TE Connectivity SGI 1.25 User guide

Application Specification
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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.
114-106497
13 DEC 23 Rev 5
NOTE
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 application of Signal Grace Inertial (SGI) 1.25 & 1.50 connector
system includes SMT header assembly and plug assembly used in the wire-to-board interconnections, cap
assembly and plug assembly used in the wire-to-wire interconnections.
The SGI 1.25 connector system is available in 2 through 18 positions for single row, 20/22/30/40 positions for
dual row, and SGI 1.50 connector system is available in 2 through 12 positions for single row, 4 through 18
positions for dual row. Wire size ranges from 26 to 30 AWG for 1.25mm pitch connector, and 24 to 28 AWG for
1.50mm pitch connector.
When corresponding with TE Connectivity 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.
SGI 1.25 Single Row
SGI 1.25 & 1.50 Connector System
Header Assembly
SGI 1.25 Single Row (5pos shown)
Plug Housing
SGI 1.25 Single Row (5pos shown)
Locking Latch
Mating Face
Mating Face
Wire Cavity
Cap Housing
SGI 1.25 Single Row (10pos shown)
Mating Face
PRELIMINARY

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SGI 1.50 Single Row
Receptacle Terminal
SGI 1.25 and 1.5 Sigle Row and Dual row
Row
Wire Barrel
Insulation Barrel
Header Assembly
SGI 1.5 Single Row (5pos shown)
Mating Face
Plug Housing
SGI 1.5 Single Row (5pos shown)
Mating Face
Locking Latch
Wire Cavity
Insulation Barrel
Wire Barrel
Or
Tab Terminal
SGI 1.25 Sigle Row and Dual row Row
Insulation Barrel
Wire Barrel

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SGI 1.25 Dual Row
TPA (5pos shown)
For SGI 1.50 Single Row only
Header Assembly
SGI 1.25 Dual Row (20pos shown)
Plug Housing
SGI 1.25 Dual Row (20pos shown)
Mating Face
Mating Face
Locking Latch
Wire Cavity
Cap Housing
SGI 1.25 Dual Row (20pos shown)
Mating Face

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SGI 1.50 Dual Row
Figure 1 (Schematic Diagram Only)
Header Assembly
SGI 1.5 Dual Row (10pos shown)
Plug Housing
SGI 1.5 Dual Row (10pos shown)
Mating Face
Mating Face
Locking Latch
Wire Cavity
TPA
SGI 1.50 Dual Row (10pos shown)

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2. REFERENCE MATERIAL
2.1. Revision Summary
Revision to this application specification include:
Add SGI 1.25 Cap Housing single row 10P, dual row 20P, Tab contact
Update crimp parameter
Add PC board and header assembly placement information in 3.10,3.11.
2.2. Customer Assistance
Reference Product Base Part numbers are stated in Figure 2. Use of these numbers will identify the product
line and help you to obtain product and tooling information when visiting www.te.com or calling the number at
the bottom of page 1.
SGI 1.25 connector
(Single Row or Dual Row)
SGI 1.50 connector
(Single Row or Dual Row)
Product Type
Base PN
Product Type
Base PN
Single Row
Dual Row
Single Row
Dual Row
Header Assembly,
SMT, Right Angle
2360538
NA
Header Assembly,
SMT, Right Angle
2360545
-
Header Assembly,
SMT, Vertical
2360540
2376974
2456589
Header Assembly,
SMT, Vertical
2360547
2427710
Plug Housing
2371404
2376950
2456588
Plug Housing
2382946
2426397
Receptacle
Terminal
2371403
2454997
2371403
2454997
Crimp Terminal
2371403
2454997
2371403
2454997
Cap Housing
2428107
2428108
-
-
-
Tab Terminal
2428106
-
-
-
TPA
2383410
2426398
Figure 2
2.3. Drawings
Customer drawings for product part numbers are available from www.te.com. Information contained in the
customer drawing takes priority.
2.4. Manuals
Manual 402-40 can be used as a guide to solder. This manual provides information on various flux types and
characteristics with the commercial designation, flux removal procedures, and a checklist for information on
soldering problems.
2.5. Specifications
Product Specification 108-106451, 108-160851 and Qualification Report 501-106475, 501-160511 provide
product performance and test results.

