i
CAUTION
!
NOTE
i
114- 2153Series 250 Positive Lock MK I Receptacle Connectors
Rev A4 of 11 Tyco Electronics Corporation
B. Crimp Length
For optimum crimp effectiveness, the crimp must be within the area shown and must meet the crimp
dimensions provided in Figure 2. Effective crimp length shall be defined as that portion of the wire barrel,
excluding bellmouth(s), fully formed by the crimping tool. Instructions for adjusting, repairing, and
inspecting tools are packaged with the tools. See Figure 12.
C. Bellmouths
Front and rear bellmouths shall be evident and conform to the dimensions given in Figure 3.
Figure 3
0.13 [.005] Max.
Wire Barrel
Flash
Section X- X
See View A Wire Barrel
Crimp Height
Wire Barrel
Crimp Width
Wire and Insulation Must
Both Be Visible In This Area
No Wire Strands
Showing In This Area
Flush to
0.76 [.030] Max
No Insulation Crimped In
Insulation Barrel Seam
Rear Bellmouth
0.38--0.64 [.015--.025]
Front Bellmouth
0.38 [.015] Max
X
X
Crimp
Length
0.13 [.005]
Max. Burr
0.00 -- 0.38
[.000 -- .015]
Cutoff Tab
View A
D. Cutoff Tab
The cutoff tab shall be cut to the dimensions shown in Figure 3.
E. Burrs
The cutoff burr shall not exceed the dimensions shown in Figure 3.
F. Wire Barrel Flash
The wire barrel flash shall not exceed the dimensions shown in Figure 3 in Section X--X.
114- 2153
Series 250 Positive Lock MK I Receptacle Connectors
Rev A 5 of 11Tyco Electronics Corporation
G. Wire Location
After crimping, the wire conductor and insulation must be visible in the transition area between the wire
and insulation barrels.
H. Conductor Location
The conductor may extend beyond the wire barrel to the maximum shown in Figure 3.
I. Wire Barrel Seam
The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam.
J. Twist and Roll
There shall be no twist, roll, deformation, or other damage to the mating portion of the crimped contact
that will prevent proper mating. See Figure 4.
Figure 4
Front of Receptacle
Contact
15_(Max)
Wire Barrel
K. Straightness
The force applied during crimping may cause some bending between the crimped wire barrel and the
mating portion of the contact. Such deformation is acceptable within the following limits.
1. Up and Down
The crimped contact, including cutoff tab and burr, shall not be bent above or below the datum line
more than the amount shown in Figure 5.
Figure 5
3_(Max)
3_(Max)
Datum Line
NOTE: Angles are drawn for clarification only and are not to scale.
114- 2153Series 250 Positive Lock MK I Receptacle Connectors
Rev A6 of 11 Tyco Electronics Corporation
2. Side to Side
The side--to--side bending of the contact may not exceed the limits provided in Figure 6.
Figure 6
Datum Line
3_(Max)
3_(Max)
NOTE: Angles are drawn for clarification only and are not to scale.
3.5. Tensile Strength
Crimped contacts should hold the wire firmly and have a crimp pull--out test value meeting that specified in the
table in Figure 7.
Adjust tensile testing machine for head travel of 25.4 mm [1 in.] per minute. Directly and gradually apply force for 1
minute.
CRIMP PULL--OUT TEST
Wire Size
m
m
2
[
A
W
G
]
Minimum Force
mm
2
[AWG] Newtons Pounds
0.5 [20] 58 13
0.7 [18] 89 20
1.5 [16] 133 30
2 [14] 222 50
3 [12] 311 70
5 [10] 356 80
Figure 7
3.6. Mating Tab Dimensions
Figure 8 shows features and dimensional requirements for tab terminals intended for mating with Series 250
Positive Lock MK I Receptacle Contacts.
Testing may be done using a gage as described in Residential Controls----Quick--Connect Terminals, ANSI/NEMA No.
DC2----1982. Test tabs shall have dimensions as shown in Figure 8.
