LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 plus 351000 / 351100 (not illustrated) 351200 / 351300 (not illustrated) Date Name Edition Author 23.10.13 kse Name Cheked 23.10.13 wie Date 35V02EN Page 1 of 21 LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing instruction Connector RAST 2.5 plus 351700 / 351800 (not illustrated) 352100 / 352300 (not illustrated) 35V02EN Page 2 of 21 LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 plus Alteration description Edition Alteration carried out 35V02EN Page 3 of 21 LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing instruction Connector RAST 2.5 plus 35V02EN Page 4 of 21 Contents: 1 System features ........................................................................................................... 5 1.1 Product types ............................................................................................................. 7 Series RAST 2.5 plus 351000 ......................................................................................... 7 Series RAST 2.5 plus 351100 ......................................................................................... 7 Series RAST 2.5 plus 351200 ......................................................................................... 8 Series RAST 2.5 plus 351300 ......................................................................................... 8 Series RAST 2.5 plus 351700 ......................................................................................... 9 Series RAST 2.5 plus 351800 ......................................................................................... 9 Series RAST 2.5 plus 352100 ....................................................................................... 10 Series RAST 2.5 plus 352300 ....................................................................................... 10 2 Contact principle ....................................................................................................... 11 Indirect plugging on the contact pin ............................................................................... 11 Direct plugging on the PCB ........................................................................................... 11 3 Application tooling and machines for 351000, 351100, 351200, 351300, 351700, 351800, 352100 und 352300 .......................................................................................... 12 Manual processing tool .................................................................................................. 12 Manual processing device ............................................................................................. 12 Pneumatic processing device ........................................................................................ 12 Semi-automatic processing device ................................................................................ 12 Automatic processing device ......................................................................................... 12 4 Cable specification .................................................................................................... 13 4.1 Cable specification cross section for connection 0,38mm² ...................................... 13 5 Assembly ................................................................................................................... 14 5.1 Connector feed ........................................................................................................ 14 5.2 Impression die stamp............................................................................................... 15 5.3 Shut heigt dimension of the termination machine .................................................... 15 5.4 Wire end position ..................................................................................................... 16 5.5 Wire (stranded wire / flat cable) ............................................................................... 17 5.6 Housing ................................................................................................................... 17 6 Cutting-off coding keys ............................................................................................ 18 6.1 Coding acc. to RAST 2.5 ......................................................................................... 18 6.2 Cutting blades .......................................................................................................... 18 7 Quality assurance...................................................................................................... 19 7.1 Quality features ....................................................................................................... 19 7.2 Quality features / IDC .............................................................................................. 19 7.3 ID slot width ............................................................................................................. 19 7.4 Symmetry of the ID slot ........................................................................................... 19 7.5 Cabel quality ............................................................................................................ 19 7.6 Contact insertion depth ............................................................................................ 20 7.7 Cable protrusion ...................................................................................................... 20 7.8 Retention force of the wire ....................................................................................... 20 7.9 Conatct gap ............................................................................................................. 21 8 Storage ....................................................................................................................... 