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

22015-02-04 / V 1.1
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

3
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

42015-02-04 / V 1.1
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

5
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

62015-02-04 / V 1.1
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

7
2015-02-04 / V 1.1 SB Series – Connectors
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

82015-02-04 / V 1.1
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

9
2015-02-04 / V 1.1 SB Series – Connectors
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

10 2015-02-04 / V 1.1
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

11
2015-02-04 / V 1.1 SB Series – Connectors
Installation
Procedure
The connection of the crimp contacts has to be carried out in
accordance with DIN EN 60352-2 – solderless connections.
► Strip jacket from cable (1) to a length of approx. 45 mm and the
insulation of the stranded wires to approx. 8 mm.
► Thread cable gland (2) (OEM part, not included in the delivery)
and connector shell (3) on the cable (1).
► Crimp cable strands with crimp tool to the contacts (4).
– While doing so, consider the cross-sections of the connection,
respective to the version of crimp contacts (see table „Over-
view crimp contacts“).
– The crimping has to be carried out midway between the inspec-
tion hole and the end of the contact (see drawing below).
► Check crimp terminals for stable and correct connection.
– Make sure that no single strands stick out.
– Check extraction forces according to DIN EN 61238-1.
► The crimp contacts have to be inserted in the contact insert
starting in the middle and moving outwards:
While doing so, every single crimp contact (4) has to be pressed
into the contact insert (5) with the insertion tool, until the contact
clearly engages.
The respective data sheets show how far exactly the con-
tacts stick out of the contact insert.
Connection Crimp contacts (Dimensions in mm)
► For assembling the contact insert into the connector shell, see
„5.6 Assembly of the contact insert“.
8
45
Crimping point
5.9
312
4
5

12 2015-02-04 / V 1.1
Installation
SB Series – Connectors
When all the connections have been established on the contacts, the
contact insert has to be pressed into the connector shell. This can be
done either with the mobile assembly pliers – directly on-site at the
construction site – or stationary in the workshop.
5.6.1 Assembly at the Construction Site with Mobile
Assembly Pliers
Required tools/auxiliary materials
► Mobile assembly pliers (A) with mounting mandrel (B)
(Ordering code: EDZ-ST)
► Ethyl alcohol as lubricant
Procedure
► Push the connector shell (D) to the completely wired contact
insert (C).
► Moisten the contact insert (C) on the circumference with ethyl
alcohol.
NOTICE
Lubricants which do not evaporate, cause the contact insert to slip
out of the connector shell.
► Do not use other lubricants, such as greases, oils, etc.
► Do only use ethyl alcohol as lubricant.
DCB
A
Mobile assembly pliers (A) with mounting mandrel (B) to mount the contact
insert (C) into the connector shell (D)
► Set the contact insert (C) onto the connector shell (D) so that the
slots (H) of the contact insert and the guides (H) on the
connector shell are congruent.
Note: The vefold coding (H) prevents improper assembly.
► Manually push the contact insert (C) into the connector shell (D)
as far as possible.
5.6 Assembly of the
Contact Insert
CHD
Slots and guides on the contact
insert and on the connector shell.

13
2015-02-04 / V 1.1 SB Series – Connectors
Installation
► Put the pre-assembled contact insert (C) and the connector shell
(D) with the cable into the assembly pliers.
► Put the mounting mandrel (B) into the holder (G) of the assembly
pliers – As for pin contacts, make sure that the mounting mandrel
is being mounted in correct position in accordance with the
arrangement of the contacts.
► Adjust the locating shoulder of the connector shell (E) so that it
lays rmly on the locating shoulder of the assembly pliers (F).
NOTICE
In order to prevent damages to the components, make sure that
before and during pressing the contact insert,
► the mounting mandrel and the contact insert in the connector
shell are laying on the same press axis;
► the locating shoulder of the connector shell (E) does not lift off
of the locating shoulder of the assembly pliers (F).
BG
FE
E
Inserting the pre-assembled connector into the assembly pliers
► In order to press the contact insert into the connector shell, press
the handles of the assembly pliers several times until the contact
insert (C) completely engages into the connector shell (D).
Contact insert completely pressed into connector shell with assembly
pliers