NOTE
i
NOTE
i
114- 2153
Series 250 Positive Lock MK I Receptacle Connectors
Rev A 7 of 11Tyco Electronics Corporation
10_+2_(Typ)
C
D
Shoulders
Optional
0.25 [.010]
Max Cutoff
Flash, No Wider
or Thicker Than
Lead Edge
See (b)
B
Tab Without
Shoulders
G
Radius
1.14 [.045]
Min
A (Front to Top
Surface Bevel
Use if
Shoulder
Exists
Use to Locate Hole if
No Shoulder Exists
0.76 [.030] Max (Side Surface Bevel to
Top Surface Bevel)
45_Approx
(2 Places) (a)
EF
IHoleDia
0.08 [.003] A
0.08 [.003]
0.13 [.005] R
Max Both Sides
H
-- A --
Shoulder May Be
Eliminated if Not
Feasible
Min Clearance
Over Length
TAB
SIZE
A +
0.13 [.005]
B +
0.13 [.005]
C +
0.03 [.001]
D +
0.08 [.003]
E +
0.20 [.008]
F +
0.08 [.003]
G +
0.13 [.005]
H
(MIN)
I
DIA
6.35 x 0.81
[.250 x .032]
0.89
[.035]
7.92
[.312]
0.81
[.032]
6.35
[.250]
4.52
[.178]
3.40
[.134]
1.27
[.050]
8.26
[.325]
1.65--2.03
[.065--.080]
NOTE(a) Bevel need not be a straight line if within confines as shown, or a radius of Gï§0.13 mm [.005 in.] may be substituted.
NOTE(b) Min Clearance is 9.78 mm [.385 in.] w/o Insulator; 10.03 mm [.395 in.] w/Insulators 154719 and 962522; and 12.06 mm
[.475 in.] w/Insulators 520961 and 520910.
NOTE Dimensional measurements shall not include plating, burrs, or flatness tolerance. Hole must be symmetrical with no burrs.
Figure 8
3.7. Mating and Testing
The forces required to mate and unmate a test mating tab and receptacle shall be as specified in Figure 9.
Measure the force using a testing device capable of holding the reading. It must also provide accurate
alignment with slow and steady mating and unmating of the test tab and receptacle.
FORCE (NEWTONS [LBS])
F
I
R
S
T
M
A
T
I
N
G
(
M
A
X
)
FIRST MATING FIRST UNMATING SIXTH UNMATING
FIRST MATING (MAX)
INDIVIDUAL
(
M
A
X
)
(MINIMUM) (MINIMUM)
I
N
D
I
V
I
D
U
A
L
(
M
A
X
)
LOCKED UNLOCKED UNLOCKED
TEST TAB AND RECEPTACLE
80 [18] 27 [6] 98 [22] 11 [2.5] 9[2]
Figure 9
114- 2153Series 250 Positive Lock MK I Receptacle Connectors
Rev A8 of 11 Tyco Electronics Corporation
3.8. Housings
Series 250 Positive Lock MK I Housings are available in one or two positions. These housings perform an
insulation function as well as protecting the mating tabs and receptacles. See Figure 10.
Figure 10
One- Position Receptacle Housings
Two- Position Receptacle Housings
Flag
Secondary
Lock
Retention
Nib
Receptacle Contact
Insertion End
Mating End
of Housing
3.9. Assembly/Disassembly Procedures
A. Assembling Connector
The contacts are retained in the housings by a window in the bottom of the contact that straddles a raised
nib in the housing. See Figure 11B and C. To achieve the straddle position, the nib must be displaced by
the receptacle when inserted into the housing. See Figure 11D. To achieve this displacement, the housing
must flex. It is important that housings remain in the closed plastic shipping bag to retain the proper
moisture content until assembled.
B. Unmating Connector
To release the lock, an integrally--designed release latch must be depressed. See Figure 11A. This is
accomplished either with a thumb (Figure 11A and B), or a cam surface (Figure 11C), inside the housing.
Unless the release latch is depressed either manually or with the optional designated area of the housing,
the receptacle cannot be removed without damage force being applied.
Tabs for use with Positive Lock MK I Receptacle Connectors must have a hole in the mating area. The
proper tab configuration for mating with Positive Lock MK I Receptacle Connectors is shown in Figure 8.
The basic tab dimensions are also found in UL Specification 310.
114- 2153
Series 250 Positive Lock MK I Receptacle Connectors
Rev A 9 of 11Tyco Electronics Corporation
Figure 11
âAâ
âBâ
âDâ
âCâ
Release Latch (Depress to Unlock Tab)
Locking Dimple
Mating Tab
Housing Retention Window
Press to Release
Retention Nib
Secondary Lock
Latch Depressing
Cam Surface
Pull to Release
Retention Nib
Retention Nib Housing Retention Window
3.10. Repair/Replacement
Damaged crimped contacts or housings must be removed, discarded, and replaced with new components.
