XG5
IDC Connectors for Discrete Wires
1
Trouble-free discrete-wire termination
with IDC Sockets that accommodate MIL
Plugs.
■Two-slot, IDC construction and insulation barrel
offer high reliability and large-current (3A) discrete
wiring capability.
■Adaptable to a variety of covers for space-saving
and discrete wire termination.
■By using the simple, unique lock-lever system,
these Connectors can be locked to either the
XG8B/XG8W Unshrouded Plugs (with right-angle
terminals) or XG4C Box-type Plugs.
■Conforms to UL standards (file no. E103202).
(Except for XG5S models)
■Terminology
• Insulation barrel
Refers to the part of a
contact that crimps the
insulating sheath of a
wire.
• Insulation height
Refers to the height of the
insulation barrel after
crimping or IDC pressing.
• Lance
Refers to the lance-like
projections arranged on a
contact to secure it in the housing.
• U-slot
Refers to the part where the wire and the contact connect to each
other. It is called a U-slot because of its shape.
■Construction
RoHS Compliant
*Excluding XG5S
*
Wire
Insulation barrel
2-slot IDC pressing
Mating end
Lance
Insulation
height
Cover (Semi-cover or Hood Cover)
Semi-cover shown here.
Socket (with polarizing guide)
Polarizing guide
IDC contacts
Lance
Wire can be connected without
stripping cable insulation.
Two-slot connection
Insulation barrel
Solderless Contact
Rise in temperature (°C)
UL1061 AWG24 (XG5M-2032-N)
UL1007 AWG26 (XG5M-2035-N)
20 wires
20
wires
Temp. rise limit 10 wires
10 wires
2
wires
2 wires
Current flow (A)
Rise in temperature (°C)
Current flow (A)
UL1061 AWG24
UL1007 AWG26
Flow rate = (no. of contacts used) × 100%
(total no. of contacts)
Temp. rise limit
■Ratings and Characteristics
Rated current 1 A (AWG28), 2 A (AWG26),
3 A (AWG24)
Rated voltage 300 VAC
Contact resistance 20 mΩ max. (at 20 mV, 100
mA max.)
Insulation resistance 1,000 MΩ min. (at
500 VDC)
Dielectric strength 650 VAC for 1 min (leakage
current: 1 mA max.)
Total insertion force 1.96 N max. per contact
Removal force 0.29 N min. (with test
gauge, 0.64 x 0.64 mm)
Insertion durability 50 times
Ambient operating
temperature
−55 to 85°C (with no icing at
low temperature)
■Current and Temperature Characteristics
Use the temperature data shown below as a reference for selecting current values and wires.
2IDC Connectors for Discrete Wires XG5
■Materials and Finish ■Applicable Wires and Contact Sizes
Note: The contact numbers are marked on the contact insulation
barrels.
■Configuration
Assembly
Note: 1. Plug dimensions are listed on the Plug's page.
2. When using the XG4A or XG4C, the number of XG4A or XG4C's slots must be the same as the number of XG5M-N polarity guides.
Housing Fiber-glass reinforced PBT resin (UL94
V-0)/black
Contacts Mating end Phosphor-bronze/nickel base, 0.15-μm
gold plating
Terminals Phosphor-bronze/nickel base, 2.0-μm
solder plating
Cover Fiber-glass reinforced polyamide resin
(UL94 V-0)/black
Cable tie Polyamide resin (UL94 V-0)/natural
Size #1 AWG24 (For UL1061) Insulation outside diame-
ter: 1.1 to 1.3 mm
Core structure: 7 strands
or more
Size #2 AWG28 or AWG26
(For UL1007)
Socket Wire
Discrete wires
Connections
IDC Tool
Hood Cover
Cover
Semi-cover
Vertical
Horizontal
Assembled unit
Double-row
Assembled
Simple IDC Tool
Double rows
with polarity
guide
(lockable)
Double rows
with polarity
guide
(lockable)
Double rows
with polarity
guide
(lockable)
■Applicable Plugs
XG4A
Flat Cable MIL Plugs with
Long Locks
XG4A
Flat Cable Plugs without
Lock Lever (Lock Levers
mounted later)
XG4A
Flat Cable Double-row
Plugs
XG4E
IDC Flat Cable Plugs
Long Locks
XG4C
Flat Cable Box-type Plugs
XG8W/XG8B
Double-row Original Plugs
IDC Connectors for Discrete Wires XG5 3
XG5M-N Double-row Sockets
■Dimensions (Unit: mm)
■Ordering Information
Note: 1. The 10-contact XG5M-1031-N and XG5M-1034-N have no polarizing guides. The distance between slots is 22.86 mm for the two guides
on 50, 60, and 64-contact Connectors.
