LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle 35V01EN Connector RAST 2.5 Page 1 of 23 3510 / 3511 (not illustrated) 3512 / 3513 (not illustrated) Date Name Edition 1 2 3 4 Author 23.09.2003 fs Name str gz sve Fs Checked 19.09.2014 pfa Date 19.04.04 21.02.07 26.07.13 16.09.2014 LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing Instruction Connector RAST 2.5 3515 / 3516 (not illustrated) 3517 / 3518 (not illustrated) 35V01EN Page 2 of 23 LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing Instruction Connector RAST 2.5 3520 / 3522 (not illustrated) 3521 / 3523 (not illustrated) 35V01EN Page 3 of 23 LUMBERG CONNECT GMBH Processing Instruction Connector RAST 2.5 Im Gewerbepark 2 58579 Schalksmühle 35V01EN Page 4 of 23 Alteration Description Edition Alterations carried out 1 5.3 and 7.6: 11-0,15 was 11,5-0,15 2 Change of name and inspection note added. 3 Produkt types 3512/3513 added, Information: “For each number of poles a special die is required” added by type 3517/3518. Processing Insruction with new layout. 4 Added illustration of mechanism for the pull-out force; Added in section 7.10 Electrical testing and information for separating the connecting of links, with image. Modified dimension for the wire end position: from 0.3 mm to 0.6 mm. LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing Instruction Connector RAST 2.5 35V01EN Page 5 of 23 Contents: 1. System features .......................................................................................................................... 6 1.1 Product types ........................................................................................................................... 8 Direct connector 3510............................................................................................................... 9 Direct connector 3511............................................................................................................... 9 Direct connector 3512............................................................................................................. 10 Direct connector 3513............................................................................................................. 10 Direct connector 3515............................................................................................................. 11 Direct connector 3516............................................................................................................. 11 Direct connector 3517............................................................................................................. 11 Direct connector 3518............................................................................................................. 11 Indirect connector 3520 .......................................................................................................... 12 Indirect connector 3522 .......................................................................................................... 12 Indirect connector 3521 .......................................................................................................... 13 Indirect connector 3523 .......................................................................................................... 13 2. Contact principle ....................................................................................................................... 13 3. Application tooling and machines for 3510, 3511, 3512, 3513, 3517, 3518, 3520, 3521, 3522 and 3523 ......................................................................................................................................... 14 4. Cable specification ................................................................................................................... 15 4.1 Cable specifications cross section for connection 0,20...0,22 mm² ......................................... 15 4.2 Cable specifications cross section for connection 0,38mm² .................................................... 15 4.3 Cable specifications cross section for connection 0,35mm² .................................................... 15 4.4 Cable specifications cross section for connection 0,14mm² .................................................... 15 5. Assembly ................................................................................................................................... 16 5.1 Connector feed ....................................................................................................................... 16 5.2 Impression die stamp.............................................................................................................. 17 5.3 Shut height dimension of the termination machine.................................................................. 17 5.4 Wire end position .................................................................................................................... 18 5.5 Wire (stranded wire / flat cable) .............................................................................................. 18 5.6 Housing .................................................................................................................................. 19 6. Cutting-off coding keys ............................................................................................................ 20 6.1 Coding acc. to RAST 2.5 ........................................................................................................ 20 6.2 Cutting blades ........................................................................................................................ 20 7. Quality assurance ..................................................................................................................... 21 7.1 Quality features ...................................................................................................................... 21 7.2 Quality features / IDC ............................................................................................................. 21 7.3 ID slot width ............................................................................................................................ 21 7.4 Symmetry of the ID slot .......................................................................................................... 21 7.5 Cable quality........................................................................................................................... 21 7.6 Contact insertion depth ........................................................................................................... 22 7.7 Cable protrusion ..................................................................................................................... 22 7.8 Retention force of the wire ...................................................................................................... 22 7.9 Contact gap ............................................................................................................................ 23 7.10 Electrical testing .................................................................................................................. 23 8. Storage ...................................................................................................................................... 