Schaltbau SB Series User manual

Connect - Contact - Control
1
Inhalt
Rundsteckverbinder für Spezialanwendungen, Baureihe SB 2
Besondere Merkmale 2
Applikationen 2
Baureihenübersicht 2
Kompetenz 2
Normen 2
Technische Daten 3
Bestellschlüssel 4
5-polig + PE Flanschstecker, Kabeldose 4
6-polig Flanschdose, Kabelstecker 5
14-polig Flanschstecker, Kabeldose 5
Montage 6
Werkzeuge Ausdrückwerkzeuge AWZ-A und AWZ-C/H, Crimpzange CWZ-600 6
Montagebohrungen 6
Kontakte Stecker: Crimpkontakte, Dosen: Lötkontakte 7
Deratingkurven 7
Sicherheitshinweise 7
ConnectorsConnectors
SB Series
Circular connectors for
special applications
Manual A30-M .en

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SB Series – Connectors
Contents
1. Important Basic Information........................................................3
1.1 Legal Notes .............................................................................3
1.2 Conventions for this Installation
and Maintenance Instructions .................................................3
2. General and Security Information ...............................................4
2.1 Observing the Installation and Maintenance Instructions........4
2.2 User Obligations......................................................................4
2.3 Proper Use ..............................................................................4
2.4 Improper Use...........................................................................5
2.5 A
mbient Conditions.................................................................... 5
3. Dangers and Security Measures .................................................5
3.1 Electrical Dangers ...................................................................5
3.2 Risk of Damage.......................................................................5
4. Description ....................................................................................6
5. Installation.....................................................................................7
5.1 Check Parts for Transport Damage.........................................7
5.2 Preparation of Mounting Holes................................................8
5.3 Details Regarding Solder Contacts – Crimp Contacts ............8
5.4 Connection Solder Contacts....................................................9
5.5 Connection Crimp Contacts ..................................................10
5.6 Assembly of the Contact Insert .............................................12
5.6.1 Assembly at the Construction Site with
Mobile Assembly Pliers ...............................................12
5.6.2 Assembly in the Workshop with Toggle Press.............14
5.7 Assembly of the Connection..................................................16
6. Maintenance ................................................................................17
6.1 Maintenance Intervals ...........................................................17
6.2 Visual Inspection at Each Plugging .......................................18
7. Specications .............................................................................19

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2015-02-04 / V 1.1 SB Series – Connectors
Important Basic Information
This instructions describe the installation and maintenance of the SB
connectors.
Cross references in this instructions are presented in bold italics.
To highlight particularly important safety instructions and other infor-
mation, the following symbols are used in this installation and mainte-
nance instructions:
DANGER
Indicates a hazardous situation with a high level of risk which, if not
avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation with a medium level of risk which, if
not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation with a low level of risk which, if not
avoided, may result in minor or moderate injury.
NOTICE
Indicates a hazardous situation which, if not avoided, may result in
property damage, such as service interruption or damage to equip-
ment or other materials.
Refers to technical features and methods aimed at fa-
cilitating work or to particularly important information.
1.2 Conventions for
this Installation
and Maintenance
Instructions
1. Important Basic Information
Without prior written consent of Schaltbau GmbH, the installation and
maintenance instructions is not allowed to be electronically or mechan-
ically reproduced – as a whole or in parts – be distributed, changed,
transmitted, translated into another language or used in any other way.
Schaltbau GmbH cannot be held liable for damage caused by not ob-
serving (or only partly observing) the Installation and maintenance in-
structions.
1.1 Legal Notes

