Connect - Contact - Control. Charging Connectors LV Series A 84.en

Transcription

1 Connect - Contact - Contro Charging Connectors LV Series A 84.en

2 LV Series charging connectors Competence, innovation and decades of experience Our new LV Series charging connectors represent the consistent further deveopment of our we-estabished connectors of the LB and LB-L series. LV Series connectors exceed the requirements of standard EN and meet a current demands of manufacturers and users of modern battery-powered machines and systems, such as materias handing and ifting vehices, vehice batteries, battery chargers, and backup systems of uninterruptibe power suppies. The charging connectors are aso avaiabe with the option, as patented by Schatbau, for batteries featuring a commercia eectroyte circuation system. Used with your products, our charging connectors ensure the highest reiabiity and safety in any appication under harsh environmenta conditions. Resistant to shock and vibration as we as to the effects of dust, most acids, akais and vapours, our charging connectors are designed for daiy use and have stood the test miionfod. A wide range of accessories is avaiabe. Features Higher ampacity of main contacts Due to the innovative design of the socket contacts there is an increased contact area which aows for higher amperage, reduced temperature rise of contacts, and ow contact resistance during continued operation. This resuts in high contact forces that do not deteriorate over time as we as ess wear and tear when mating and unmating. Permanenty ow contact resistance Reduced temperature rise of contacts Increased ampacity Constanty high contact forces High quaity contact system with hyperboic stamped grid and cyinder Longasting contact system, free of wear Increased contact area Resistant to shock, vibration and extremes of temperature LV Series: Benefits of innovative design of main contacts Improved resistance to acids and extremes of temperature The housing materia, incuding the hande, is a new thermopastic which is highy resistant to suphuric acid of high concentration - exceeding the requirement of standard EN of 1.1 g/cm³ up to tested 1.34 g/cm³. The materia makes for the connector's rugged design and suitabiity for operation with temperatures ranging from -40 C to +110 C. This exceeds the usua range of -5 C to +90 C significanty. Option for eectroyte circuation systems The charging connectors are aso avaiabe with the option, as patented by Schatbau, of an air bow-in system passing through both connector haves. This option makes the connector the first choice for use with batteries featuring a commercia eectroyte circuation system. Integrated interocking There is an interocking integrated in the connector that aows easy joining and separating of the haves and ensures its reiabiity even under shock and vibration. LV80, LV160, LV30 Series: Named after the nomina oad according to the type specification, the connector series exceeds it by far. Thus the LV160 Series, for instance, has a maximum amperage of 50 A! This is the resut of an innovative contact design. The moduar design and intermateabiity with a commercia connector systems, even with option for eectroyte circuation systems, are further typica features of this connector innovation. Keying to DIN Coour coded keying pugs are used for keying of conventiona battery votages according to DIN : Green for dry-ce batteries, grey for wet-ce batteries, and yeow (universa) for the vehice pug. They prevent two different coour or votage coded housings from mating. Moduar design The sma number of individua components and their intermateabiity with other connector series aows for an individua and cost-effective reaisation of your appications and avoids unnecessary stock items. Intermateabe with systems of other manufacturers LV Series connectors outperform the requirements of EN in many respects. Yet they are intermateabe with a commerciay avaiabe charging connectors of comparabe design - even with option for eectroyte circuation systems. Standards Eectrica 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-isted: C US

3 3 Specifications Series LV 30 LV160 LV80 Rated operating current * 1 Main contacts Piot contacts 400 A 0 A 50 A 0 A 160 A 0 A Rated votage 150 V 150 V 150 V Rated operating votages (for keying) (4 V, 36 V, 48 V, 7 V, 80 V, 96 V) Main contacts, wire cross-section* Number of 5 mm² 35 mm² 50 mm² 70 mm² 95 mm² Main contacts, reducing bushings 5 / 16 mm² 50 / 5 mm² 50 / 35 mm² 70 / 50 mm² Piot contacts, wire cross-section Number of.5 mm² Contact diameter Auxiiary contacts, wire cross-section Number of.5 mm² Contact diameter Cabe connection * 3 Main contacts Piot contacts 4 mm 4 mm w/ crimping crimping 4 mm.3 mm w/ crimping crimping.3 mm.3 mm w/ crimping crimping Degree of protection* 4 (IEC 6059) IP3 IP3 IP3 Temperature range * 5 (Observe derating curves) Number of mating cyces (in accordance with EN ) Air bow-in system for eectroyte circuation Inside diameter of air tube 6 mm 9 mm* 6 10 mm* 6 Shes PBT GF30 (free of PBB and PBDE) Integrated interocking Strain reief Shes, fammabiity rating Hande, type snap-on hande screw-on hande Hande, coour back / red (for emergency cutout) Standards EN DIN (except air bow-in system) DIN ISO/DIS 0898 Approva -40 C C -40 C C -40 C C > 5,000 > 5,000 > 5,000 UL 94-V0 / UL 94-V0 / UL 94-V0 Description pages 6, 7 pages 8, 9 pages 10, 11 C US / * 1 For further information about maximum permissibe amperage dependent on wire cross-section, type of conductor, and impuse oad, see page 14 * For AWG sizes refer to the conversion tabe on our homepage * 3 For crimping instructions and size of w/ crimping dies see page 14 * 4 IPx3 when mounted horizontay * 5 Temperature range, derating curves, see page 7 (LV30), page 9 (LV160) and page 11 (LV80) respectivey * 6 To be connected by means of extra air tube adapter, see page 16

