EW – 35 Processing Instruction LUMBERG CONNECT GMBH 30 V 01 EN Connector MICROMODUL MICA – MICAL – MICALD - 3005 Page 1 of 18 MICA 3005 EW 1 QT 1 PT 1 PMO 1 Q2 1 LAB 1 M1 1 M2K 1 PO 1 Author Checked Date Name Edition 1 2 3 21.08.2002 Hegel Name Hegel Hegel Gazke Date 12.12.2002 07.07.2004 21.02.2007 4 5 6 7 8 EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 MICAL MICALD 30 V 01 EN Page 2 of 18 EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 3 of 18 Alteration Description Edition Alterations carried out 1 Graphics reformatted, text amended, country code changed 2 7.2.4 Test specifications for the contact insertion depth changed 3 Change of name and inspection note added. EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 4 of 18 Contents: 1 System features ............................................................................................. 6 2 Contact principle ............................................................................................ 7 2.1 Indirect mating on the contact tab.........................................................................7 2.2 Soldering on the PCB...............................................................................................7 3 Application tooling and machines ................................................................ 8 3.1 Tools .........................................................................................................................8 3.1.1 WM30 .................................................................................................................8 3.1.2 HZ-WM30 ...........................................................................................................8 3.1.3 KHP-WM30AD....................................................................................................8 3.2 Machines ..................................................................................................................8 3.2.1 PP30....................................................................................................................8 3.3 Semi-automatic machine.........................................................................................9 3.3.1 HA30-R ...............................................................................................................9 3.3.2 HA30-Z ...............................................................................................................9 3.4 Fully-automatic machines........................................................................................9 3.4.1 VA30...................................................................................................................9 4 Cable specification ....................................................................................... 10 4.1 Cable specifications cross section for connection 0,09...0,135 mm²....................10 5 Assembly ...................................................................................................... 11 5.1 Connector feed ......................................................................................................11 5.2 Cutting clearance...................................................................................................11 5.3 Termination head ..................................................................................................11 5.4 Contact insertion depth ........................................................................................11 5.5 Cable protrusion ....................................................................................................13 5.6 Strain relief embossing..........................................................................................13 5.7 Geometry of the embossing die............................................................................14 5.8 Positions for the strain relief embossing ..............................................................15 5.9 Cable.......................................................................................................................15 5.10 Housing ................................................................................................................15 6 Guarantee against incorrect mating........................................................... 16 6.1 Coding ....................................................................................................................16 6.2 Torsion safety.........................................................................................................16 6.3 Colour coding.........................................................................................................16 7 Quality assurance ......................................................................................... 17 7.1 Quality features .....................................................................................................17 7.2 Quality features / IDC ............................................................................................17 7.2.1 ID slot width.....................................................................................................17 7.2.2 Symmetry of the ID slot...................................................................................17 7.2.3 Cable quality ....................................................................................................17 EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 5 of 18 7.2.4 Contact insertion depth ..................................................................................17 7.2.5 Cable protrusion ..............................................................................................18 7.3 Retention force of the wire ..................................................................................18 EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 1 System features One-piece body Contact springs in pre-latching position Pitch 1,27mm Wire termination Insulation displacement connection by pressing the contacts Wire exit 90° 30 V 01 EN Page 6 of 18 EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 2 Contact principle 2.1 Indirect mating on the contact tab (types MICA and 3005) Insulation displacement connection (test acc. to DIN EN/IEC 60352-4) 2.2 Soldering on the PCB (types MICAL and MICALD) Insulation displacement connection (test acc. to DIN EN/IEC 60352-4) 30 V 01 EN Page 7 of 18 EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 8 of 18 3 Application tooling and machines 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. 3.1 Tools 3.1.1 WM30 For the connector processing the cutter module WM30 is available. The cutter module WM30 is a combination tool. For the connector processing an HZ or KHP actuation is required. 3.1.2 HZ-WM30 In combination with the HZ actuation the processing of smallest series, samples production and repairing of cable harnesses on location is possible. 