2. See the previous page for Plug information.
3. Applicable wire is AWG24 (UL1061) for size #1.
4. Applicable wire is AWG28 to AWG26 (UL1007) for size #2. For details, see the previous page.
Size no.
Polarizing guide
Appearance
No. of
contacts
No. of
polarizing
guide
Size #1 (See note 1.) Size #2 (See note 2.)
10 0 XG5M-1031-N XG5M-1034-N
1 XG5M-1032-N XG5M-1035-N
14 1 XG5M-1432-N XG5M-1435-N
16 1 XG5M-1632-N XG5M-1635-N
20 1 XG5M-2032-N XG5M-2035-N
26 1 XG5M-2632-N XG5M-2635-N
30 1 XG5M-3032-N XG5M-3035-N
34 1 XG5M-3432-N XG5M-3435-N
40 1 XG5M-4032-N XG5M-4035-N
50 1 XG5M-5032-N XG5M-5035-N
2 XG5M-5033-N XG5M-5036-N
60 1 XG5M-6032-N XG5M-6035-N
2 XG5M-6033-N XG5M-6036-N
64 1 XG5M-6432-N XG5M-6435-N
2 XG5M-6433-N XG5M-6436-N
4IDC Connectors for Discrete Wires XG5
XG5S Semi-covers
■Dimensions (Unit: mm)
■Ordering Information
■Assembled Dimensions (Socket with Semi-cover)
No. of
contacts
Model Applicable Connector
5 XG5S-0501 XG5M-103@-N
7 XG5S-0701 XG5M-143@-N
8 XG5S-0801 XG5M-163@-N
10 XG5S-1001 XG5M-203@-N
13 XG5S-1301 XG5M-263@-N
15 XG5S-1501 XG5M-303@-N
17 XG5S-1701 XG5M-343@-N
20 XG5S-2001 XG5M-403@-N
25 XG5S-2501 XG5M-503@-N
30 XG5S-3001 XG5M-603@-N
32 XG5S-3201 XG5M-643@-N
Semi-covers
XG5S-@@01
Double-row Sockets
XG5M-@@3@-N
Note: One Semi-cover is used per row.
Each XG5M Connector requires two
semi-covers.
Dimensions
No. of
contacts
Dimensions (mm)
AB
10 17.3 32.0
14 22.3 37.1
16 24.9 39.6
20 30.0 44.7
26 37.6 52.3
30 42.7 57.4
34 47.7 62.5
40 55.4 70.1
50 68.1 82.8
60 80.8 95.5
64 85.8 100.6
Original Plug + Semi-
cover + Lock Lever
MIL Plug + Semi-cover
IDC Connectors for Discrete Wires XG5 5
XG5S Hood Covers
■Dimensions (Unit: mm)
■Ordering Information
Note: Includes cable tie.
Appearance Vertical Horizontal
No. of contacts
(double rows)
Model (See note.) Model (See note.)