4 4 LV80, LV160, LV30 Ordering code, stock items Exampe: Specia variant, onine configuring too LV80-T-S5-0-0-L0-H1 Series LV80 LV160 LV30 Keying pug T green, dry-ce battery N grey, wet-ce battery U yeow (universa), vehice pug A green, grey, yeow* 1, to choose from Main contacts, wire cross-section * LV30 Series P95 Pin, 95 mm² P70 Pin, 70 mm² P50 Pin, 50 mm² LV160 Series P50 Pin, 50 mm² LV80 Series P5 Pin, 5 mm² LV30 Series S95 Socket, 95 mm² S70 Socket, 70 mm² S50 Socket, 50 mm² LV160 Series S50 Socket, 50 mm² LV80 Series S5 Socket, 5 mm² Piot contacts *3 0 none two piot contacts Auxiiary contacts 0 none two auxiiary contacts Air bow-in system *3 L0 none L1 Air bow-in system for eectroyte circuation Hande H0 none H1 Snap-on hande, back H Snap-on hande, red (for emergency cutout) H1/S Screw-on hande, inc. screws, back H/S Screw-on hande, inc. screws, red * 1 Yeow keying pug ony deivered with charging and vehice pug * For AWG sizes refer to the conversion tabe on our homepage: * 3 Pease note that there is space ony for one adapter in the connector: either the one for the piot contacts or the one for the connection of the air tube. If you need a specia variant of the charging connector, pease do not hesitate to contact us. Maybe the type of connector you are ooking for is among our many specia designs. If not, we can aso suppy customized designs. In this case, however, minimum ordering quantities appy. Or visit our home page. There is a configuring too for each series you can use to configure the type of charging connector you reay need. The tabes represent our stock items which can be suppied in short deivery time. LV30 Series with main contacts 95 mm² Description Ordering code Battery type LV30-T-S L0-H1 dry-ce LV30-N-S L0-H1 wet-ce Battery receptace LV30-N-S L1-H1 wet-ce with ECS** LV30-T-S L0-H0 dry-ce LV30-N-S L0-H0 wet-ce LV30-N-S L1-H0 wet-ce with ECS** LV30-T-P L0-H0 dry-ce Charging pug LV30-N-P L0-H0 wet-ce LV30-N-P L1-H0 wet-ce with ECS** Vehice pug LV30-U-P L0-H0 dry-ce / wet-ce LV30 Series with main contacts 70 mm² Description Ordering code Battery type LV30-T-S L0-H1 dry-ce LV30-N-S L0-H1 wet-ce Battery receptace LV30-N-S L1-H1 wet-ce with ECS** LV30-T-S L0-H0 dry-ce LV30-N-S L0-H0 wet-ce LV30-N-S L1-H0 wet-ce with ECS** LV30-T-P L0-H0 dry-ce Charging pug LV30-N-P L0-H0 wet-ce LV30-N-P L1-H0 wet-ce with ECS** Vehice pug LV30-U-P L0-H0 dry-ce / wet-ce LV160 Series with main contacts 50 mm² Description Ordering code Battery type LV160-T-S L0-H1 dry-ce LV160-N-S L0-H1 wet-ce Battery receptace LV160-N-S L1-H1 wet-ce with ECS** LV160-T-S L0-H0 dry-ce LV160-N-S L0-H0 wet-ce LV160-N-S L1-H0 wet-ce with ECS** LV160-T-P L0-H0 dry-ce Charging pug LV160-N-P L0-H0 wet-ce LV160-N-P L1-H0 wet-ce with ECS** Vehice pug LV160-U-P L0-H0 dry-ce / wet-ce LV80 Series with main contacts 5 mm² Description Ordering code Battery type LV80-T-S5-0-0-L0-H1 dry-ce LV80-N-S5-0-0-L0-H1 wet-ce Battery receptace LV80-N-S5-0-0-L1-H1 wet-ce with ECS** LV80-T-S5-0-0-L0-H0 dry-ce LV80-N-S5-0-0-L0-H0 wet-ce LV80-N-S5-0-0-L1-H0 wet-ce with ECS** LV80-T-P5-0-0-L0-H0 dry-ce Charging pug LV80-N-P5-0-0-L0-H0 wet-ce LV80-N-P5-0-0-L1-H0 wet-ce with ECS** Vehice pug LV80-U-P5-0-0-L0-H0 dry-ce / wet-ce ** ECS for eectroyte circuation system The compete ist of a spare parts and individua components such as reducing bushings, piot contact sets, and auxiiary contacts you wi find on the opposite page. Cabe assemby and accessories For pre-assembed wires, cabe assembies, toos and mounting accessories pease refer to pages 1 and 13. She Sider Hande (avaiabe as snap-on or screw-on hande) Keying pug Sampes Order your sampe from one of our Schatbau saes offices in Germany or from one of our internationa saes partners. You wi find our saes offices at: Adapter for * piot contacts or air bow-in system Auxiiary contacts Main contacts Charging pug or vehice pug, front view