3.1.3 KHP-WM30AD In combination with the KHP actuation the cutter module WM 30 is mated with the LUMBERG standard toggle lever press. Used for single and small series. The adapter AD is used in order to fix the cutter module WM30 on the toggle lever press KHP. 3.2 Machines 3.2.1 PP30 Pneumatic press for the production of small and medium-sized series. The processing machine possesses a cable stop position interrogation with automatic release of the press. EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 9 of 18 3.3 Semi-automatic machine 3.3.1 HA30-R Semi-automatic machine for cost-effective termination of ribbon wires to automaticfeed connectors. Used for medium-sized and large series. Only for MICA connectors. The connectors are supplied on coils. 3.3.2 HA30-Z Semi-automatic machine for cost-effective termination of ribbon wires to automaticfeed connectors. Used for medium-sized and large series. The loose connectors are fed to the machine by using a feeding device (vibroconveyer). 3.4 Fully-automatic machines 3.4.1 VA30 A fully-automatic machine where the ribbon wire is cut and mated on both sides with the connectors. An electrical continuity check and short circuit test is optionally integrable. Termination versions 1 on 1, 1 on N and optional the „Z“ version are available. Used for large-scale industrial series production. EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 10 of 18 4 Cable specification This instruction is not valid for shielded flat cables. The cable specifications must be kept. Any deviation must be discussed and approved by LUMBERG. 4.1 Cable specifications cross section for connection 0,09...0,135 mm² Flat cable AWG28 ( 7 x ∅0,127mm = 0,09mm²); tin-plated Technical specification sheet 901 01 Flat cable AWG28 ( ∅0,32mm = 0,09mm²); tin-plated Technical specification sheet 901 02 Flat cable AWG26 ( 69 x ∅0,05mm = 0,135mm²); tin-plated Technical specification sheet 901 04 Other cables see LUMBERG release list. EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 11 of 18 5 Assembly The cables are mated with the contact equipped connectors. At type 3005 there is also the strain relief embossing mounted in the same step. 5.1 Connector feed Depending on the kind of delivery the connector feed is as follows • vibroconveyer (for bulk material) • bar stock carrier consisting of antistatic, transparent PVC • coils adhesive taped in 4 different uncoil directions A to D 5.2 Cutting clearance Wire cross section for connection (conductor) and insulation displacement area (ID slots) have to correspond. Only released cables are to be used for the ID slots. 5.3 Termination head In order to guarantee a correct positioning of the contacts and not to damage the bodies during the termination of the contacts, termination head, contact and connector have to correspond. The termination heads are part of the application machines. One mounting form exists for the types MICA and 3005, another mounting form exists for the types MICAL and MICALD. 5.4 Contact insertion depth In order to guarantee a correct insulation displacement connection and the mating with suitable MICS tab headers, the contact insertion depth must comply. Attention must be paid on the correct shut height dimension of the LUMBERG application equipment. EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 12 of 18 The shut height dimension of the termination head is 6,4-0,05mm. This is the height of the contacts in the pre-latching position (measured from the upper edge of the contacts to the area of support). The insertion dimension of the contacts is 4,3-0,2mm (measured from the upper edge of the contacts to the area of support). EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 13 of 18 5.5 Cable protrusion There must be the correct cable protrusion to guarantee good wire termination in the ID slots. It must be between 0mm and 0,5mm. After termination the cable protrusion must be visually checked. 5.6 Strain relief embossing At type 3005 the strain relief embossing will be fixed in the housing by means of flanged dies. Attention must be paid on the correct insertion depth of the die. Termination head and embossing die must correspond and be according to specification. embossing die EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 14 of 18 The embossing depth of the die is 1,0-0,2mm (measured from the top of the die to the area of support). When the embossing is too deep the connection to the strain relief embossing can be damaged. This can lead to a reduction of the forces because the fixation of the connection is not permanently guaranteed then. When the embossing is not deep enough the specified forces cannot be achieved due to inadequate hooking. embossing die 5.7 Geometry of the embossing die The geometry of the embossing die must be according to specification because otherwise damages of the cable or housing can occur and the specified retention force cannot be achieved. EW – 35 Processing Instruction LUMBERG CONNECT GMBH Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 15 of 18 5.8 Positions for the strain relief embossing The positions for the strain relief embossing must be kept because otherwise damages on the wires can occur. When using the LUMBERG tooling equipment these positions are guaranteed. 4 pole 6 pole more than 8 pole embossing (not tolerated measures ±0,05) 5.9 Cable No damaged insulation of the cable in direction wire exit is allowed (visual check). The ends of the cable must be cut off without burr and deformity. 5.10 Housing After the termination no visual damages of the housing are allowed (visual check). The mating function must be guaranteed (functional check). The contact must be in correct position in the housing (visual check). EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 16 of 18 6 Guarantee against incorrect mating 6.1 Coding Not available. 6.2 Torsion safety Available. Incorrect mating of the types MICA and 3005 is avoided through various wide grooves at the beginning and the end of the connector. The grooves are positive-fit with the MICS tab headers. 6.3 Colour coding Not available. EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 17 of 18 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 ID slot Cable quality Contact insertion depth Cable protrusion 7.2.1 ID slot width LUMBERG guarantees correct ID slot. 7.2.2 Symmetry of the ID slot Symmetry of ID slot and cable tolerance ±0,1 is guaranteed by the body. 7.2.3 Cable quality The cable must meet LUMBERG specification. 7.2.4 Contact insertion depth The contact insertion depth determines the position of the conductor in the ID slot area. The locking hook of the contact spring must be concentric in the locking window. All single conductors must be in the ID slot area. EW – 35 LUMBERG CONNECT GMBH Processing Instruction Connector MICROMODUL MICA – MICAL – MICALD - 3005 30 V 01 EN Page 18 of 18 7.2.5 Cable protrusion The cable protrusion according to point 5.5 must be kept. A protrusion of the cable in the housing leads to an incorrect mating. An exceeding of the maximal cable protrusion leads to uncertainties when actuating the connection. 7.3 Retention force of the wire Specification regarding the retention force of the wire from the body on request.