20 XG5S-2012 ---
26 XG5S-2612 ---
30 XG5S-3012 ---
34 --- XG5S-3422
40 --- XG5S-4022
50 --- XG5S-5022
60 --- XG5S-6022
Horizontal/XG5S-@@22
(Left and right halves)
Dimensions
No. of
contacts
Dimensions (mm)
ABCD
34 47.7 38.7 32.0 14.6
40 55.4 40.7 34.0 16.6
50 68.1 44.1 39.4 20.0
60 80.8 47.4 42.8 23.4
6IDC Connectors for Discrete Wires XG5
■Assembled Dimensions (Socket and Hood Cover) (Unit: mm)
Vertical Hood Cover
Dimensions
No. of
contacts
Dimensions (mm)
AB
20 30.0 44.7
26 37.6 52.3
30 42.7 57.4
Assembled Unit
MIL Plug + Vertical Hood Cover
Horizontal Hood Cover
Dimensions
No. of
contacts
Dimensions (mm)
ABCDEF
34 47.7 39.0 45.7 62.5 46.4 53.1
40 55.4 41.0 47.7 70.1 48.4 55.1
50 68.1 46.4 51.1 82.8 53.8 58.5
60 80.8 49.8 54.4 95.5 57.2 61.8
Assembled Unit
MIL Plug + Horizontal Hood Cover
IDC Connectors for Discrete Wires XG5 7
■XG5 Accessories (Sold Separately)
Material: Polyamide resin
(UL94 V-2)/natural
Material: Polyamide resin
(UL94 V-2)/natural
Lock Levers
XG5Z-0002
Use to lock Unshrouded Plugs (XG8B and XG8W, with right-
angle terminals).
Lock Levers II
XG4Z-0002
Use to lock XG4C Box-type Plugs.
Mounting the Lock Lever
For Sockets with polarity guides, mount the
Lock Lever to the tab to lock the Socket to the
Unshrouded Plug as shown in the diagram on
the right.
Note: When you order the above
products, order them in multi-
ples of the minimum ordering
quantity (pieces).
Model
XG5Z-0002
XG4Z-0002
Size no.
Spare Contacts
XG5W-0031-N (Size #1)
XG5W-0034-N (Size #2)
Note: 1. When you order the above
products, order them in multi-
ples of the minimum ordering
quantity (pieces).
2. These Contacts can be used
as replacements if a wrong
connection is made.
3. The applicable wire for size
No. 1 is AWG24 (UL1061).
The applicable wire for size
No. 2 is AWG28 to AWG26
(UL1007).
See page 2 for details.
Model
XG5W-0031-N
XG5W-0034-N
8IDC Connectors for Discrete Wires XG5
■XG5 IDC Tools
Simple IDC Tool
XY2B-7006
This tool is a compact, light-weight model,
ideal for use in the laboratory or for mainte-
nance.
Specifications
■Tools for the XG5
Contact Removal Tool
XY2E-0001
Used to remove from the housing, contacts
which are wrong.
Replacing Contacts
Use only this tool to remove incorrect IDC
contacts.
1. Remove the cover.
2.
Insert the tool into the housing lance holes
and push the lance into the housing.
3. Pull out the contact while holding the
lance down.
4. Insert a new contact.
■Tools
Simple Wire IDC Tool Set
XY2B-2104-N
This Wire IDC Tool Set is designed for XG5
Discrete-wire Connectors.
Specifications
Note: For function and operation details,
see the user’s manual for the Pres-
sure Welder provided separately.
Model
XY2B-7006
Applicable con-
nector
XG5M-N
Applicable wire AWG24 to AWG28
(with an insulation
outer diameter of 1.1
to 1.3 mm)
Dimensions 25 (W) × 100 (D) ×
80 (H) mm
Weight Approx. 180 g
Model
XY2E-0001
Lance Holding
Par t
XY2E-0001
Lance hole
Housing
Model
XY2B-2104-N
Stroke 13 mm
Motor speed 83/100 rpm (50/60 Hz)
Feed pitch 2.54 mm
Operation Foot switch
Weight Approx. 6 kg
Rated voltage 0.5 A, 100 VAC (50/60 Hz)
Fuse 1 A
Dimensions 120 (W) × 225 (D) ×
225 (H) mm
Applicable Connectors and Wires
Note: Use only wires specified in the table above.