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2.6. 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. Instructional material
that pertain to this product are:
408-8040 Heavy Duty Miniature Quick-Change Applicators with Mechanical Feed System
408-9640 Crimp Quality Monitor (CQM) Applicators for Side-Feed and End-Feed Applications
408-10389 Ocean Side-Feed Applicators
3. REQUIREMENTS
3.1. Safety
Do not stack product shipping containers so high that the containers buckle or deform.
3.2. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the product
material.
B. Shelf Life
The product should remain in the shipping containers until ready for use to prevent deformation to
components. The product should be used on a first in, first out basis to avoid storage contamination that
could adversely affect performance.
C. Reels
When using reeled contacts, store coil wound reels horizontally. When storing partial reeled contacts, the
end of the strip should be secured to the flange using a wire tie or similar method.
D. Chemical Exposure
Do not store product near any chemical listed below as they may cause stress corrosion cracking in the
material.
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfur Nitrites Tartrates
3.3. Wire Selection and Preparation
The contacts accept stranded wire sizes 24-30 AWG [0.205 –0.0507 mm2] with an insulation diameter range
given in Figure 3. The wire must be stripped to the dimension given in Figure 3.

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CAUTION
Care shall be taken during the stripping operation to ensure the conductor is not nicked, scraped, or cut.
CONTACT
WIRE
TYPE
PART NUMBER
WIRE SIZE (AWG)
[mm2]
INSULATION DIAMETER
STRIP LENGTH (±0.2)
SGI Receptacle Terminal
2371403-1
2454997-1
26-30
[0.128 –0.0507]
0.76 - 1.0
1.50
2371403-2
2454997-2
24-28
[0.205 –0.0804]
0.85 - 1.10
1.70
2371403-3
2454997-3
24-28
[0.205 –0.0804]
0.76 - 1.30
1.70
SGI Tab Terminal
2428106-1
26-30
[0.128 –0.0507]
0.76 - 1.0
1.50
Figure 3
3.4. Crimp Requirements
Contacts must be terminated according to the instructions packaged with the tooling.
A. Bellmouth
The rear bellmouth shall be evident and be within the dimensions given in Figure 4.
B. Cutoff Tab and Burr
The cutoff tab is the remaining portion of the carrier strip after the contact is cut from the strip. The cutoff tab
and burr shall not exceed the dimension given in Figure 4.
C. Wire Barrel Flash
Wire barrel flash is the formation that may appear on both sides of the wire barrel as the result of the crimping
process. The wire barrel flash shall not exceed the dimension given in Figure 4.
D. Wire Barrel Crimp
The crimp applied to the wire barrel 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 must be centered
on the closed wire barrel. The crimp must result in an “F” crimp where the wire barrel forms a closed seam with
no evidence of loose wire strands or wire strands visible in the seam. The crimp height and width must be
within the dimensions given in Figure 4.
E. Insulation Barrel Crimp
The crimp applied to the insulation barrel of the contact must result in an “F” crimp. The crimp height and width
must be within the dimensions provided in Figure 4. Slight scratch is acceptable on insulation crimp.
F. Effective Crimp Length
Effective crimp length shall be defined as that portion of the wire barrel, excluding the rear bellmouth, fully
formed by the crimping tool. Refer to Figure 4.
Strip Length (See Table)

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G. Wire Location
All conductors must be held firmly inside the wire barrel. No strands can be folded back over the wire
insulation. The wire insulation must be inside the insulation barrel but must not enter the wire barrel. The wire
insulation and conductors must be visible in the transition area between the wire barrel and insulation barrel.
See Figure 4.
H. Wire Brush
The conductors may extend beyond the wire barrel within the dimensions given in Figure 4.
I. Wire Barrel Seam
The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam.
K. Twist and Roll
There should be no twist or roll of the wire barrel or mating portion of the crimped contact that would cause
overstress or impair usage. See Figure 4 for allowable limits.
NOTE
The effective crimp length depends on the crimping dies used and should not be measured for inspection purposes.
Wire Barrel Seam Closed with
No Visible or Loose Wire Strands
Wire Insulation and Conductors Both Visible in Transition
Area (Between Wire Barrel and Insulation Barrel)
No Wire Insulation Visible
in Insulation Barrel Seam
Insulation Barrel
Width (See Table)
Wire Brush (Conductors Extend
Beyond Wire Barrel) (See Table)
Rear Bellmouth
(See Table)
Contact Spring
is Not Deformed
Effective Crimp Length (Ref)
X
X
See Detail A
1.0 max. for Box Area
1.35 +/-0.05
Gap Should Not
Change After Crimp

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3° Max
3° Max
Avoid Twist and Roll
Detail A
Section X-X
0.13 Max Burr
0.25mm Max
Cutoff Tab
Wire Barrel Crimp
Width (See Table)
Wire Barrel Crimp
Height
(See Table)
0.20 Max Wire Barrel Flash
1.0 max. for Box Area
Contact beam should not
change after crimp

