Connect - Contact -Control. Charging Connectors LV Series A84.en

Transcription

1 Connect - Contact -Control Charging Connectors LV Series A84.en

2 LV Series charging connectors Competence, innovation and decades of experience Our new LV Series charging connectors represent the consistent further development of our well-established connectors of the LB and LB-L series. LV Series connectors exceed the requirements of standard EN and meet all current demands of manufacturers and users of modern battery-powered machines and systems, such as materials handling and lifting vehicles, vehicle batteries, battery chargers, and backup systems of uninterruptible power supplies. The charging connectors are also available with the option, as patented by Schaltbau, for batteries featuring a commercial electrolyte circulation system. Used with your products, our charging connectors ensure the highest reliability and safety in any application under harsh environmental conditions. Resistant to shock and vibration as well as to the effects of dust, most acids, alkalis and vapours, our charging connectors are designed for daily use and have stood the test millionfold. A wide range of accessories is available. Features LV series Higher ampacity of main contacts Due to the innovative design of the socket contacts there is an increased contact area which allows for higher amperage, reduced temperature rise of contacts, and low contact resistance during continued operation. This results in high contact forces that do not deteriorate over time as well as less wear and tear when mating and unmating. Permanently Constantly high low contact resistanc e contact forces Inc reased High quality contact cont actarea Reduced temperature system with hyperbolic stamped grid rise of contact s Re and cylinder sistant to shock, vibra tion and extremes Long- of temperature Increased ampacity lasting cont act system, free ofwear LV Series: Benefits of innovative design of main contacts Improved resistance to acids and extremes of temperature The housing material, including the handle, is a new thermoplastic which is highly resistant to sulphuric acid of high concentration - exceeding the requirement of standard EN of 1.1 g/cm³ uptotested 1.34 g/cm³. Thematerial makes for the connector's rugged design and suitability for operation with temperatures ranging from -40 C to +110 C. This exceeds the usual range of -5 C to +90 C significantly. Option for electrolyte circulation systems The charging connectors are also available with the option, as patented by Schaltbau, of an air blow-in system passing through both connector halves. This option makes the connector the first choice for use with batteries featuring a commercial electrolyte circulation system. Integrated interlocking There is an interlocking integrated in the connector that allowseasyjoiningandseparatingofthehalvesandensures its reliability even under shock and vibration. LV80, LV10, LV30 Series: Named after the nominal load according to the type specification, the connector series exceeds it byfar. Thus the LV10 Series, for instance, has a maximum amperage of 50 A! This is the result of an innovative contact design. The modular design and intermateability with all commercial connector systems, even with option for electrolyte circulation systems, are further typical features of this connector innovation. Keying to DIN Colour coded keying plugs are used for keying of conventional battery voltages according to DIN : Green for dry-cell batteries, grey for wet-cell batteries, and yellow (universal) for the vehicle plug. They prevent two different colour or voltage coded housings from mating. Modular design The small number of individual components and their intermateability with other connector series allows for an individual and cost-effective realisation of your applications and avoids unnecessary stock items. Intermateable with systems of other manufacturers LV Series connectors outperform the requirements of EN in many respects. Yet they are intermateable with all commercially available charging connectors of comparable design - even with option for electrolyte circulation systems. Standards Electrical equipment, protection against foreign objects, water and contact according to DIN Approved to requirements and tests of charging connectors with reference to EN to ISO/DIS 0898 to DIN UL-listed: C U S

3 3 Specifications LV series Series LV30 LV10 LV80 Rated operating current * 1 Main contacts Pilot contacts 400A 0A 50A 0A 10A 0A Rated voltage 150 V 150 V 150 V Rated operating voltages (for keying) (4 V, 3 V, 48 V, 7 V, 80 V, 9 V) Main contacts, wirecross-section* Number of 5 mm² 35 mm² 50 mm² 70 mm² 95 mm² Main contacts, reducing bushings 5 /1 mm² 50 /5 mm² 50 /35 mm² 70 /50 mm² Pilot contacts, wirecross-section Number of.5 mm² Contact diameter Auxiliary contacts, wirecross-section Number of.5 mm² Contact diameter Cable connection * 3 Main contacts Pilot contacts 4mm 4mm w/ crimping crimping 4mm.3mm w/ crimping crimping.3mm.3mm w/ crimping crimping Degree of protection* 4 (IEC059) IP3 IP3 IP3 Temperature range * 5 (Observe derating curves) Number of mating cycles (in accordance with EN1175-1) Air blow-in system for electrolyte circulation Inside diameter of airtube mm 9 mm* 10 mm* Shells PBT GF30 (free of PBB and PBDE) Integrated interlocking Strain relief Shells, flammability rating Handle, type snap-on handle screw-on handle Handle, colour black / red (for emergencycutout) Standards EN DIN (except air blow-in system) DIN ISO/DIS 0898 Approval -40 C C -40 C C -40 C C > 5,000 > 5,000 > 5,000 UL94-V0 / UL94-V0 / UL94-V0 Description pages, 7 pages 8, 9 pages 10, 11 C US / * 1 For further information about maximum permissible amperage dependent on wire cross-section, type of conductor, and impulse load, see page 14 * For AWG sizes refer to the conversion table on our homepage * 3 For crimping instructions and size of w/ crimping dies see page 14 * 4 IPx3 when mounted horizontally * 5 Temperature range, derating curves, see page 7 (LV30), page 9 (LV10) and page 11 (LV80) respectively * To be connected by means of extra air tube adapter, see page 1

