EW – 35 Processing Instruction LUMBERG CONNECT GMBH 354 V 01 EN Pin header / chassis pin header in insulation displacement technique Page 1 of 15 3541 / 3542 3545 / 3546 EW 1 QM 1 PT/PP 1 VK-PMO 1 QWS2 1 EW-L 1 M1 1 M2K 1 PO 1 Author Checked Date Name Edition 03.01.2003 Pfaffenbach Name Gazke 1 Datum 21.02.2007 2 3 4 5 6 7 8 EW – 35 LUMBERG CONNECT GMBH Processing Instruction Pin header / chassis pin header in insulation displacement technique Alteration Description Edition 1 Alterations carried out Change of name and inspection note added. 354 V 01 DE Page 2 of 15 EW – 35 LUMBERG CONNECT GMBH Processing Instruction Pin header / chassis pin header in insulation displacement technique 354 V 01 DE Page 3 of 15 Contents: 1 System features ............................................................................................. 4 1.1 Product types ...........................................................................................................6 2 Contact principle ............................................................................................ 7 3 Application tooling and machines ................................................................ 8 3.1 Tools .........................................................................................................................8 3.1.1 Hand press KHP 354...........................................................................................8 3.2 Machines ..................................................................................................................8 3.2.1 Semi-automatic termination machine HA 354.................................................8 3.2.2 Fully-automatic termination machine basis type Varicon 6000 ......................8 4 Cable specification ......................................................................................... 9 4.1 Cable specifications cross section for connection 0,20...0,22 mm²........................9 4.2 Cable specifications cross section for connection 0,38mm²...................................9 4.3 Cable specifications cross section for connection 0,50mm²...................................9 5 Assembly ...................................................................................................... 10 5.1 Pin header feed......................................................................................................10 5.2 Cutting clearance...................................................................................................10 5.3 Termination head ..................................................................................................10 5.4 Shut height dimension of the termination machine and contact pins...............11 5.5 Cable protrusion ....................................................................................................11 5.6 Cable.......................................................................................................................12 5.7 Housing ..................................................................................................................12 6 Coding according to RAST2,5 ...................................................................... 13 7 Quality assurance ......................................................................................... 14 7.1 Quality features .....................................................................................................14 7.2 Quality features / IDC ............................................................................................14 7.2.1 ID sloth width ..................................................................................................14 7.2.2 Symmetry of the ID slot...................................................................................14 7.2.3 Cable quality ....................................................................................................14 7.2.4 Contact insertion depth ..................................................................................15 7.2.5 Cable protrusion ..............................................................................................15 7.3 Retention force of the wire ..................................................................................15 EW – 35 LUMBERG CONNECT GMBH Processing Instruction Pin header / chassis pin header in insulation displacement technique 1 System features One-piece body Delivered in bar stock carriers Wire termination Insulation displacement connection by pressing the contacts Wire exit 90° 90° 354 V 01 DE Page 4 of 15 EW – 35 LUMBERG CONNECT GMBH Processing Instruction Pin header / chassis pin header in insulation displacement technique Connector according to RAST2,5 Pin header Chassis pin header 354 V 01 DE Page 5 of 15 EW – 35 LUMBERG CONNECT GMBH Processing Instruction Pin header / chassis pin header in insulation displacement technique 1.1 Product types Pin headers in insulation displacement technique (IDT) pitch 2,5mm for 4A 2....12-pole 354x 354x..S01 cross section for connection 0,22mm²....0,38mm² cross section for connection 0,34mm² (7-wire) max. insulation diameter ∅1,65mm 354x-1 S01 cross section for connection 0,50mm² max. insulation diameter ∅2,20mm Pin header 3541 Partition 2,5mm acc. to