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WIRE SIZE
CONTACT 2371403-1, 2454997-1
mm2
AWG
WIRE BARREL CRIMP
INSULATION
BARREL CRIMP
WIDTH
INSULATION
BARREL
CRIMP HEIGHT
WIRE BRUSH
REAR BELLMOUTH
HEIGHT
±0.03
WIDTH
APPLICATOR
APPLICATOR
0.128
26
0.51
1.0 max
(0.84 Crimper
Width)
F shape
1.0 max.
(0.84 Crimper
Width)
F shape
(1) As required
0.0 - 0.45
0.15-0.35
0.0804
28
0.46
0.0507
(2) 30
0.41
WIRE SIZE
CONTACT 2371403-2, 2454997-2
mm2
AWG
WIRE BARREL CRIMP
INSULATION
BARREL CRIMP
WIDTH
INSULATION
BARREL
CRIMP HEIGHT
WIRE BRUSH
REAR BELLMOUTH
HEIGHT
±0.03
WIDTH
APPLICATOR
APPLICATOR
0.205
24
0.68
1.2 max
(0.95 Crimper
Width)
F shape
1.2 max.
(1.05 Crimper
Width)
F shape
1.60 +/-0.05
0.0 - 0.45
0.15-0.35
0.128
26
0.60
0.0804
(2) 28
0.56
WIRE SIZE
CONTACT 2371403-3, 2454997-3
mm2
AWG
WIRE BARREL CRIMP
INSULATION
BARREL CRIMP
WIDTH
INSULATION
BARREL
CRIMP HEIGHT
WIRE BRUSH
REAR BELLMOUTH
HEIGHT
±0.03
WIDTH
APPLICATOR
APPLICATOR
0.205
24
0.68
1.2 max
(0.95 Crimper
Width)
F shape
1.2 max.
(0.95 Crimper
Width)
F shape
(3) 1.4 ~ 1.8
0.0 - 0.45
0.15-0.35
0.128
26
0.60
0.0804
(2) 28
0.56
CONTACT 2428106-1
mm2
AWG
WIRE BARREL CRIMP
INSULATION
BARREL CRIMP
WIDTH
INSULATION
BARREL
CRIMP HEIGHT
WIRE BRUSH
REAR BELLMOUTH
HEIGHT
±0.03
WIDTH
APPLICATOR
APPLICATOR
0.128
26
0.51
1.0 max
(0.84 Crimper
Width)
F shape
1.0 max.
(0.84 Crimper
Width)
F shape
(1) As required
0.0 - 0.45
0.15-0.35
0.0804
28
0.46
0.0507
(2) 30
0.41
* Note:
(1) Insulation crimp height will be variable depending on insulation diameter.
(2) Slight touch bottom is acceptable for 2371403-1 / 2454997-1 / 2428106-1 with 30AWG wire and 2371403-2
/ 2454997-2 / 2371403-3 / 2454997-3 with 28AWG wire.
(3) Insulation crimp height for 2371403-3 / 2454997-3 will be variable in 1.4~1.8mm depending on insulation
diameter.
Figure 4
L. 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:
The side-to-side bending of the contact may not exceed the limits provided in Figure 5.
The crimped contact, including cutoff tab and burr, shall not be bent above or below the datum line more than
the amount given in Figure 5.

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Figure 5
3.5. Inserting Contact into Housing
Grasp the wire directly behind the contact insulation barre and push the contact straight into the cavity until it
bottoms (there should be an audible click). Be aware that the contact must be installed in correct orientation as
specified below. Pull back lightly on the wire to be sure the contact is locked in place. Refer to Figure 6
Side-to-Side Alignment
3° Max
3° Max
1° Max
5°Max
Datum Line
Up and Down Alignment
NOTE: Angles are drawn for clarification only and are not to scale.
Plug Single Row
Be aware of contact
install orientation
Be aware of contact
install orientation
Plug Dual Row

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Figure 6
3.6. Installing TPA (If Applicable)
Grasp the TPA and push it straight into the housing until it bottoms (there should be an audible click). Pull back
lightly to be sure the TPA is locked in place. See Figure 7.
Single Row
Cap Single Row
Cap Dual Row
Be aware of contact
install orientation
Be aware of contact
install orientation

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Figure 7
3.7. Un-installing TPA (For SGI 1.50 only)
Use special tool (like sharp object) to lift the tip of TPA latch at both sides carefully and then remove the TPA
from plug housing. Be careful not to damage TPA during the operation. See Figure 8.
Figure 8
Single Row
Dual Row
Dual Row

