Processing Instruction

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
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Author
Checked
Date
Name
Edition
03.01.2003
Pfaffenbach
Name
Gazke
1
Datum
21.02.2007
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3
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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.