4 4 LV80, LV10, LV30 Ordering code, stock items LVseries Series LV80 LV10 LV30 Keying plug T N U A Example: green, dry-cell battery grey, wet-cell battery yellow (universal), vehicle plug green, grey, yellow* 1, to choose from Main contacts, wire cross-section * P95 P70 P50 P50 P5 S95 S70 S50 S50 S5 LV30 Series Pin, 95 mm² Pin, 70 mm² Pin, 50 mm² LV10 Series Pin, 50 mm² LV80 Series Pin, 5 mm² LV30 Series Socket, 95 mm² Socket, 70 mm² Socket, 50 mm² LV10 Series Socket, 50 mm² LV80 Series Socket, 5 mm² Pilot contacts *3 0 none two pilot contacts Auxiliary contacts 0 none two auxiliary contacts Air blow-in system *3 L0 L1 Handle H0 H1 H H1/S H/S Special variant, online configuring tool LV80-T-S5-0-0-L0-H1 none Air blow-in system for electrolyte circulation none Snap-on handle, black Snap-on handle, red (for emergency cutout) Screw-on handle, incl. screws, black Screw-on handle, incl. screws, red * 1 Yellow keying plug only delivered with charging and vehicle plug * For AWG sizes refer to the conversion table on our homepage: * 3 Please note that there is space only for one adapter in the connector: either the one for the pilot contacts or the one for the connection of the air tube. If you need a special variant of the charging connector, please do not hesitate to contact us. Maybe the type of connector you are looking for is among our manyspecial designs. If not, we can also supply customized designs. In this case, however, minimum ordering quantities apply. Or visit our homepage. Thereis a configuring tool for eachseries you canuseto configure thetype of charging connectoryoureally need. The tables represent our stock items which can be supplied in short delivery time. LV30 Series with main contacts 95 mm² Description Ordering code Batterytype LV30-T-S L0-H1 dry-cell LV30-N-S L0-H1 wet-cell Battery receptacle LV30-N-S L1-H1 wet-cell with ECS** LV30-T-S L0-H0 dry-cell LV30-N-S L0-H0 wet-cell LV30-N-S L1-H0 wet-cell with ECS** LV30-T-P L0-H0 dry-cell Charging plug LV30-N-P L0-H0 wet-cell LV30-N-P L1-H0 wet-cell with ECS** Vehicleplug LV30-U-P L0-H0 dry-cell / wet-cell LV30 Series with main contacts 70 mm² Description Ordering code Batterytype LV30-T-S L0-H1 dry-cell LV30-N-S L0-H1 wet-cell Battery receptacle LV30-N-S L1-H1 wet-cell with ECS** LV30-T-S L0-H0 dry-cell LV30-N-S L0-H0 wet-cell LV30-N-S L1-H0 wet-cell with ECS** LV30-T-P L0-H0 dry-cell Charging plug LV30-N-P L0-H0 wet-cell LV30-N-P L1-H0 wet-cell with ECS** Vehicleplug LV30-U-P L0-H0 dry-cell / wet-cell LV10 Series with main contacts 50 mm² Description Ordering code Batterytype LV10-T-S L0-H1 dry-cell LV10-N-S L0-H1 wet-cell Battery receptacle LV10-N-S L1-H1 wet-cell with ECS** LV10-T-S L0-H0 dry-cell LV10-N-S L0-H0 wet-cell LV10-N-S L1-H0 wet-cell with ECS** LV10-T-P L0-H0 dry-cell Charging plug LV10-N-P L0-H0 wet-cell LV10-N-P L1-H0 wet-cell with ECS** Vehicleplug LV10-U-P L0-H0 dry-cell / wet-cell LV80 Series with main contacts 5 mm² Description Ordering code Batterytype LV80-T-S5-0-0-L0-H1 dry-cell LV80-N-S5-0-0-L0-H1 wet-cell Battery receptacle LV80-N-S5-0-0-L1-H1 wet-cell with ECS** LV80-T-S5-0-0-L0-H0 dry-cell LV80-N-S5-0-0-L0-H0 wet-cell LV80-N-S5-0-0-L1-H0 wet-cell with ECS** LV80-T-P5-0-0-L0-H0 dry-cell Charging plug LV80-N-P5-0-0-L0-H0 wet-cell LV80-N-P5-0-0-L1-H0 wet-cell with ECS** Vehicleplug LV80-U-P5-0-0-L0-H0 dry-cell / wet-cell ** ECS for electrolyte circulation system The complete list of all spare parts and individual components such as reducing bushings, pilot contact sets, and auxiliary contacts you will find on the oppositepage. Cable assembly and accessories For pre-assembled wires, cable assemblies, tools and mounting accessories please refer to pages 1 and 13. Shell Slider Handle (available as snap-on or screw-on handle) Keying plug Samples Order your sample from one of our Schaltbau sales offices in Germany or from one of our international sales partners. You will find our sales offices at: Adapter for * pilot contacts or air blow-in system Auxiliary contacts Maincontacts Charging plug or vehicle plug, front view