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3.8. Mating Connectors
Ensure that the mating connectors have identical number of circuits and a pin contact mating with a socket
contact. Align the mating faces of the connectors and push them together until the locking latch fully engages
the locking tab. Pull back to ensure proper engagement and to prevent any deformation of the locking
mechanism. See Figure 9.
During mating connector, please don’t stack up the wire to the middle in case damage the connector, the
correct operation should be gripping the wire in up and down direction, as Figure 11 show.
Locking Tab
Locking Latch
Single Row
Locking Latch
Locking Tab

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Dual Row

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NOTE
Align the plug housing with header assembly or cap housing and then mate them without giving “KOJIRI” motions. Be sure
that they are locked in position.
Figure 9
3.9. Unmating Connectors
To disengage mating connectors, depress latch of plug housing with thumbnail, and pull the connectors apart.
Refer to Figure 10.
During unmating connector, please don’t stack up the wire to the middle in case damage the connector, the
correct operation should be gripping the wire in up and down direction, as Figure 11 show.
NOTE
DO NOT pull the connectors by the wires.
Depress Locking Latch Here
Pull Straight Away
Single Row
Pull Straight Away
Depress Locking Latch Here

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Figure 10
Dual Row
Pull Straight Away
Depress Locking Latch Here
Depress Locking Latch Here
Pull Straight Away
Pull Straight Away
Depress Locking Latch Here

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Figure 11
3.10. PC Board
The PC board pads must be solderable in accordance with EIA-638(Electronic Industries Alliance).
Recommended PC board pad pattern, dimensions and tolerances are shown in customer drawing.
3.11. PC Board Header Assembly Placement
CAUTION
If connectors are placed on the board manually, the connector should be handled only by housing to avoid deformation,
contamination, or damage to the contact solder tines and metal pegs.
A. Manual Placement
When placing the Surface Mount Connectors, the contact solder tines should be centered on the PC
board circuit pads. However, slight misalignment is permissible as shown in Figure 12.
Figure 12
B. Robotic Placement
The robotic equipment must be adjusted to feed, pick up, and place the headers on the PC board with an
accuracy as required. The header assembly datum surfaces detailed on the customer drawing will ensure
correct placement of the header.
3.12. Replacement and Repair
Do not use defective or damaged product. These products cannot be repaired. For replacement information,
call the number at the bottom of page 1.
3.13. Strain Relief and Wire Dress
Wires can be bundled together and supported using cable ties or electrical tap. The wires must remain
perpendicular to the housing and avoid an excessively sharp bend radius. The wire bundle must be at least
76mm [3.0 inch] from the back of the housing before bending in any direction. Do not bend unsupported wires
as this may cause strain on the contacts.

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3.14. Soldering
A. Process
The contacts can be soldered using reflow soldering or equivalent soldering techniques. Temperature and
exposure time shall be as specified in 108-106451.
B. Flux Selection
The contact Stabilizer Barrel must be fluxed prior to soldering with a 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
number at the bottom of page 1 for consideration of other types of flux. Flux that is compatible with these
connectors are provided in Figure 13.
TYPE
ACTIVITY
RESIDUE
COMMERCIAL DESIGNATION
ALPHA
KESTER
RMA (Mildly Activated)
Mild
Noncorrosive
611
186
Figure 13
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. Cleaners must be free of dissolved flux and other
contaminants. It is recommended that cleaning takes place with the PC board on its edge. If using an
aqueous cleaner, it is recommended using standard equipment, such as a soak tank or automatic in-line
machine. Common cleaning solvents with times and temperatures that will not affect these contacts is
specified in Figure 14.
NOTE
For solvents not listed, call the number on the bottom of page 1 for recommendations.
CLEANER
TIME (Minutes)
TEMPERATURE (Max)
NAME
TYPE
ALPHA 2110
Aqueous
1
132°C [270°F]
BIOACT EC-7
Solvent
5
100°C [212°F]
Butyl CARBITOL
Solvent
1
Ambient Room
Isopropyl Alcohol
Solvent
5
100°C [212°F]
KESTER 5778
Aqueous
KESTER 5779
Aqueous
LONCOTERGE 520
Aqueous
LONCOTERGE 530
Aqueous
Terpene
Solvent
Figure 14
D. Drying
When drying cleaned contacts and PC boards, temperature limitations must not be exceeded: -55° to
105°C [-67° to 221°F]. Excessive temperatures may cause contact degradation.

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4. TOOLING
Applicators contain the tooling for feeding and crimping strip-form terminals. Automatic machines provide the
power to operate the applicator. See Figure 15 for representative images.
Tooling information for product part numbers is available from www.te.com or by calling the Product Information
Center at the number at the bottom of page 1.
Applicators for product part numbers are available from the Applicator Search Portal on www.te.com or by
calling the Product Information Center at the bottom of page 1.
Figure 15
Ocean Applicator
Semi Automatic Machine