Processing Instruction LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 357V01EN Seite 1 von 17 3570 3575 357099 Date Name Edition 3 4 5 Author 03.06.03 Heg Name dg Sve Fs Checked 21.10.13 wie Date 26.02.07 10.07.09 09.09.13 LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 357V01EN Seite 2 von 17 Alteration Description Edition Alterations carried out 1 Measure of altitude in pre-latching position adapted from 18,25mm in 18,5mm and assembly measure 15,1-0,15mm in 15-0,1mm for optimization of the component. 2 revision of cable specification 3 Change of name and inspection note added. 4 Change connectors height from 15 -0,1mm in 15,1 -0,2mm, tolerance 18,5-0,15 added. Type 357099 added 5 Add new template, pull-out force of conductors adjusted, designation adjusted, changed from 35X10EN to 357V01EN. LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing Instruction Connector RAST 2.5 357V01EN Seite 3 von 17 Contents: 1 2 Series 3570................................................................................................................. 4 Cutting-off coding keys ............................................................................................ 5 2.1 Cutting blades ......................................................................................................... 5 3 Series 3575................................................................................................................. 6 4 Serie 357099............................................................................................................... 7 5 System features ......................................................................................................... 8 6 Contact principle ....................................................................................................... 9 6.1 Indirect mating on the contact pin ........................................................................... 9 6.2 Direct mating on the PCB ........................................................................................ 9 7 Application tooling and machines for 3570, 3575 and 357099 ............................ 10 7.1 Manual processing tool ......................................................................................... 10 7.2 Manual processing device ..................................................................................... 10 7.3 Semi-automatic processing device........................................................................ 10 7.4 Automatic processing device................................................................................. 10 8 Cable specification .................................................................................................. 10 8.1 Cable specification cross section for connection 0,5...0,75 mm² ........................... 10 9 Assembly ................................................................................................................. 11 9.1 Connector feed...................................................................................................... 11 9.2 Termination head .................................................................................................. 12 9.3 Shut height dimension of the termination head and connector height after termination ..................................................................................................................... 12 9.4 Cable protrusion .................................................................................................... 13 9.5 Housing ................................................................................................................. 13 9.6 Cable ..................................................................................................................... 14 10 Quality assurance ................................................................................................... 15 10.1 Quality features ..................................................................................................... 15 10.2 Quality features / IDC ............................................................................................ 15 10.3 ID slot width........................................................................................................... 15 10.4 Symmetry of the ID slot ......................................................................................... 15 10.5 Cable quality ......................................................................................................... 15 10.6 Cable protrusion .................................................................................................... 15 10.7 Cable insertion depth ............................................................................................ 16 10.8 Retention force of the wire .................................................................................... 16 11 Storage ..................................................................................................................... 17 LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 357V01EN Seite 4 von 17 1 Series 3570 Connector for direct and indirect mating in ID Technology, coding in conjunction with RAST 2.5 guide frames or pin assembly, all-insulated and tapped. Pitch 5 mm for 6A / 10A 2-10-pole / 2-5-pole Cross section for connection 0,5...0,75 mm² Cross section for connection 0,22...0,35 mm (cutting clearance S01) • acc. to specification sheet 3570 01 • - Indirect mating Direct mating LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 357V01EN Seite 5 von 17 2 Cutting-off coding keys Connectors can be supplied to the machine as basic types with all coding keys in place. The machine can cut off the keys in any selected position. It is the responsibility of the customer to make a correct arrangement of the connectors, coding device and colour. Caution! The connectors, tab headers and guide frames are always drawn in mating direction. Connector basic type: Example: Coding keys I and j are cut: 2.1 Cutting blades To ensure a good cutting-off of the coding keys, use only LUMBERG cut-off blades. Remaining cutting edge max. 0.15mm. LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing Instruction Connector RAST 2.5 357V01EN Seite 6 von 17 3 Series 3575 Connector for direct mating in ID Technology, with latching on the PCB, alternatively with or without keying ribs and closed side walls, all-insulated and tapped. for 6A 2-10-pole cross section