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General and Security Information
SB Series – Connectors
2. General and Security Information
The connectors described here are part of a low voltage system for spe-
cial applications. They have been designed and checked in accordance
with approved engineering regulations. Electrical equipment can gen-
erally cause severe harm to one’s health and also material damage if
used or operated improperly, or if not maintained sufciently. The main-
tenance and installation instructions for the connectors must therefore
be strictly followed.
Any uncertainties must be claried and all queries must include details
of the type of device and the serial number. The planning and carrying
out of mechanical and electrical installations, transportations, assem-
blies and commissioning as well as maintenance and repair work during
installation, operation and maintenance, must therefore only be carried
out by responsible experts with the appropriate expertise.
This also applies to adherence to the general assembly and security
regulations regarding electric power installations, as well as the correct
use of certied tools. Electrical devices are to be protected, as much as
possible, from dust and moisture during maintenance or storage.
► All staff must read and understand the instructions and adhere to
them when working with the device.
►
Always carefully observe all safety warnings!
2.1 Observing the
Installation and
Maintenance
Instructions
► Observe all applicable national regulations, all safety, injury and envi-
ronmental precautions as well as the recognised technical regulations
with regards to safe and professional work .
► The proper functioning of all available protection and safety de-
vices is to be checked regularly
► Work on electrical devices must only be carried out by experts or by
instructed persons under the guidance and supervision of an expert
according to the electro-technical regulations.
► An expert is a person who can judge and recognise the possi-
ble dangers of the jobs commended to him based on his training,
knowledge and experience and by knowledge of the appropriate
regulations.
► Staff must be informed clearly about who is responsible for the
maintenance of the connectors.
► According to IEC 61984, connectors are components which must
not be plugged or unplugged when voltage is present during inten-
ded use.
2.2 User Obligations
2.3 Proper Use

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2015-02-04 / V 1.1 SB Series – Connectors
Dangers and Security Measures
► The connectors must not be converted or otherwise modied with-
out prior written consent of Schaltbau GmbH. Violations against
this will result in the exclusion of liability on the part of the manu-
facturer.
► None of the operating conditions dened in our catalogue A30.en
in section „Specications“, such as voltages, currents, or ambient
conditions, etc. may be changed.
► Work on the connectors must only be carried out by staff who
meets the requirements set out in these installation and mainte-
nance instructions.
► The bridging of switches or other control devices is prohibited.
NOTICE
The connectors are constructed for specic ambient conditions.
► Use the connectors only under the ambient conditions as
dened in our catalogue A30.en in section „Specications“.
2.4 Improper Use
2.5 A
mbient Conditions
3. Dangers and Security Measures
3.1 Electrical Dangers
DANGER
The connectors contain live voltage components. There is a risk of
electric shock!
Always consider the following safety rules before carrying out work
on the connectors:
► Disconnect.
► Ensure that it is not possible to reconnect unintentionally.
► Make sure that there is no voltage present.
NOTICE
Improper handling of the connectors, e.g. when hitting the oor with
some impact, can result in breakage, cracks and deformation.
► Make sure that the connectors are always used properly.
► Regularly sight-check the connectors for potential damages.
► Immediately replace damaged components.
3.2 Risk of Damage

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Description
SB Series – Connectors
4. Description
Connectors of the SB-series are circular connectors for special
applications. They are particularly designed for operation locations in
rail vehicles, where harsh ambient conditions have to be handled in
daily operation.
The connectors are permanently resistant to harsh weather conditions
as they are equipped with silver plated or gold plated contacts in
rubber sealed contact inserts.
The connectors are typically used for systems and components that
require high reliability and safety. This is why the SB-connectors are,
for instance, used
► as supply line and control cable connectors for train protection
systems installed in bogies of railway vehicles;
► as special connectors for harsh industrial applications.
The connectors of the SB-series have a modular structure and
are available in different versions, each as ange socket with the
corresponding connector.
Overview SB-series – ange sockets and connectors
Number of poles Flange sockets Connectors
5-pole + PE (protective
conductor)
5 + PE pin contact
Solder terminal: silver
5 + PE socket contact
- Solder terminal:silver
- Crimp terminal: silver
6-pole
6x socket contact
Solder terminal: silver or gold
6x pin contact
- Solder terminal: silver or gold
- Crimp terminal: silver or gold
14-pole
14x pin contact
Crimp terminal: silver
14x socket contact
Crimp terminal: silver

