EW – 35 Processing Instruction LUMBERG CONNECT GMBH & CO KG 67 V 01 EN Connector 6770 Page 1 of 17 6770 EW 1 QM 1 PI/PP 1 VK-PMO 1 Q2 1 LAB 1 M1 1 M2K 1 Author Checked Date Name Edition 16.01.2002 Kippelt Name Date 1 2 3 4 5 6 7 8 EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 2 of 17 Alteration Description Edition Alterations carried out EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 3 of 17 Contents: 1 System features ............................................................................................................4 2 Contact principle ..........................................................................................................6 2.1 Indirect mating on the contact pin..............................................................................6 3 Application tooling and machines ..............................................................................7 3.1 Tools .........................................................................................................................7 3.1.1 Toggle lever press Type KHP67 .........................................................................7 3.2 Machines...................................................................................................................7 3.2.1 Semi-automatic termination machine Type HA67 ...............................................7 3.2.2 Fully-automatic termination machine Type VA67 ................................................7 4 Cable specification .......................................................................................................8 4.1 Cable specifications 0,38...0,75 mm² ........................................................................8 5 Assembly.......................................................................................................................9 5.1 Connector feed..........................................................................................................9 5.2 Cutting blades .........................................................................................................10 5.3 Termination head ....................................................................................................10 5.4 Shut height dimension of the termination head and connector height after termination .....................................................................................................................11 5.5 Cable protrusion ......................................................................................................12 5.6 Housing ...................................................................................................................12 5.7 Cable.......................................................................................................................13 6 Guarantee against incorrect mating .........................................................................14 7 Quality assurance.......................................................................................................15 7.1 Quality features .......................................................................................................15 7.2 Quality features / IDC ..............................................................................................15 7.3 ID slot width.............................................................................................................15 7.4 Symmetry of the ID slot ...........................................................................................15 7.5 Cable quality............................................................................................................15 7.6 Cable protrusion ......................................................................................................15 7.7 Cable insertion depth ..............................................................................................16 7.8 Retention force of the wire.......................................................................................16 8 Accessories: ...............................................................................................................17 8.1 Handle latch for locking: ..........................................................................................17 EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 4 of 17 1 System features Connector for direct and indirect mating in ID Technology, coding in conjunction with additional coding parts or injection-moulded, with all-insulation and test hole. Pitch 5,08 mm - - for 6A 1-7-pole Cross section for connect. 0,5...0,75 mm² Cross section for connect. 0,22...0,38 mm² (cutting clearance S01, colour coding blue) acc. to specification sheet 6770 01 Colour coding blue Indirect mating EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 5 of 17 Two-part body Supplied in following stacks Wire termination Insulation displacement connection by pressing the cover Wire exit 90° and 180° 180° 90° EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 6 of 17 2 Contact principle 2.1 Indirect mating on the contact pin Insulation displacement connection (test acc. to DIN EN/IEC 60352-4) EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 7 of 17 3 Application tooling and machines The function, safety and quality of the connectors are only guaranteed by using of LUMBERG processing equipment. The user bears full responsibility if any other processing equipment is used. In case of using any lubricants or sliding agents in the feed and press areas residues (impurities) must not come into contact with the connectors. 3.1 Tools 3.1.1 Toggle lever press Type KHP67 For fitting single wires. For single and small series. 