5 5 LV80, LV10, LV30 Individual componets, spare parts LV LVseries Series b a a 1b Item Identification Orderingcode Description 1a 1b Plug shell Receptacleshell LV80Series LV10Series LV30Series LV80 G-P LV10 G-P LV30 G-P LV80G-SP LV10 G-SP LV30G-SP LV80G-SL LV10G-SL LV30G-SL Shell to enclose pin contacts Rec. shell with pre-assembled item 10a Receptacle shell with added item 15a Slider LV80S LV10S LV30S interlocks main contacts (LV30 also auxiliary contacts) 3 Clamp LV80D LV10/30 D x for strainrelief 4 Screw forclamp SC3.5x1 SC3.5x a 10 b Keying plug, Main contact, (socket) Main contact, (pin) green grey yello w 95mm² 70mm² 50mm² 5mm² 95mm² 70mm² 50mm² 5mm² Reducing bushing, 70/50 50/35 50/5 5/1 8 Aux. contact,.5mm² (socket) 9 Aux. contact,.5mm² (pin) Pilot contact adapter (socket) Pilot contact adapter (pin) 11 Pilot contact,.5mm² (socket) 1 Pilot contact,.5mm² (pin) LV80 Tgn LV80 Ngr LV80Uge LV80S/5 LV80P/5 LVRH5/1 LV10 S8.5/50 LV10P8.5/50 LVRH50/35 LVRH50/5 SC 3.5x5 (95 mm²) SC3.5x19 (70/50 mm²) LV10/30 Tgn LV10/30 Ngr LV10/30 Uge LV30 S10/95 LB30L S10/70 LB30L S10/50 LV30 P10/95 LV30 P10/70 LV30P10/50 LVRH70/50 x self-tapping screw for strain relief clamp, tightening torque 1.5 Nm max. for dry-cell batteries for wet-cell batteries universal for vehicleplug x main contact for battery receptacle x main contact for charging plug or vehicleplug 70 mm² down to 50 mm² 50 mm² down to 35 mm² 50 mm² down to 5 mm² 5 mm² down to 1 mm² LV80BBC-.5-Ag LV10BBC-.5-Ag LV30BCC-.5-Ag x auxiliary contact for battery receptacle LV80SBC-.5-Ag LV10SBC-.5-Ag LV30SCC-.5-Ag x auxiliary contact for charging plug or vehicleplug LV80PA-S LV10/30 PA-S Pilot contact adapter for socket contacts LV80PA-P LV10/30 PA-P Pilot contact adapter for pin contacts LV80BBC-.5-Ag BCC-.5-Ag x pilot contact for battery receptacle LV80SBC-.5-Ag SCC-.5-Ag x pilot contact for charging plug or vehicleplug 13 Pilot contact set (socket) LV80P-S/S LV10/30 P-S/S Set, including items 10a, Pilot contact set (pin) LV80P-P/S LV10/30 P-P/S Set,including items 10b, 1 15a Air tubeadapter (receptacle) 15b Spacer (receptacle) 1 Air tubeadapter (plug) 17 Handle LV, blac LV80H1 LV80H k (snap-on handle) red Handle LV, blac LV80 H1/S LV80H/S k (screw-on handle) red Extra air tubeadapter LV80/10/30 V-S / LV80/10/30 V-S /10 LV80LV-S LV10/30 LV-S for air tube with inside Ø mm LV80DS-L LV10/30 DS-L Spacer for securing air tube adapter (item 15a) in receptacle shell (item 1b) LV80LV-P LV10/30 LV-P for air tube with inside Ø mm LV10/30 H1 LV10/30 H LV10/30 H1/S LV10/30 H/S Snap-on handle for receptacle or plug shell Screw-on handle for receptacle or plug shell, set including screws for air tube with inside Ø mm for air tube with inside Ø mm