14 2015-02-04 / V 1.1
Installation
SB Series – Connectors
Check
► Check whether the engage contours (J) of the contact insert (C)
are completely engaged into the connector shell (D), by measu-
ring the distance between the contact tip and the end of the con-
nector shell (target distance 103.2 mm, see drawing on the left).
NOTICE
If the contact insert does not completely engage, it can slip out of the
connector shell during plugging or unplugging.
If the contact insert has not completely engaged:
► Readjust the assembly pliers and press the contact insert with
the mounting mandrel again until the distance between the
contact tip and the end of the connector shell is 103.2 mm.
5.6.2 Assembly in the Workshop with Toggle Press
Required tools/auxiliary materials
► Insertion tool for contact inserts (Ordering code: EWZ-6P)
► Toggle press
► Suitable contact surface for the connector shell with cable recess
► Ethyl alcohol as lubricant
Procedure
► Push the connector shell (D) to the completely wired contact
insert (C).
► Moisten the contact insert (C) on the circumference with ethyl
alcohol.
NOTICE
Lubricants which do not evaporate, cause the contact insert to slip
out of the connector shell.
► Do not use other lubricants, such as greases, oils, etc.
► Do only use ethyl alcohol as lubricant.
J
C D
Engage contours of the contact
insert
103.2
Target distance between contact tip
and the end of the connector shell
EWZ-6P Insertion tool

15
2015-02-04 / V 1.1 SB Series – Connectors
Installation
► Set the contact insert (C) onto the connector shell (D) so that the
slots (H) of the contact insert and the guides (H) on the
connector shell are congruent.
Note: The vefold coding (H) prevents improper assembly.
► Manually push the contact insert (C) into the connector shell (D)
as far as possible.
► Put the connector shell with the cable side onto the prepared
contact surface so that the cable route is guided in the cable
recess without being crushed.
► Clamp the insertion tool into the toggle press – As for pin
contacts, make sure that the insertion tool is being clamped
in correct position in accordance with the arrangement of the
contacts.
NOTICE
In order to prevent damages to the components, make sure that
before and during pressing the contact insert, the insertion tool and
the contact insert in the connector shell are laying on the same press
axis.
► Press the contact insert (C) into the connector shell (D) with the
insertion tool and the toggle press until the contact insert com-
pletely engages.
Check
► Check whether the engage contours (J) of the contact insert (C)
are completely engaged into the connector shell (D), by measu-
ring the distance between the contact tip and the end of the con-
nector shell (target distance 103,2 mm, see drawing on the left).
NOTICE
If the contact insert does not completely engage, it can slip out of the
connector shell during plugging or unplugging.
If the contact insert has not completely engaged:
► Readjust the toggle press and press the contact insert with the
insertion tool again until the distance between the contact tip and
the end of the connector shell is 103,2 mm.
CHD
Slots and guides on the contact
insert and on the connector shell.
J
C D
Engage contours of the contact insert
103.2
Target distance between contact tip
and the end of the connector shell

16 2015-02-04 / V 1.1
Installation
SB Series – Connectors
Required tools/auxiliary materials
► Open-end spanner, AF (across ats) 30 and 46
Procedure
NOTICE
Torsional forces on the contact insert can damage the connector.
► Always use the hexagon AF (across ats) 30 on the connec-
tor shell as counter support when assembly operations could
exert torsional forces on the contact insert.
► Screw in the cable gland (2) (OEM part, not included in the
delivery) into the connector shell (3). While doing so, use
the hexagon AF (across ats) 30 on the connector shell with
the open-end spanner as counter support in order to prevent
torsional forces on the cable strands.
► If necessary, lubricate the thread of the union nut (4) / ange
socket (5).
► In order to establish the connection, plug the connector into the
ange socket (5).
► Screw on and tighten the union nut (4).
Torque: 35 Nm up to max. 40 Nm.
► In the end, check all components for correct connection and tight
seat.
Assembly of the connection
5.7 Assembly of the
Connection
3245
46 30