spec sheet 3541 01 Pin header 3542 Partition 5mm acc. to spec sheet 3542 01 354 V 01 DE Page 6 of 15 EW – 35 LUMBERG CONNECT GMBH Processing Instruction Pin header / chassis pin header in insulation displacement technique Pin header 3545 Partition 2,5mm acc. to spec sheet 3545 01 Pin header 3546 Partition 5mm acc. to spec sheet 3546 01 2 Contact principle Insulation displacement connection (test according to DIN EN/IEC 60352-4) 354 V 01 DE Page 7 of 15 EW – 35 LUMBERG CONNECT GMBH Processing Instruction Pin header / chassis pin header in insulation displacement technique 354 V 01 DE Page 8 of 15 3 Application tooling and machines 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 Hand press KHP 354 For cost-effective termination of single wires or ribbon cables. For single and small series. 3.2 Machines 3.2.1 Semi-automatic termination machine HA 354 For cost-effective termination of single wires or ribbon cables to automatic-feed connectors with process monitoring through stop position control for series manufacture. 3.2.2 Fully-automatic termination machine basis type Varicon 6000 Termination of connections with multiple cable pulling and automatic magazine bar feed. After termination an electric continuity check and a short circuit test is carried out. According to the test results the connectors are sorted. For large-scale industrial series production. EW – 35 LUMBERG CONNECT GMBH Processing Instruction Pin header / chassis pin header in insulation displacement technique 354 V 01 DE Page 9 of 15 4 Cable specification The cable specifications must be kept. Any deviation must be discussed and approved by LUMBERG. 4.1 Cable specifications cross section for connection 0,20...0,22 mm² Technical specification sheet 902 01 flat cable Technical specification sheet 902 03 flat cable Technical specification sheet 902 04 flat cable =0,20mm² =0,22mm² =0,22mm 4.2 Cable specifications cross section for connection 0,38mm² Technical specification sheet 908 14 PVC-stranded wire =0,38mm² 4.3 Cable specifications cross section for connection 0,50mm² Technical specification sheet 908 15 PVC-stranded wire Other cables see Lumberg – release list. =0,50mm² EW – 35 LUMBERG CONNECT GMBH Processing Instruction Pin header / chassis pin header in insulation displacement technique 354 V 01 DE Page 10 of 15 5 Assembly The cables are mated with the contact equipped connectors. 5.1 Pin header feed Depending on the kind of delivery the pin header feed is as follows: • to the hand press The as bulk material delivered pin headers are put in the hand press by hand. • to the machine The as bar stock carrier of transparent PVC delivered pin headers are fed to the termination machine. 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 Termination head according to Lumberg specification. 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. Termination head must be free from lubricants. surface polished measured in mating direction Processing Instruction Pin header / chassis pin header in insulation displacement technique 354 V 01 DE Page 11 of 15 5.4 Shut height dimension of the termination machine and contact pins An essential feature for the function of the pin header is the contact pin height after the termination. This is determined by the shut height dimension at the termination head. Depending on the used pin header and cable an adjustment of the shut height dimension could be required in order to keep the contact pin height. Termination head Shut height dimension (standard gauge 2,75) EW – 35 LUMBERG CONNECT GMBH Support 5.5 Cable protrusion There must be the correct cable protrusion to guarantee good wire termination in the ID slots. After termination the cable protrusion must be visually checked. If touching EW – 35 LUMBERG CONNECT GMBH Processing Instruction Pin header / chassis pin header in insulation displacement technique 354 V 01 DE Page 12 of 15 5.6 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. Flat cables must be punched out. 5.7 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). The contact insertion height must be kept (dimensional inspection). EW – 35 LUMBERG CONNECT GMBH Processing Instruction Pin header / chassis pin header in insulation displacement technique 354 V 01 DE Page 13 of 15 6 Coding according to RAST2,5 Basic plug in mating direction Coding openings EW – 35 LUMBERG CONNECT GMBH Processing Instruction Pin header / chassis pin header in insulation displacement technique 354 V 01 DE Page 14 of 15 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 sloth 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 specifications according to point 4.1, 4.2 and 4.3. Customized cables, which are listed in the release lists, have to correspond with the available specification sheets. Processing Instruction Pin header / chassis pin header in insulation displacement technique 354 V 01 DE Page 15 of 15 7.2.4 Contact insertion depth The cable insertion depth must be kept, it determines the position of the conductors in the ID slot area. All single conductors must be in the ID slot area. ID slot area EW – 35 LUMBERG CONNECT GMBH 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. 7.3 Retention force of the wire Minimal retention force of the wire: PVC – stranded wire: 0,38mm² > 50N.