If a damaged contact is apparent before the contacts are inserted into the housing, cut the wire in back of the contact
and reterminate the wire end. If contacts or housing are damaged after insertion, the wire must be cut directly in back
of the housing and reterminated with new contacts and housing. See Section 5, TOOLING.
CAUTION
!
114- 2153Series 250 Positive Lock MK I Receptacle Connectors
Rev A10 of 11 Tyco Electronics Corporation
4. QUALIFICATIONS
Series 250 Positive Lock MK I Receptacle Connectors are Component Recognized by Underwriters
Laboratories Inc. (UL) in File E66717 and E28476. They are also Certified by CSA International in File
LR7189A.
5. TOOLING
This section provides a selection of tools for various application requirements. They include semi--automatic
and automatic machines for power--assisted application of strip form contacts. Modified designs and additional
tooling concepts may be available to meet other application requirements. For additional information, contact
one of the service group numbers at the bottom of page 1. A listing of tooling recommendations covering the
full wire size range is provided in Figure 12.
Tyco Electronics Tool Engineers have designed machines for a variety of application requirements. For assistance in
setting up prototype and production line equipment, contact Tyco Electronics Tool Engineering through your local Tyco
Electronics Representative or call the Tooling Assistance Center number at the bottom of page 1.
SApplicator
Applicators are designed for the full wire size range of strip--fed, precision formed contacts, and provide
for high volume, heavy duty, production requirements. The applicators can be used in bench or floor
model power units.
Each applicator is shipped with a metal identification tag attached. DO NOT remove this tag or disregard the
information on it. Also, a packet of associated paperwork is included in each applicator shipment. This information
should be read before using the applicator; then it should be stored in a clean, dry area near the applicator for future
reference. Some changes may have to be made to the applicators to run in all related power units. Contact the Tooling
Assistance Center number at the bottom of page 1 for specific changes.
SPower Units
A power unit is an automatic or semi--automatic device used to assist in the application of a product.
Power unit includes the power source used to supply the force or power to an applicator.
The Model âKâ AMP--O--LECTRIC Terminating Machine PN 565435--5 has been superseded by the Model âGâ
Terminating Machine PN 354500--1 (Customer Manual 409--5842) for new applications. For existing applications, the
Model âKâ is still recommended because of the large number of installed machines.
WIRE SIZE INSULATION APPLICATOR POWER UNIT
mm2AWG
I
N
S
U
L
A
T
I
O
N
DIAMETER
A
P
P
L
I
C
A
T
O
R
(DOCUMENT)
P
O
W
E
R
U
N
I
T
(DOCUMENT)
0.5--1.5 20--16 2.29--3.30 [.090--.130] 567181--2 (408--8040)
0.7--2.0 18--14 2.41--3.18 [.095--.125] 466542--3 (408--8040) 354500--1
(
409--5842
)
,
2.6--4.0 13--11 3.56--4.32 [.140--.170] 466883--2 (408--8040)
3
5
4
5
0
0
1
(
4
0
9
5
8
4
2
)
,
565435--5 (409--5128)
3.0--5.0 12--10 3.43--5.08 [.135--.200] 567417--2 (408--8040)
Figure 12
Typical Heavy Duty
Miniature Applicator
(Side--Feed)
(408--8040)
AMP--O--LECTRIC
Model âGâ Terminating
Machine 354500--1
AMP--O--LECTRIC
Model âKâ Terminating
Machine 565435--5
NOTE
i
NOTE
i
NOTE
i
114- 2153
Series 250 Positive Lock MK I Receptacle Connectors
Rev A11 of 11Tyco Electronics Corporation
6. VISUAL AID
Figure 13 shows a typical application of Series 250 Positive Lock MK I 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 13. VISUAL AID
RELEASE LATCH SHALL
NOT BE DEFORMED
RECEPTACLE CONTACT SHALL
BE LOCKED IN PLACE. PULL
BACK GENTLY ON WIRE TO
ENSURE LOCKING
ENGAGEMENT
NO WIRE IN WIRE
BARREL SEAM
NO INSULATION IN
INSULATION BARREL SEAM
CONTACT NOT
DEFORMED
HOUSING NOT
DAMAGED OR
CRACKED
WIRE MUST BE FLUSH
OR PROTRUDE SLIGHTLY
WIRE AND
INSULATION
BOTH VISIBLE