Applicable Con-
nector
Size No. Applicable wires
UL file
No.
Size
[No. of wires/
diameter (mm)]
Cross-sec-
tional area
(mm2)
Covering
diameter
(mm)
XG5M-@@31-N
XG5M-@@32-N
XG5M-@@33-N
No. 1 UL1061 AWG24 [7/0.203] 0.21 1.1
XG5M-@@34-N
XG5M-@@35-N
XG5M-@@36-N
No. 2 UL1007 AWG26 [7/0.16] 0.13 1.3
AWG28 [7/0.127] 0.09 1.2
IDC Connectors for Discrete Wires XG5 9
■Precautions
Correct Use
IDC Connectors
•For best results, use only the XG5 IDC
To o l .
•Contact your OMRON representative for
details on the XG5 IDC Tool.
•Check the Contact size (No. 1 or No 2)
and wire size before connecting.
•OMRON has a IDC Tool Reference Man-
ual. Contact your OMRON representative
to request a copy.
Mounting the Cover
•The cover is used to protect the connec-
tion position and prevent shorting out.
Mounting the Semi-cover
•See the above diagram.
1. Insert part A of the Semi-cover into part
B of the Socket.
2. Push the claws on both sides of the
Semi-cover onto the Socket.
3. Make sure the claws are firmly inserted
in the slots.
4. To protect the wires, use cable ties to
bind wires that may be subject to ten-
sion even when a Semi-cover is used.
Mounting the Hood Cover
Vertical Hood Cover
•See the above diagram.
1. Insert the claws of part A of the Hood
Cover into the slots.
2. Insert claws B on the Hood cover into
part C on the other part of the Hood
Cover.
3. Wrap the wires with a cable tie.
Horizontal Hood Cover
•Follow the mounting procedure for the
vertical cover.
•The left and right parts of the cover are
different. Assemble carefully.
XG5M-N Double-row Socket Contact
Numbers
XG4M Contact Numbers
•The Contact numbers on the Double-row
Assembled Socket match the numbers on
the XG4M Flat Cable MIL Socket. (See
the above diagrams.)
•When making IDC connections on the
Double-row Assembled Connector, use
the polarity guide to distinguish the front
and back. (Note: The 10-contact Connec-
tor does not have a guide.)
Applicable Plugs
•XG4A, XG4C and XG8 are recom-
mended.
•XG4C and XG8 Plugs do not have locks.
To p r event accidental removal, use a Lock
Lever (XG4Z-0002, XG5Z-0002). (Lock
Levers cannot be used with XG8W
Straight Terminal Connectors.)
•When mounting the XG8 Original Plug
(with right-angle terminals) to a circuit
board, be sure that the cover is positioned
off the board as shown below.
Slot
Claw
Semi-cover
Cable tie
Triangular mark Contact
numbers Polarizing guide
Triangular mark Not marked on connector.
Original PlugCover
Board
XG5
Edge7 mm max.
• Application examples provided in this document are for reference only. In actual applications, confirm equipment functions and safety before using the product.
• Consult your OMRON representative before using the product under conditions which are not described in the manual or applying the product to nuclear control systems, railroad
systems, aviation systems, vehicles, combustion systems, medical equipment, amusement machines, safety equipment, and other systems or equipment that may have a serious
influence on lives and property if used improperly. Make sure that the ratings and performance characteristics of the product provide a margin of safety for the system or
equipment, and be sure to provide the system or equipment with double safety mechanisms.
Cat. No. G042-E1-04
0816(0412)(O)
Note: Do not use this document to operate the Unit.
OMRON Corporation
Electronic and Mechanical Components Company
Contact: www.omron.com/ecb