21 LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 plus 1 System features Two-post body Supplied following stacks Wire termination Insulation displacement connection by pressing the top Wire exit 90° 35V02EN Page 5 of 21 LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle 35V02EN Connector RAST 2.5 plus Page 6 of 21 The connectors are used with pin headers as indirect connectors or with guide frames as direct connectors (edge connectors). Connector acc. RAST 2.5 Pin header Guide frame PCB LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle 1.1 Product types Series RAST 2.5 plus 351000 Partition 2,5 mm - for 2 A - 2-11-pole - cross section 0,22…0,38 mm² - acc. to spec sheet 351000 01 Series RAST 2.5 plus 351100 Partition 5 mm - for 2 A - 2-6-pole - cross section 0,22…0,38 mm² - acc. to spec sheet 351100 01 Connector RAST 2.5 plus 35V02EN Page 7 of 21 LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle Series RAST 2.5 plus 351200 Partition 2,5 mm - for 2 A - 2-11-pole - cross section 0,22…0,38 mm² - acc. to spec sheet 351200 01 Series RAST 2.5 plus 351300 Partition 5 mm - for 2 A - 2-6-polig - cross section 0,22…0,38 mm² - acc. to spec sheet 351300 01 Connector RAST 2.5 plus 35V02EN Page 8 of 21 LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle Series RAST 2.5 plus 351700 Partition 2,5 mm - for 2 A - 2-11-pole - cross section 0,22…0,38 mm² - acc. to spec sheet 351700 01 Series RAST 2.5 plus 351800 Partition 5 mm - for 2 A - 2-6-pole - cross section 0,22…0,38 mm² - acc. to spec sheet 351800 01 Connector RAST 2.5 plus 35V02EN Page 9 of 21 LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle Series RAST 2.5 plus 352100 Partition 2,5 mm - for 2 A - 2-11-pole - cross section 0,22…0,38 mm² - acc. to spec sheet 352100 01 Series RAST 2.5 plus 352300 Partition 5 mm - for 2 A - 2-6-pole - cross section 0,22…0,38 mm² - acc. to spec sheet 352300 01 Connector RAST 2.5 plus 35V02EN Page 10 of 21 LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 plus 2 Contact principle Indirect plugging on the contact pin Insulation displacement connection (test acc. to DIN EN/IEC 60352-4) Direct plugging on the PCB Insulation displacement connection (test acc. to DIN EN/IEC 60352-4) 35V02EN Page 11 of 21 LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing instruction Connector RAST 2.5 plus 35V02EN Page 12 of 21 3 Application tooling and machines for 351000, 351100, 351200, 351300, 351700, 351800, 352100 und 352300 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 onto contact with the connectors. Manual processing tool For fitting single wires and ribbon cables. For single and small series. Manual processing device For fitting single wires and ribbon cables. For small series. Pneumatic processing device Pneumatically assisted processing device with manual cable feed and connector feed. For small and middle series. Semi-automatic processing device To the economic assembling of automatic connector feed and manual cable feed. For serial production. Automatic processing device For optimal assembling of automatic wire feed and connector feed. For industrial mass production. LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 plus 35V02EN Page 13 of 21 4 Cable specification The cable specification must be kept. Any deviation must be discussed and approved by LUMBERG. 4.1 Cable specification cross section for connection 0,38mm² Technical specification sheet 908 14 Other approved cable see LUMBERG release list in the internet at www.lumberg.com LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing instruction Connector RAST 2.5 plus 35V02EN Page 14 of 21 5 Assembly Connector and cross section should be adapted with each other acc. LUMBERG specification (see technical Datasheet). 5.1 Connector feed The links are processed with taped connectors. The connectors are separated for processing. Before assemble is a separation of the chain links needed. To optimize the processing of the chain can, if necessary, by simple assembly of chain links (see figure) are automatically fair. LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 plus 35V02EN Page 15 of 21 5.2 Impression die stamp Only use impression die stamps from LUMBERG Impression die stamps: free of lubricants and sliding agents. 5.3 Shut heigt dimension of the termination machine An important feature for the correct function of the connector is the connector height, messed 30 min. after assembling. It is determined by the shut height dimension of the termination machine. The height adjustment will be determined max. 30 minutes after the pressing process and must be within the specification. Shut height dimension (standard gauge 5,45) impression die stamp LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing instruction Connector RAST 2.5 plus 35V02EN Page 16 of 21 5.4 Wire end position There must be the correct cable protrusion to guarantee good wire termination in both ID slots of the contact. The stop position of the wire is taken into account when processing and checked with appropriate measures after termination. LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 plus 35V02EN Page 17 of 21 5.5 Wire (stranded wire / flat cable) The cable ends must be cut off without burr deforming. 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. 5.6 Housing No damage of the connector is allowed after termination (visual check). The links must be cut off without burr. burr max. 0,1 LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle 35V02EN Connector RAST 2.5 plus Page 18 of 21 6 Cutting-off coding keys The cutting-off coding keys acc. to RAST 2.5 standard at the termination machine. The allocation of connector, color marking and cutting-off keys are the sole responsibility of the customer. Caution! Connectors, pin headers and guide frames are always marked in mating direction. 6.1 Coding acc. to RAST 2.5 basic connector in mating direction coding 6.2 Cutting blades To ensure a correct cutting-off of the coding keys, use only LUMBERG cutting blades. A minimal remaining burr is permitted (the measures 5,4 mm in the plug-in area must not be exceeded). LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 plus 35V02EN Page 19 of 21 7 Quality assurance For all working 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 of 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 (cable tolerance ±0,1) is guaranteed by the body. 7.5 Cabel quality The cable must meet LUMBERG specification acc. 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. LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle 35V02EN Connector RAST 2.5 plus Page 20 of 21 7.6 Contact insertion depth ID slot area The wire insertion depth is determined by the height of the body. All singles conductors must be in the ID slot area. 7.7 Cable protrusion The cable protrusion acc. to point 5.4 must be kept. Aprotrusion of the cable in the housing leads to an incorrect mating. 7.8 Retention force of the wire Minimal retention force of the wire from the insulation displacement contact: LIYV - stranded wire: 0,38 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 0,38 mm² line. All values were determined under laboratory conditions and serve as a reference. LUMBERG CONNECT GMBH Processing instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 plus 35V02EN Page 21 of 21 7.9 Conatct gap Contact gap after termination. 8 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.