Need help identify wire-to-board/wire connector type - Page 1
Forum section: electronics / projects

author: humgar
author_rank: Regular Contributor
timestamp: July 05, 2022, 01:56:54 am
content: I was given a big batch of 2.54mm pitch wire-to-board/wire connectors (housing & header) a long time ago but couldn't identify the type and model to find the crimp terminals for it.It looked a little like KK254 but the notches are at difference places. Not KF2510 or KLS1-2.54 either since the botches are at different places and there's a fat clip in the middle.Any help pointing me in the right direction would be appreciated. Please see attached pictures. I'm also trying to find out the type and model of the crimp terminals and what tools do I need to crimp it.

author: Jeff eelcr
author_rank: Frequent Contributor
timestamp: July 05, 2022, 01:35:20 pm
content: Check older JAE connectors for type.Jeff

author: tooki
author_rank: Super Contributor
timestamp: July 05, 2022, 01:40:34 pm
content: Bear in mind that it might even be 2.50mm pitch.

author: tooki
author_rank: Super Contributor
timestamp: July 05, 2022, 01:47:29 pm
content: Quote from: Jeff eelcr on July 05, 2022, 01:35:20 pmSure looks like it!JAE IL-G serieshttps://www.jae.com/en/connectors/series/detail/id=64296&type_code=T1040

author: humgar
author_rank: Regular Contributor
timestamp: July 06, 2022, 02:50:16 am
content: Thanks a lot! They mated with 2.54mm so I've been searching 2.54mm pitch instead of 2.5mm! No wonder why I couldn't find it.The crimping tool cost $3822!https://www.mouser.com/ProductDetail/JAE-Electronics/CT150-2B-ILG?qs=sPbYRqrBIVl5sEhow6MJHA%3D%3DI wonder if Molex Mini-Fit Jr crimp tool works with IL-G series.https://www.molex.com/molex/products/part-detail/application_toolin/0638111000

author: tooki
author_rank: Super Contributor
timestamp: July 06, 2022, 05:22:28 am
content: If you already have that tool I’d give it a shot. Despite the Mini-fit Jr contact being more than twice as long overall, the actual crimp area is only 0.5mm longer. But I wouldn’t buy it for them. I’d sooner get an IWISS-3220 from China — it’s a ratcheting tool with decent dies for $25.

author: humgar
author_rank: Regular Contributor
timestamp: July 07, 2022, 07:30:19 am
content: The bag of crimp conductor I was given along with the IL-G headers/housings (which the hooks fit the IL-G housings and I verified it mates correctly with the headers) looked a little different from JAE's picture on mouser: it has the same 'butterfly' style at the conductor section like Mini-Fit Jr (so it crimped perfectly with my Mini-Fit Jr tool) but I don't know what's the right tool to crimp the 'wrap' style for the insulation section. (Sorry that I don't know the right names for these crimp 'styles'. Really appreciate if somebody can correct me on the terminologies)Please see attached picture. If anybody can tell it's a the crimp conductor for a different style/brand/type, please drop me a hint

author: tooki
author_rank: Super Contributor
timestamp: July 07, 2022, 10:56:59 pm
content: Hmm, I looked a bit and came across the IL (without -G) series, whose contacts appear to be precisely what you have, so my initial suggestion was likely wrong.https://www.jae.com/en/connectors/series/detail/id=64297

author: humgar
author_rank: Regular Contributor
timestamp: July 08, 2022, 12:46:17 am
content: You are exactly right! It's the IL series, not IL-G because the the notch aligns with the middle of the header pins, not the top! (Please see annotated pictures of the two drawings)The remaining question is how to crimp the 'wrap' style insulator of the IL series. The conductor side crimps perfectly with the manual Mini-fit Jr tool.

author: tooki
author_rank: Super Contributor
timestamp: July 08, 2022, 06:10:16 am
content: Yeah. I am quite torn on the offset diagonal “hug the insulator” type contacts. On the one hand I love the end result, but on the other hand, they’re so damned unforgiving with regards to the tool.I’m still baffled that the Chinese have not really started making crimp tools for them. If anything, I’d think they’d be cheaper to make. Surely the m-shaped die is harder to cut than circular!!

author: humgar
author_rank: Regular Contributor
timestamp: July 08, 2022, 11:59:57 am
content: I never had good experience with CCC (Cheap Chinese Crap). The CCC for mini-fit jr made terrible crimps and I ended up biting the bullet and buying a real Molex crimp and it saved the day. Sometimes the Chinese just make unusable garbage that's a waste of materials and have no redeeming value. (I wouldn't feel right to sell the crap that's nothing but pure frustration for the next victim)Do you know any Molex model series that uses the 'hug style' insulator crimp? Maybe we can look up their crimp tools and see if there are cheap ones available just to do the insulator crimp. My manual mini-fit jr crimp tool is dirt cheap compared with the double-rachet crimper.

author: tooki
author_rank: Super Contributor
timestamp: July 08, 2022, 12:18:18 pm
content: Some (but not all, according to what I’ve been told) of the KK 396 series contacts do. But they’re a fair bit larger.C-Grid III uses sort of stubby offset wings. The official hand tool (63825-8100) uses a circular die. But it’s not a budget tool.