I'm working on a WPC pin that has the connector at J101 burned up. Its one of those crazy loop around connectors that really can't be replaced like factory even if you wanted to. So after much research, I came to the conclusion that I don't really like the IDC connectors even though they are fairly quick to install with the proper tools. So after even more research, I've come to the conclusion that I would like to replace my IDC plugs with something better. I just thought I would seek the sage wisdom of the community as to what I've come up with.
I'd like to swap over my connectors, headers, and crimp pins. And after a lot more research, this is what I've come up with.
Connectors: Series 41695 plugs (capable of using stadard, Trifurcon, and the MarKK pins)
Crimp Pins: Series 45570 (aka MarKK rated at 13Amps)
Headers: Series 41671, or 41791 (both are polarized, rated 7 amp@250V, and have a UL 94 V-0 heat resistance rating.
Exact specs can be found at mouser by searching for molex and the series numbers above.
The headers are the missing link. I believe the 41791 has just a slightly larger footprint than the TE/AMP headers. Although, it appears as to be the better of the two. The 41671 headers are a little smaller than the factory headers, built a little lighter and are "Breakaway" headers in case you need to cut them down. Although they are a lighter design, they look more like they might be interchangeable with the TE/Amp connectors. Since the crimp pins require, a square header pin, and the Molex KK system is all designed to work together, more or less, my thought was that I would need to swap the headers out as well....which is a good idea since they probably got hot as well.
The drawback of changing the headers out is that the board would no longer be interchangeable, unless of course, the IDC connector plugs would work with one of these headers types. I hope someone will know if that might be the case. I've also heard that IDC headers will accept certain molex plugs without any problems. Although, I would again need to check the drawing specs to see if the pins are the same size and both square. Third, its a lot of work and most people will tell you, don't reinvent the wheel.
SO my question is,
1. Does anyone know the mouser part number for the exact header pins WPC used for J101 so I can check the engineering drawing for compatibility.
2. Anyone out there ran into this before and just happens to know the answer.
3. Any thoughts as to how useful this would be in general. I know I'm not the only one who doesn't particularly care for IDC plugs. Any words of wisdom would be appreciated.
I'm not looking to swap out all my IDC plugs on all my pins. I'm just looking for a system that I can keep hand to take care of all future WPC plug and wiring problems as they inevitably pop up.
FWIW, I also know you can use the series 41661 headers and the above connector (and presumably those MarKK crimp pins) to fix the GI at J120 and J121. Although the headers are not polarized, it doesn't really need to be for the GI since they are all tied together.