23 LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 1. System features Two-part body Supplied in following stacks Wire termination Insulation displacement connection by pressing the top Wire exit 90° 35V01EN Page 6 of 23 LUMBERG CONNECT GMBH Processing Instruction 35V01EN Connector RAST 2.5 Im Gewerbepark 2 58579 Schalksmühle Page 7 of 23 The connectors are used with pin headers as indirect connectors or with guide frames as indirect connectors (edge connectors). Connector acc. to RAST 2.5 Pin header Guide frame LUMBERG CONNECT GMBH Processing Instruction Connector RAST 2.5 Im Gewerbepark 2 58579 Schalksmühle 1.1 Product types Direct or indirect connectors in insulation displacement technology (IDT) acc. to Rast 2.5 Material of the connector: PBT PA Connectable wire in insulation displacemnent area for 4A 2....20-pole 351x (-1,-2) 351x (-1,-2) S01 351x (-1,-2) S02 351x (-1,-2) S03 352x (-1,-2) 352x (-1,-2) S01 352x (-1,-2) S02 352x (-1,-2) S03 cross section for connection 0,22mm²....0,38mm² cross section for connection 0,34mm² cross section for connection 0,14mm²….0,22mm² special application, e.g. varnisched wire cross section for connection 0,22mm²....0,38mm² cross section for connection 0,34mm² cross section for connection 0,14mm²….0,22mm² special application, e.g. varnisched wire V = finishing variant max. insulation diameter ∅1,6mm standard design design -1 for bus capable flat cable design -2 for flat cable 35V01EN Page 8 of 23 LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle 35V01EN Connector RAST 2.5 Page 9 of 23 Direct connector 3510 Coding (optional) Partition 2.5mm acc. to spec sheet 3510 01 Positioning (optional) Direct connector 3511 Partition 5mm acc. to spec sheet 3511 01 Coding (optional) Positioning (optional) LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 35V01EN Page 10 of 23 Direct connector 3512 Partition 2.5mm acc. to spec sheet 3512 01 For each number of poles a special die is required Locking Direct connector 3513 Partition 5mm acc. to spec sheet 3513 01 For each number of poles a special die is required Locking LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 35V01EN Page 11 of 23 Direct connector 3515 Partition 2.5mm acc. to spec sheet 3515 01 For each number of poles a special die is required Locking Direct connector 3516 Partition 5mm acc. to spec sheet 3516 01 For each number of poles a special die is required Locking Direct connector 3517 Partition 2.5mm acc. to spec sheet 3517 01 For each number of poles a special die is required Locking LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 35V01EN Page 12 of 23 Direct connector 3518 Partition 5mm acc. to spec sheet 3518 01 For each number of poles a special die is required Verrastung Locking Indirect connector 3520 Partition 2.5mm acc. to spec sheet 3520 01 interior locking Indirect connector 3522 Partition 5mm acc. to spec sheet 3522 01 interior locking LUMBERG CONNECT GMBH Processing Instruction Connector RAST 2.5 Im Gewerbepark 2 58579 Schalksmühle 35V01EN Page 13 of 23 Indirect connector 3521 Partition 2.5mm acc. to spec sheet 3521 01 Indirect connector 3523 Partition 5mm acc. to spec sheet 3523 01 2. Contact principle Insulation displacement connection (test acc. to DIN EN/IEC 60352-4) Contact pin 1,5 mm PCB 1,5mm LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing Instruction Connector RAST 2.5 35V01EN Page 14 of 23 3. Application tooling and machines for 3510, 3511, 3512, 3513, 3517, 3518, 3520, 3521, 3522 and 3523 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. 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 35V01EN Connector RAST 2.5 Page 15 of 23 4. Cable specification The cable specification 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 =0,22mm² 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 0,35mm² Technical specification sheet 908 32 FLR-stranded wire =0,35mm² 4.4 Cable specifications cross section for connection 0,14mm² Technical specification sheet 908… Other approved cable see LUMBERG release list in the internet at www.lumberg.com =0,14mm² LUMBERG CONNECT GMBH Im Gewerbepark 2 58579 Schalksmühle Processing Instruction 35V01EN Connector RAST 2.5 Page 16 of 23 5. Assembly Connector and cross section should be adapted with each other acc. LUMBERG specification (see technical Datasheet). 5.1 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. The cutting-off of the single connector from the stack is done by the machine. The links will remain on the connector. The connection of links typically remain on the connector in this case. These links can be removed if the customer requires it. cut-off lower housing first stack following stacks to the machine LUMBERG CONNECT GMBH Processing Instruction 35V01EN Connector RAST 2.5 Im Gewerbepark 2 58579 Schalksmühle Page 17 of 23 5.2 Impression die stamp Only use impression die stamps from LUMBERG Impression die stamps: free of lubricants and sliding agents. 5.3 Shut height dimension of the termination machine Impression die stamp 11 -0,15 Shut height dimension (standard gauge 5.45) 13,5 -0,1 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. LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 35V01EN Page 18 of 23 5.4 Wire end position The correct position of the wire guarantees the mating of both ID slots. After termination no cable protrusion is allowed at the connector in order to ensure a correct mating and dismating of the connection. The correct position of the wire ensures the mating of both ID slots. The wire insulation may only be removed from the area specified. 5.5 Wire (stranded wire / flat cable) No cuts in the insulation are allowed in wire exit direction (visual check). The cables must be cut off without burr and deformity. 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 35V01EN Connector RAST 2.5 Page 19 of 23 5.6 Housing After termination no visual damages of the housing are allowed (visual check). The links must be cut off without burr. The mating function must be guaranteed (functional test). The contact must be in correct position in the housing (visual check). burr Max. 0,1 Standard burr +0,6 0 Separated of links Make sure that the cut-off links are no longer adhering to the component and that they do not remain in the connector after they are cut off. LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle 35V01EN Connector RAST 2.5 Page 20 of 23 6. Cutting-off coding keys The cutting-off coding keys acc. to RAST 2.5 standard at the termination machine and the allocation of connector, color marking and cutting-off coding 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. LUMBERG CONNECT GMBH Processing Instruction Im Gewerbepark 2 58579 Schalksmühle Connector RAST 2.5 35V01EN Page 21 of 23 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 may 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 the ID slot Cable quality Cable insertion depth Cable protrusion Electrical testing 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 Cable 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 35V01EN Connector RAST 2.5 Page 22 of 23 7.6 Contact insertion depth 11 -0,15 ID slot area The wire insertion depth is determined by the height of the body. All single conductors must be in the ID slot area. 7.7 Cable protrusion The cable protrusion acc. to point 5.4 must be kept. A protrusion 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: PVC – stranded wire: 0,38mm² > 50N. F 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 35V01EN Page 23 of 23 7.9 Contact gap Contact gap after termination. 7.10 Electrical testing Electrical testing shall be performed in accordance with IPC/WHMA-A-620. The nature and extent of the electrical tests (short circuit testing, continuity testing, insulation testing, high voltage testing, etc.) should be specified depending on the application and the processing machine. 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.