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Installation
5. Installation
DANGER
The connectors contain live voltage components. There is a risk of
electric shock!
Always consider the following safety rules before carrying out work
on the connectors:
► Disconnect.
► Ensure that it is not possible to reconnect unintentionally.
► Make sure that there is no voltage present.
NOTICE
During installation, ensure that dirt caused by surrounding construc-
tion activities does not get into the connectors.
NOTICE
If parts are damaged, the functional reliability of the connectors is no
longer given.
► Before installation, check all parts for any possible transport
damage.
► Do not install any damaged parts.
5.1 Check Parts for
Transport Damage

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Installation
SB Series – Connectors
Dimensions
The precise dimensions of the respective connectors and the ange
socket versions are indicated in the respective data sheets or in our
catalogue A30.en.
Mounting holes
For the assembly of the ange socket, a mounting hole as shown in the
drawing below is required.
The ange socket has to be xed with four M5 screws.
Tightening torque: Determined by the user, in consideration of the ma-
terials used for the construction
Length of the screws: In consideration of the assembly situation
The dimensions and the arrangement of the mounting holes are both
shown in the drawing below.
M5 oder Ø5,8 +0,2
38 ±0,1
38 ±0,1
40,2
+0,4
Dimensions and arrangement of the mounting holes (Dimensions in mm)
Version solder contacts
Solder contacts are permanently assembled in the contact insert. The
cable strands can be soldered directly to the pre-assembled contacts.
Version crimp contacts
Crimp contacts are not yet assembled to any component. When as-
sembling the crimp contacts, the cable strands have to be crimped
to the contacts rst. Then, the contacts have to be pressed into the
contact insert.
5.2 Preparation of
Mounting Holes
5.3 Details Regarding
Solder Contacts –
Crimp Contacts

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Installation
Required tools/auxiliary materials
► Soldering tools
► Suitable solder
► Tools for removing insulation
Procedure
► Strip jacket from cable (1) to a length of approx. 45 mm and the
insulation of the stranded wires to approx. 10 mm.
► Thread cable gland (2) (OEM part, not included in the delivery)
and connector shell (3) on the cable (1).
► Solder the cable strands to the contacts (4) on the contact insert.
Make sure that no single strands stick out.
► In the end, check all solder terminals for stable and correct con-
nection.
Connection solder contacts (Dimensions in mm)
► For assembling the contact insert into the connector shell, see
„5.6 Assembly of the contact insert“.
5.4 Connection Solder
Contacts
10
45
3124

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Installation
SB Series – Connectors
(Dimensions in mm)
Required tools/auxiliary materials
► Crimp tool for cross-section of connection 0.14 mm2... 6 mm2
(Ordering code: CWZ-600-1)
► Insertion tools for crimp contacts:
- Insertion tool for pin contacts and socket contacts
B 4,2C 1,5 AG, Pin B 4,2 C 0,75-1 and SZC-1,50-Au Pin
(Ordering code: EWZ-4,2)
- Insertion tool for pin contacts and socket contacts
SAC xxx-AG and BAC-xxx-AG (Ordering code: EWZ-A)
► Tools for removing insulation
5.5 Connection Crimp Contacts
Overview crimp contacts
Number of poles Contact type Ordering
code
Connection
cross section
5-pole + PE
Socket contact for connector
33
Ø 6
Connection
cross section
B 4,2C 1,5 AG 1.5 mm2
6-pole
Pin contact for connector
39
Ø 4.2
Connection
cross section
Pin 4,2 C 0,75-1
SZC-1,50-Au Pin
0.75 ... 1 mm2
1 ... 1.5 mm2
14-pole
Pin contact for ange socket
28.6
Ø
1.58
Ø 3.76
Connection
cross section
SAC-0,50-Ag
SAC-1,00-Ag
SAC-1,50-Ag
SAC-2,50-Ag
0.5 mm2
0.75 ... 1 mm2
1.5 mm2
2.5 mm2
14-pole
Socket contact for connector
28.6
Ø
1.58
Ø
3.76 Connection
cross section
BAC-0,50-Ag
BAC-1,00-Ag
BAC-1,50-Ag
BAC-2,50-Ag
0.5 mm2
0.75 ... 1 mm2
1.5 mm2
2.5 mm2