6 Ø.5 Ø LV30 Features LV30 series Rated operating current: Main contacts 400A Pilot/aux. contacts 0A Rated voltage: 150 V DC Rugged, fiber glass reinforced shells: Resistant to 1.34 g/cm³ sulphuric acid Temperature range -40 C C Resistant to shock and vibration due to interlocking Intermateable with connectors of other manufacturers Keying to DIN EN : Voltage keying: 4 / 3 / 48 / 7 / 80 / 9 V DC Different keying plugs for dry-cell and wet-cell batteries Universal keying plug for vehicle plug Contacts: Slotted socket contacts, same as in LB-L Series; pin contacts: cold-heading die (E-Cu), silver plated; w/ crimping Can be retrofitted with pilot and/or auxiliary contacts max., screw-machined, silver plated; crimping LV30 Series: Charging connector with option for electrolyte circulation Dimension diagrams Charging plug / vehicle plug, battery rece ptacle LV30 series Charging plug / vehicle plug with snap-on handle Charging plug / vehicle plug with screw-on handle Handle optional LV10/30 H1 or LV10/30 H Handle optional LV10/30 H1/S or LV10/30 H/S Battery receptacle with snap-on handle Ø.5 Battery receptacle with screw-on handle Ø.5 Handle optional LV10/30 H1 or LV10/30 H Handle optional LV10/30 H1/S or LV10/30 H/S

7 Ø A Ø B Current (A) Ø A Ø B Current (A) Ø A Ø B 7 LV30 P10/xx, LV30 S10/xx Main contacts, reducing bushings LV30 series Main contacts for charging plug / vehicle plug Maximum current carrying capacity curves LV30 L1 Ordering code Wirecross-section* 1 L1 ØA ØB LV30 P10/95* 95 mm² LV30 P10/70 70 mm² LV30 P10/50 50 mm² /95 10/70 10/ Ambient temperature ( C) Main contacts for battery receptacle, slotted *3 L Ordering code Wirecross-section* 1 L1 ØA ØB LV30 S10/95* 95 mm² LB30L S10/70 70 mm² LB30L S10/50 50 mm² * 1 For AWG sizes refer to the conversion table on our homepage: Derating curves LV30 (according to IEC 051-3, test 5b) 10/95 10/70 10/ Ambient temperature ( C) Please refer to the crimping and assembly instructions on page 14. The values shown in the diagram of the maximum current carrying capacity are only valid for w/ crimping. W/ crimping is required for our main contacts. * Dimensional deviation at termination of 95 mm² wire * 3 We recommend regreasing of the socket contacts with e.g. Cramolin Paste or any comparable product after 500 mating cycles at a time, in order to ensure 5,000 cycles of mechanical operation at a constant low contact resistance Reducing bushings for main contacts For connecting wires with smaller cross-sections reducing bushings are available reducing 70 mm² down to 50 mm². L3 Ordering code Rated operating current with reducing bushing L3 ØA ØB LV RH-70/50 50A Example LV RH-70/50 Reducing bushing 70 mm² 50 mm² Note: The use of reducing bushings has no bearing on the derating and maximum current carrying capacity curves. Reduced scale diagrams / dimensions in mm

8 LV10 Features LV10series Rated operating current: Main contacts 50A Pilot/aux. contacts 0A Rated voltage: 150 V DC Rugged, fiber glass reinforced shells: Resistant to 1.34 g/cm³ sulphuric acid Temperature range -40 C C Resistant to shock and vibration due to interlocking Intermateable with connectors of other manufacturers Keying to DIN EN : Voltage keying: 4 / 3 / 48 / 7 / 80 / 9 V DC Different keying plugs for dry-cell and wet-cell batteries Universal keying plug for vehicle plug Contacts: Socket contacts featuring hyperbolic stamped grid made of BeCu for increased amperage; pin contacts: coldheading die (E-Cu), silver plated; w/ crimping Can be retrofitted with pilot and/or auxiliary contacts max., screw-machined, silver plated; crimping LV10 Series: Charging connector with option for electrolyte circulation Dimension diagrams Charging plug / vehicle plug, battery rece ptacle LV10series Charging plug / vehicle plug with snap-on handle Ø.5 Charging plug / vehicle plug with screw-on handle Ø.5 Handle optional LV10/30 H1 or LV10/30 H Handle optional LV10/30 H1/S or LV10/30 H/S DC Battery receptacle with snap-on handle Ø.5 Battery receptacle with screw-on handle Ø.5 Handle optional LV10/30 H1 or LV10/30 H Handle optional LV10/30 H1/S or LV10/30 H/S

9 Ø A Ø B Current (A) Ø A Ø B Current (A) Ø A Ø B 9 LV10 P8.5/50, LV10 S8.5/50 Main contacts, reducing bushings LV10series Main contacts for charging plug / vehicle plug L1 Ordering code Wirecross-section* L1 ØA ØB LV10 P8.5/50 50 mm² Maximum current carrying capacity curves LV10* 8.5/50 8.5/50 + RH-50/35 8.5/50 + RH-50/ Ambient temperature ( C) Main contacts for battery receptacle L Ordering code Wirecross-section* L1 ØA ØB LV10 S8.5/50 50 mm² * For AWG sizes refer to the conversion table on our homepage: Reducing bushings for main contacts Derating curves LV10* (according to IEC 051-3, test 5b) 8.5/50 8.5/50 + RH-50/35 8.5/50 + RH-50/ Ambient temperature ( C) Please refer to the crimping and assembly instructions on page 14. The values shown in the diagram of the maximum current carrying capacity are only valid for w/ crimping. W/ crimping is required for our main contacts. For connecting wires with smaller cross-sections reducing bushings are available reducing 50 mm² down to 35 mm² and 5 mm² respectively. L3 Ordering code Rated operating current with reducing bushing L3 ØA ØB LV RH-50/35 00A LV RH-50/5 10A Example Reducing bushing 50 mm² 35 mm² / 5 mm² LV RH-50/35 Note: The use of reducing bushings has no bearing on the derating and maximum current carrying capacity curves. Reduced scale diagrams / dimensions in mm