for connection 0,5...0,75 mm² cross section for connection 0,22...0,35 mm (cutting clearance S01) • acc. to specification sheet 3575 01 • - Direct mating LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 357V01EN Seite 7 von 17 4 Serie 357099 Connector for direct and indirect mating in ID Technology, double-side keying in conjunction with 355299 pin header, all-insulated and tapped. Pitch 5mm. for 6A / 10A 2-10-pole / 2-5-pole cross section for connection 0,5...0,75 mm² cross section for connection 0,22...0,35 mm (cutting clearance S01) • acc. to specification sheet 357099 01 • - Indirect mating Direct mating LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 357V01EN Seite 8 von 17 3570 / 3575 / 357099 5 System features Two part moulded body Supplied in following stacks Wire termination Insulation displacement connection by pressing the top Wire exit 90° and 180° LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 357V01EN Seite 9 von 17 6 Contact principle 6.1 Indirect mating on the contact pin Insulation displacement connection acc. to DIN 41611 part 6 6.2 Direct mating on the PCB PCB 1,5mm Insulation displacement connection acc. to DIN 41611 part 6 LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 357V01EN Seite 10 von 17 7 Application tooling and machines for 3570, 3575 and 357099 The function, safety and quality of the connectors are only guaranteed by using of LUMBERG processing equipment. It has to be taken into account that the connectors aren’t checked electrically before the processing / assembling. Because of that an electrical test should be carried out after processing / assembling. 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. 7.1 Manual processing tool For fitting single wires. For single and small series. 7.2 Manual processing device For fitting single wires. For single and small series. 7.3 Semi-automatic processing device For cost-effective termination of single wires to automatic-feed connectors. For series manufacture. 7.4 Automatic processing device For the assembly of fully-automatic feed single-wires and connectors. For large-scale industrial series production. 8 Cable specification Cables used to terminate the connectors must be according to specification. Any deviation must be discussed and approved by LUMBERG. 8.1 Cable specification cross section for connection 0,5...0,75 mm² Techn. specification sheet 908 15 stranded wire = 0,50 mm² Techn. specification sheet 908 13 stranded wire = 0,75 mm² Other release wires see LUMBERG release list of appropriate connectors LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing Instruction Connector RAST 2.5 357V01EN Seite 11 von 17 9 Assembly Connector and cross section for connection have to correspond. 9.1 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 following stacks to the machine The stacks are securely linked when the measure of altitude 18,5 mm 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. LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing Instruction Connector RAST 2.5 357V01EN Seite 12 von 17 9.2 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. 9.3 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 3570, 3575 and 357099 Processing Instruction LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 357V01EN Seite 13 von 17 9.4 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. if touching 9.5 Housing No damage of the connector is allowed after termination (visual check). The terminated connector must mate with the male header (functional test). The contacts must be in correct position in the housing (visual check). burr max. 0,1 LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 357V01EN Seite 14 von 17 9.6 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. LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 357V01EN Seite 15 von 17 10 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 may affect the product quality, the responsible departments have to take care for appropriate quality assurance steps. 10.1 Quality features The following quality features must be taken into consideration. 10.2 Quality features / IDC • • • • • ID slot width Symmetry of the ID slot Cable quality Cable insertion depth Cable protrusion 10.3 ID slot width LUMBERG guarantees correct ID slot. 10.4 Symmetry of the ID slot Symmetry of ID slot (cable tolerance ±0,1) is guaranteed by the body. 10.5 Cable quality The cable must meet LUMBERG specification. 10.6 Cable protrusion The minimum cable protrusion must be kept, because shorter cable protrusions do not guarantee correct contact. LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle 357V01EN Connector RAST 2.5 Seite 16 von 17 10.7 Cable insertion depth Cutting area The cable insertion depth is determined by the height of the contact support. All single wires must be in the ID slot area. 10.8 Retention force of the wire The retention force of the wire in the ID slot must be as follows: Stranded wire LIYV : 0,75 mm² > 50 N F The stated value for the conductor's pull-out force is the typical value established during a test carried out with a standard 0.75 mm² line. All values were determined under laboratory conditions and serve as a reference. LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing Instruction Connector RAST 2.5 357V01EN Seite 17 von 17 11 Storage Tin-plated and silver-plated surfaces can undergo a physical aging process that may negatively affect their ability to be soldered. In order to maintain the best connection characteristics, make sure that the following instructions are closely followed during additional processing steps: Storage conditions: The parts should ideally be stored in the original packaging, at a constant temperature of 21 – 25° C, with a relative humidity of no more than 55%. The components should not be exposed to direct light. They should also be protected from any extreme ambient conditions (such as air pollution). The storage time should be kept as short as possible, especially for silver-plated components and for solder connections in general. Our experience is that tin-plated components can be soldered for about a year after delivery when using the proper conventional flux. Silver-plated components, owing to their physical characteristics, should be processed within about six months of delivery. These specifications are based on experience using components stored under optimal conditions. They do not constitute a binding commitment for the fulfillment of any characteristics.