17
2015-02-04 / V 1.1 SB Series – Connectors
Maintenance
6. Maintenance
Note the expert knowledge which is essential for carrying out mainte-
nance work, mentioned in chapter: „2. General and Security Infor-
mation“.
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.
The following is a list of maintenance work which may be carried out
on the connectors, by a trained specialist.
The state of the connectors is dependent on environmental conditions.
To ensure the correct function and prolonged operational life span of
the connectors, the following checks and maintenance must be per-
formed regularly:
Test / Maintenance Interval
Visual inspection of
-
Connector
-
Cable
- Union nut
- Flange socket
- Contacts
-
Contact insert
► At each plugging
6.1 Maintenance
Intervals

18 2015-02-04 / V 1.1
Maintenance
SB Series – Connectors
At each plugging, the connectors with cable, the ange socket and all
plug contacts and socket contacts have to be visually inspected.
NOTICE
In case of visible damages to cable, connectors, ange socket,
contacts or contact inserts, the functional safety of the connection is
no longer given.
► Immediately replace all damaged components.
6.2 Visual Inspection at
Each Plugging
Connector-element Visual inspection and function check Measures
Connector Check for:
► Ease of movement during plugging
► Dirt
► Visible damages to connector shell,
contacts, contact insert
► Loose or missing fastening elements
In case of defects:
► Remove potential dirt
(abrasion of the contact
surfaces), e.g. with com-
pressed air or a nylon
brush.
► Immediately replace de-
fective components
► Repair the elements
Union nut on the connector Check for:
► Ease of movement of the thread
► Damage to the thread
In case of defects:
► Immediately replace de-
fective components
► If necessary, lubricate the
thread
Flange socket Check for:
► Ease of movement during plugging
► Dirt
► Visible damages to socket shell,
contacts, contact insert
► Loose or missing fastening elements
► Damage to the thread
In case of defects:
► Remove potential dirt
(abrasion of the contact
surfaces), e.g. with com-
pressed air or a nylon
brush.
► Immediately replace de-
fective components
► Repair the elements

19
2015-02-04 / V 1.1 SB Series – Connectors
Specications
7. Specications
Specications and information on the material characteristics for the connectors of the SB-series are given
in our catalogue A30.en.

Schaltbau GmbH
For detailed information on our products
and services visit our website –
or give us a call!
Schaltbau GmbH
Hollerithstrasse 5
81829 Munich
Germany
Phone [phone]
Fax [phone]
Internet www.schaltbau-gmbh.com
e-Mail [email protected]
Connectors
Connectors manufactured to industry standards
Connectors to suit the special requirements of
communications engineering (MIL connectors)
Charging connectors for battery-powered
machines and systems
Connectors for railway engineering,
including UIC connectors
Special connectors to suit customer requirements
Snap-action switches Snap-action switches with positive opening operation
Snap-action switches with self-cleaning contacts
Enabling switches
Special switches to suit customer requirements
Contactors Single and multi-pole DC contactors
High-voltage AC/DC contactors
Contactors for battery powered vehicles and power supplies
Contactors for railway applications
Terminal bolts and fuse holders
DC emergency disconnect switches
Special contactors to suit customer requirements
Electrics for rolling stock Equipment for driver's cab
Equipment for passenger use
High-voltage switchgear
High-voltage heaters
High-voltage roof equipment
Equipment for electric brakes
Design and engineering of train electrics
to customer requirements
Electrical Components and Systems for
Railway Engineering and Industrial Applications
Electrical Components and Systems for
Railway Engineering and Industrial Applications
with compliments:
RoHS
2011/65/EC
S
c
h
a
l
t
b
a
u
Q
u
a
l
i
t
y
y
o
u
c
a
n
c
o
u
n
t
o
n
S
c
h
a
l
t
b
a
u
Q
u
a
l
i
t
y
y
o
u
c
a
n
c
o
u
n
t
o
n
Schaltbau GmbH
manufactures in
compliance
with RoHS.
The production facilities
of Schaltbau GmbH have
been IRIS certied since
2008.
Certied to
DIN  EN  ISO  14001
since 2002. For the most
recent certicate visit
our website.
Certied to
DIN  EN  ISO  9001
since 1994. For the most
recent certicate visit
our website.
Printed in Germany
We reserve the right to make technical alterations without prior notice.
For updated product information visit www.schaltbau-gmbh.com..