10 LV80 Features LV80 series Rated operating current: Main contacts 10A Pilot/aux. contacts 0A Rated voltage: 150 V DC Rugged, fiber glass reinforced shells: Resistant to 1.34 g/cm³ sulphuric acid Temperature range -40 C C Resistant to shock and vibration due to interlocking Intermateable with connectors of other manufacturers Keying to DIN EN : Voltage keying: 4 / 3 / 48 / 7 / 80 / 9 V DC Different keying plugs for dry-cell and wet-cell batteries Universal keying plug for vehicle plug Contacts: Socket contacts featuring hyperbolic stamped grid made of BeCu for increased amperage; pin contacts: coldheading die (E-Cu), silver plated; w/ crimping Can be retrofitted with pilot and/or auxiliary contacts max., screw-machined, silver plated; crimping LV80 Series: Charging connector with adapter for pilot contacts Dimension diagrams Charging plug / vehicle plug, battery rece ptacle LV80 series Charging plug / vehicle plug with snap-on handle Charging plug / vehicle plug with screw-on handle Ø.4 Handleoptional LV80 H1 or LV80 H 9 39 Ø.4 Handleoptional LV80 H1/S or LV80 H/S Battery receptacle with snap-on handle Battery receptacle with screw-on handle Ø.4 Handleoptional LV80 H1 or LV80 H 9 39 Ø.4 Handleoptional LV80 H1/S or LV80 H/S

11 Ø A Ø B Current (A) Ø A Ø B Current (A) Ø A Ø B 11 LV80 P/5, LV80 S/5 Main contacts, reducing bushings LV80 series Main contacts for charging plug / vehicle plug L1 Ordering code Wirecross-section* L1 ØA ØB LV80P/5 5 mm² Maximum current carrying capacity curves LV /5 /5 + RH-5/ Ambient temperature ( C) Main contacts for battery receptacle L Ordering code Wirecross-section* L1 ØA ØB LV80S/5 5 mm² * For AWG sizes refer to the conversion table on our homepage: Derating curves LV80 (according to IEC 051-3, test 5b) 40 /5 /5 + RH-5/ Ambient temperature ( C) Reducing bushings for main contacts Please refer to the crimping and assembly instructions on page 14. The values shown in the diagram of the maximum current carrying capacity are only valid for w/ crimping. W/ crimping is required for our main contacts. For connecting wires with smaller cross-sections reducing bushings are available reducing 5 mm² down to 1 mm². L3 Ordering code Rated operating current with reducing bushing L3 ØA ØB LV RH-5/1 15A Example LV RH-5/1 Reducing bushing 5 mm² 1 mm² Note: The use of reducing bushings has no bearing on the derating and maximum current carrying capacity curves. Reduced scale diagrams / dimensions in mm

12 1 Pre-assembled cables LV series Do you need assembled connectors? If so, do not hesitate to contact us! On request we supply receptacles and plugs assembled complete with cables of different lengths and cross-sections, and with a variety of cable terminal ends for the battery to suit your requirements. Schaltbau guarantees a constant high quality of the assembled connector. LV80, LV10 or LV30 Series Battery terminal conductor 'Flex' Battery terminal conductor 'Perfect' Charging plug, vehicle plug Battery terminal conductor with calbe lug Battery receptacle Pre-assembled cables: Schaltbau supplies pre-assembled battery terminal conductors of different lengths and cross-sections to meet your requirements. Features Pre-assembled cables LVseries Stock item cables and battery terminal conductors: Welding cables with rubber jackets according to DIN VDE 08-, e.g. H01N-D Frötek Perfect battery terminal conductor Frötek Flex battery terminal conductor Wire cross-section*: mm² Connection: Main contacts: Pilot /aux. contacts Strain relief: w/ crimping crimping All cables are secured against stress and strain by the strain relief clamp integrated in the plug and receptacle shell of the connector. * For AWG sizes refer to the conversion table on our homepage: Marking of cables: Red shrink tube Blue shrink tube - terminal - terminal Product named on rubber jacket of cable Air passage for electrolyte circulation: Air tube with inside diameter mm, wall thickness 1.5 mm, Shore 73 hardness. For tubes with other inside diameter or wall thickness we recommend our extra air tube adapters (see page 1). Quality assurance: DIN EN ISO 9001:000 EN ISO 14001:199 Minimum ordering quantities: Aminimum quantity of 50 applies for orders directly from Schaltbau. For orders below that minimum quantity we can recommend an authorized manufacturing and sales partner in your vicinity.