3.2 Machines 3.2.1 Semi-automatic termination machine Type HA67 For cost-effective termination of single wires to automatic-feed connectors. For series manufacture. 3.2.2 Fully-automatic termination machine Type VA67 For the assembly of fully-automatic feed single wires and connectors. For large-scale industrial series production. EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 8 of 17 4 Cable specification The cable specifications must be kept. Any deviation must be discussed and approved by LUMBERG. 4.1 Cable specifications 0,38...0,75 mm² Techn. specification sheet 908S10 stranded wire LiY 0,38 mm² Techn. specification sheet 908 15 stranded wire H05V2-K 0,50 mm² Techn. specification sheet 908 13 stranded wire H05V2-K0,75 mm² Other cables see LUMBERG – release list. EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction 67 V 01 EN Connector 6770 Page 9 of 17 5 Assembly Connector and cross section for connection have to correspond. 5.1 Connector feed The lower housing must be cut off before the first stack of connectors is fed into the termination head. To feed a new stack into the machine the upper housing of the stack in the machine must be placed into the lower housing of the new stack. cut off lower housing first stack to the machine following stacks The stacks are securely linked when the height dimension 20,75±0,1 is reached in the pre-latching position. The cutting-off of the single connector from the stack is done by the machine, the links will remain on the connector. links EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 10 of 17 5.2 Cutting blades In order to guarantee a clean cutting off of each connector, only LUMBERG cutting blades are to be used. Remaining burr max. 0,1mm. 5.3 Termination head The connector will be terminated by using a flat termination head. The connector must be perpendicular to the base of the termination head and also the base must be parallel to the top. EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 11 of 17 5.4 Shut height dimension of the termination head and connector height after termination An important feature for the correct function of harness is the connector height after termination. It is determined by the shut height dimension of the termination head. Termination head Base Connector 6770 EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 12 of 17 5.5 Cable protrusion There must be the correct cable protrusion to guarantee good wire termination in both ID slots of the contact. After termination the cable protrusion must be visually checked. max. = if touching 5.6 Housing No damage of the connector is allowed after termination (visual check). The terminated connector must mate with the male header (functional check). The contacts must be in correct position in the housing (visual check). burr Gratmax. max.0,1 0,1 EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 13 of 17 5.7 Cable The cables must be cut off without burr and deformity. No cuts in the insulation are allowed in wire exit direction (visual check). Insulation cuts are permitted between the ID slots of the contact. Flat cables must be punched out. EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 14 of 17 6 Guarantee against incorrect mating The connectors can be delivered with injection-moulded coding or with slots for belated, alternatively coding. The customer bears full responsibility for the correct arrangement of the connectors and colours. Caution ! Connectors and pin headers are always marked in mating direction. Connector basis type K00: Coding alternatively belated with coding elements. Example with injection-moulded coding e. g. K01 codings: closed open EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 15 of 17 7 Quality assurance For all working and processing steps and alterations (e. g. product launch, changes of the cable, changes of the tool or machine ...), which can affect the product quality, the responsible departments have to take care for appropriate quality assurance steps. 7.1 Quality features The following quality features must be taken into consideration: 7.2 Quality features / IDC • • • • • ID slot width Symmetry of the ID slot Cable quality Cable insertion depth Cable protrusion 7.3 ID slot width LUMBERG guarantees correct ID slot. 7.4 Symmetry of the ID slot Symmetry of ID slot and cable, tolerance ±0,1, is guaranteed by the body. 7.5 Cable quality The cable must meet LUMBERG specification according to point 4.1. Customized cables, which are listed in the release lists, have to correspond with the available specification sheets. Only LUMBERG released cables are to be used. The customer bears full responsibility for the correct mating when cables are used which are not listed in the release lists. 7.6 Cable protrusion The min. cable protrusion according to point 5.5 must be kept. Smaller cable protrusions lead to an incorrect mating. Processing Instruction 67 V 01 EN Connector 6770 Page 16 of 17 7.7 Cable insertion depth The cable insertion depth is determined by the height of the body. All single conductors must be in the ID slot area. ID slot area EW – 35 LUMBERG CONNECT GMBH & CO KG 7.8 Retention force of the wire The minimal retention force of the wire from the ID contact: Stranded wire Stranded wire Stranded wire LIY 0,38 mm² >50 N H05V2-K 0,50 mm² >75 N H05V2-K 0,75 mm² >100 N F EW – 35 LUMBERG CONNECT GMBH & CO KG Processing Instruction Connector 6770 67 V 01 EN Page 17 of 17 8 Accessories: 8.1 Handle latch for locking: (only possible with wire exit 90°) According to the following pictures the handle latch can be locked by hand or automatically to the looking hooks, which are provided with 180° wire exit for the strain relief of the cables. For the connectors are appropriate handle latches available for 2-pole, polypole even and odd numbers of poles, which can be centrically locked on the connector.