13 Ø Ø 13 Extra air tube adapter Accessories The extra air tube adapter becomes necessary when air tubes are used with: inside Ø mm inside Ø mm and thicker walls. LV80LV-S LV80LV-P LV10/30 LV-S LV10/30 LV-P Fig. 1 Airtube Air tube inside Ø mm Ordering code Extra air tube adapter Fig. LV80/10/30 V-S/ for mm air tubes with greater 1 wall thickness LV80/10/30 V-S/10 from mm to 10 mm LV80LV-S LV80LV-P LV10/30 LV-S LV10/30 LV-P Fig. Airtube Air tube inside Ø mm Stocko WHPH 10 Crimp tools, extracting tools Accessories Stocko WHPH 10 Crimp tool for main contacts The applicable standard for crimping of main contacts is IEC 035- Solderless crimped connections - General requirements, test methods and practical guidance. Schaltbau requires w/ crimping of the main contacts. Crimp tool WHPH 10: For that purpose Schaltbau recommends the use of hand tool WHPH 10 and for major quantities the hydraulic crimping heads WHK 8S, WHK 8 or WHK 9 respectively of the company Stocko (or comparable tools of other manufacturers). Crimp tool Stocko WHPH10 for the main contacts CWZ-00 Crimp tool mm² (AWG9... AWG9) for pilot and auxiliary contacts The applicable standard for crimping the main contacts is IEC 035- Solderless crimped connections - General requirements, test methods and practical guidance. Crimp tool CWZ-00: Schaltbau recommends the use of crimp tool CWZ-00. Crimping of the pilot contacts is done by means of a set of dies for wire gauge AWG 13 (.5 mm²). For that purpose, slide crimp ferrule of contact (pin or socket) over the stripped wire until it shows in the inspection hole. Feed the contact with the inserted wire in the crimp tool as far as it will go. Close the tool handles beyond the lock-in position. Crimp tool CWZ-00 for both pilot and auxiliary contacts AWZ-C/H Extraction tool for pilot and auxiliary contacts Series Type of contact Extraction tool LV80 LV10 LV30 Pilot contacts LV80 BBC-.5-Ag LV80SBC-.5-Ag Aux. contacts LV80 BBC-.5-Ag LV80SBC-.5-Ag Pilot contacts BCC-.5-Ag SCC-.5-Ag Aux. contacts LV10 BBC-.5-Ag LV10 SBC-.5-Ag Pilot contacts BCC-.5-Ag SCC-.5-Ag Aux. contacts LV30 BCC-.5-Ag LV30 SCC-.5-Ag * 1 LV30 Series auxiliary contacts are secured from falling out of the shell by means of the slider. Reduced scale diagrams / dimensions in mm LV80AWZ-B AWZ-C/H LV10 AWZ-B AWZ-C/H * 1 Extraction tool AWZ-C/H for pilot contacts LV10, LV30 Extraction tool LV10 AWZ-B for auxiliarycontacts Extraction tool LV80AWZ-B for pilot and auxiliary contacts

14 14 Main contacts Crimping instructions LVseries Applicable standard The applicable standard for crimping of the main contacts is IEC 035- Solderless crimped connections. Contact resistance With w/ crimping, done according to the rules, contact resistance of crimped contact in new condition ranges between 10 and 90 μω - depending on the cross-sectional area of the conductor. Permissible conventional thermal current Only rubber insulated conductors may be used (harmonized welding cables with rubber jackets according to DIN VDE 08-, e.g. H01N-D). In accordance with DIN EN these conductors may carry currents of 1.1-fold or 1.37-fold maximum capacity. Crimping of main contacts Only w/ crimping ensures a sufficient deformation. W/ crimping causes only low oxidation during operation and results in permanently low contact resistance and, for this reason, a low self-heating of crimped contacts carrying high currents. Crimp tools and size of dies Schaltbau recommends the use of the hand tool WHPH 10 and for major quantities the hydraulic crimping heads WHK 8S, WHK 8 or WHK 9 respectively of the company Stocko (or comparable tools of other manufacturers). For the right size of dies please refer to the opposite table. Temperature range, derating curves Temperature ranges between -40 C and +110 C in consideration of the max. current carrying capacity curves (base curve) and the revised max. current carrying capacity curves of the continuous operating range, the derating curves according to IEC 051-3, test 5b. The derating curve with correction factor 0.8 In (base curve) is, therefore, valid for currents which may continuously and not intermittently flow through the main contacts of the charging connector, with pilot contacts simultaneously carrying currents of 0 A, without exceeding the upper limiting temperature of +110 C. Size of dies (Stocko WHPH10, WHK, WHK9) for w/ crimping Wirecrosssection* Reducin g bushing Size of dies with # embossed in Anvil Indentor 1 mm² LV RH5/ mm² LV RH50/ mm² LV RH50/ mm² LV RH70/ mm² mm² * For AWG sizes refer to the conversion table on our homepage: Pilot and auxiliary contacts Crimping instructions LVseries Applicable standard The applicable standard for crimping the pilot and auxiliary contacts is IEC 035- Solderless crimped connections - General requirements, test methods and practical guidance. Crimp tool Schaltbau recommends the use of crimp tool CWZ-00. (See also previous page) Crimping of pilot and auxiliary contacts Crimping of pilot and auxiliary contacts is done bymeans of a set of dies for wire gauge.5 mm². For that purpose, slide crimp ferrule of contact (pin or socket) over the stripped wire until it shows in the inspection hole. Feed the contact with the inserted wire in the crimp tool as far as it will go. Close the tool handles beyond the lock-in position. Maximum current carrying capacity dependent on wire gauge LV series The following table informs about the maximum current carrying capacity dependent on wire gauge. Main contacts must be w/ crimped. In addition to that, please strictly observe the maximum current carrying capacity and derating curves of the respective charging connector. Wire cross-section* Reducing bushing LV80 LV10 LV30 95 mm² 380A* 70 mm² 30A 50 mm² LV RH-70/50 used with LV30 50A 50A 35 mm² LV RH-50/35 used with LV10 00A 5 mm² LV RH-50/5 used with LV10 10A 10A 1 mm² LV RH-5/1 used with LV80 15A

15 15 Assembly instructions LV series a b 8 7 Assembly of main contacts: Use the recommended tools to crimp main contacts (item 1) to welding cables. Important: Please observe information for proper crimping as mentioned in our master catalogue. See also page 1. Mark and cable terminal end by using red and blue shrink tube respectively. Insert main contacts (item 1) including crimped cables into contact cavities (item ) of the shell as far as it will go. Note: Mind polarity marking for and cable on plug and receptacle shell (item ). Assembly of pilot/auxiliary contacts: Use the tools as recommended by Schaltbau to crimp pilot contacts (item 7) and auxiliary contacts (item ) respectively to signal cables. See also page 1. Insert auxiliary contacts (item ) includingcrimpedcablesinto the contactcavities ofthe shell (item ) until lockedin place, so they cannotbe pulled out. Note concerning LV30: Here the auxiliary contacts are secured from falling out of the shell by means of the slider (item 9). Adapter for pilot contacts or air blow-in system: Assembly of pilot contact adapter: Insert pin pilot contacts (item 7) including crimped cables into adapter for pilot contacts (item 8) until locked in place, so they cannot be pulled out. After that insert pilot contact adapter (item 8) into the shell (item ) until locked in place, so the adapter cannot be pulled out. There is a preassembled pilot contact adapter (item 8) in the receptacle shell (item ). Insert socket pilot contacts (item 7) with crimped cables into adapter (item 8) until locked in place, so they cannot be pulled out. Note: For accommodating socket contacts (item 7) a pilot contact adapter (item 8) is pre-assembled in the receptacle (item ). Assembly of air tube adapter: Pushairtube(insidediameter mm) ontoadapter(item 3a / 3b) as far as possible. The receptacle shell always comes with an added air tube adapter and spacer (item 11). For air tubes with a larger inside diameter use the extra adapter (see page 1). Insert air tube adapter into the shell (item ) until locked in place, so it cannot be pulled out. Assembly of keying plug: Insert keying plug for voltage keying (item 4) from front to back into plug/receptacle shell (item ) until locked in place, so the nominal voltage of the battery shows in the inspection hole. Important note: Keying plugs for charging plug and vehicle plug respectively must show the same voltage keying as the battery receptacle. With LV80 Series connectors mount keying plug (item 4) prior to slider (item 9). Caution! Wornor damagedkeying plugs in the mating area must be replaced. Assembly of shell: Insert slider (item 9) for arresting the main contacts into shell (item ) until locked in place. Note: Slightly pull at welding cables to check whether the main contacts rest in place. After the assembly of the main contacts, we recommend mating of theconnectorhalvesbeforetighteningthestrainreliefscrews. This ensures an ideal concentricity of the main contacts. See also page 1. Screw-connect the upper and lower halves of the strain relief clamp (item 5), so that the cables are best protected against stress and strain. Tightening torque 1.5 Nm max. Use appropriate crosstip screwdriver. Cable diameter may be between 17 mm max. and 9 mm min. - the draw-off force 00 N per cable. Use cable ties for strain relief to fix cables of pilot/auxiliary contacts to main cables. The same can be done with the air tube as used with options for electrolyte circulation systems. Snap-onhandle: Placehandle(item 10) overprovidedmounting holes and snap it on until locked in place. LV10 and LV30 snap-on handles can be additionally fixed by means of two extra screws (tightening torque 0.5 Nm max.). Alternatively, screw-onhandlesarealsoavailabe. Thetightening torque for the screws is.0 Nm. Use appropriate crosstip screwdriver.

16 1 Assembly details LV series Mating and unmating forces In order to ensure easy engaging and disconnecting the mating and unmating forces should remain within normal range (150 N max.). Note: Tominimize torsion forces in the cable: adjust both main contacts evenly in the shell (see left-hand diagram) align crimp points in parallel to bearing surface of cable lug; this is particularly important in case of short cables where there is not muchroom for manoeuvre (see right-hand diagram). By observing the instructions mentioned above optimal mating and unmating forces can be achieved. Shell-side assembly of main contacts After the assembly of the main contacts, we recommend mating of the connector halves before tightening the strain relief screws. This ensures an ideal concentricity of the main contacts. See also page 15. Bearing surface (here: at cable lug) Main contacts with w/ crimp points Maincontact (here: socket contact) Cable (e.g. H01N-D) Battery terminal end (here: cable lug) Even adjustment of main contacts in plug/receptacle shell improves mating and unmating forces Mounting of plug or receptacle shell For mounting the plug or receptacle shell of LV10 and LV30 Series connectors onto materials handling vehicles or equipment use M screws with Ø.4 mm Parallel alignment of crimp points of main contacts and cable lugs to bearing surface washers (according to DIN 134). For LV80 Series connectors use M pan head and socket head screws (according to DIN 91) without washers. Tightening torque 3 Nm max. Safety instructions LV series Disconnecting when live or under load Disconnecting the connector when live or under load is generallyonlypermittedunderexceptionalcircumstances or in the case of imminent danger to operational safety according to EN Optional auxiliary contacts are available for switching off the load before disengaging the connector and switching on the load after engaging the connector, respectively. If the charging connector is used without auxiliary contacts thelifeofthemaincontactscanbeconsiderablyshortened becauseofcontactweldingwhenengagingordisengaging the connector. When unmating the connector when live or under load, an arc is generated. That is why disconnecting under load is prohibited in the neighbourhood of explosives and other ignition sources. LV80/10/30 Series: Inverse-polarity protection Inverse-polarity protection guaranteed when engaging connectors of the same LV Series In order to guarantee inverse-polarity protection the LV80/10/30 Series must always be fitted with a pilot contact adapter or an air tube adapter when intended for intermating with existing connectors of comparable design made by other manufacturers. Schaltbau, therefore, delivers LV80/10/30 Series stock items (see page 4) generally with a pilot contact adapter pre-assembled in the receptacle shell or an added air tube adapter with connectors for electrolyte circulation systems! Visual inspections Be sure to make visual inspections regularly. Improper handling of the connector, e.g. when hitting the floor with some impact, can result in breakage, visible cracks and deformation. Defective and/or leaky parts must be replaced instantaneously!

17 17 Keying LV series Keying Schaltbau charging connectors feature keying to DIN Keying plugs of different colours with markings of six different standard battery voltages from 4 V to 9 V prevent mating with the wrong voltage or battery type. Types ofkeying Application keying: This type of keying only allows for mating of connector halves for the same battery type. Thus a battery receptacle for dry-cell batteries is only intermateable with the plug of the charging station for dry-cell batteries. Voltage keying: There are six standard battery voltages to choose from: 4, 3, 48, 7, 80, 9 V. The voltages are marked on the sides of the hexagonal keying plug. The keyed voltage shows in the inspection hole of the plug and receptacle shell. LV Series: Keying plugs for wet-cell battery / charging station (grey), vehicle plug (yellow), and dry-cell battery / charging station (green) Application keying for 4 V rated operating voltage Keying receptacle shell Battery green: dry-cell battery `T Dry-cell battery `T Wet-cell battery `N grey: wet-cell battery `N Front view receptacle shell Keying plug shell Charging station green for charging station dry-cell battery `T Cross section of implemented 4 V keying when mated grey for charging station wet-cell battery `N Front view plug shell Front view plug shell Keying plug shell Materials handling vehicle yellow: universal `U Charging station dry-cell battery `T Materials handling vehicle `U Charging station wet-cell battery `N Voltage keying LV80, LV10 or LV30 Series Pin Socket Application keying LV80Ngr, LV10/30 Ngr Voltage keying Implementedin Receptacl e shell Plug shell Application keying Keying plug for Plug shell Charging station wet-cell battery «N» Battery receptacle Wet-cell battery «N» LV80Tgn, LV10/30 Tgn Plug shell Charging station dry-cell battery «T» Battery receptacle Dry-cell battery «T» LV80Uge, LV10/30 Uge Plug shell Vehicle plug (universal) «U» Battery receptacle

18 18 RoHS 00/95/EC Schaltbau GmbH manufactures i n compliance with RoHS. The LV Series connectors are RoHS compliant. Schaltbau GmbH has an environment management system that has been certified since 00. Schaltbau GmbH has a quality management system that has been certified since Electrical Components and Systems for Railway Engineering and IndustrialApplications Connectors Snap-action switches Contactors Electrics for rolling stock 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 with positive opening operation Snap-action switches with self-cleaning contacts Enabling switches Special switches to suit customer requirements Single and multipole 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 stop switches Special contactors to suit customer requirements 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 Schaltbau GmbH Hollerithstrasse München Germany Phone Fax Internet A184/091/ contact@schaltbau.de Printed ingermany withcompliments: We reserve the right to make technical alterations withoutprior notice. For updated product information visit Issued1-009