5 5 LV80, LV160, LV30 Individua componets, spare parts LV LV Series series b a a 1b Item 1a 1b Identification Pug she Receptace she Ordering code LV80 Series LV160 Series LV30 Series LV80 G-P LV80 G-SP LV80 G-SL LV160 G-P LV160 G-SP LV160 G-SL LV30 G-P LV30 G-SP LV30 G-SL Sider LV80 S LV160 S LV30 S Description 3 Camp LV80 D LV160/30 D x for strain reief 4 Screw for camp SC 3.5x16 SC 3.5x a 10b 11 1 Keying pug, Main contact, (socket) Main contact, (pin) green grey yeow 95 mm² 70 mm² 50 mm² 5 mm² 95 mm² 70 mm² 50 mm² 5 mm² Reducing bushing, 70/50 50/35 50/5 5/16 Aux. contact,.5 mm² (socket) Aux. contact,.5 mm² (pin) Piot contact adapter (socket) Piot contact adapter (pin) Piot contact, (socket) Piot contact, (pin).5 mm².5 mm² LV80 Tgn LV80 Ngr LV80 Uge LV80 S6/5 LV80 P6/5 LV RH5/16 LV160 S8.5/50 LV160 P8.5/50 LV RH50/35 LV RH50/5 SC 3.5x5 (95 mm²) SC 3.5x19 (70/50 mm²) LV160/30 Tgn LV160/30 Ngr LV160/30 Uge LV30 S10/95 LB30L S10/70 LB30L S10/50 LV30 P10/95 LV30 P10/70 LV30 P10/50 LV RH70/50 She to encose pin contacts Rec. she with pre-assembed item 10a Receptace she with added item 15a interocks main contacts (LV30 aso auxiiary contacts) x sef-tapping screw for strain reief camp, tightening torque 1.5 Nm max. for dry-ce batteries for wet-ce batteries universa for vehice pug x main contact for battery receptace x main contact for charging pug or vehice pug 70 mm² down to 50 mm² 50 mm² down to 35 mm² 50 mm² down to 5 mm² 5 mm² down to 16 mm² LV80 BBC-.5-Ag LV160 BBC-.5-Ag LV30 BCC-.5-Ag x auxiiary contact for battery receptace LV80 SBC-.5-Ag LV160 SBC-.5-Ag LV30 SCC-.5-Ag LV80 PA-S LV80 PA-P LV160/30 PA-S LV160/30 PA-P x auxiiary contact for charging pug or vehice pug Piot contact adapter for socket contacts Piot contact adapter for pin contacts LV80 BBC-.5-Ag BCC-.5-Ag x piot contact for battery receptace LV80 SBC-.5-Ag SCC-.5-Ag x piot contact for charging pug or vehice pug 13 Piot contact set (socket) LV80 P-S/S LV160/30 P-S/S Set, incuding items 10a, Piot contact set (pin) LV80 P-P/S LV160/30 P-P/S Set,incuding items 10b, 1 15a 15b Air tube adapter (receptace) Spacer (receptace) Air tube adapter (pug) Hande LV, (snap-on hande) Hande LV, (screw-on hande) Extra air tube adapter back red back red LV80 LV-S LV160/30 LV-S for air tube with inside Ø 6 mm LV80 DS-L LV160/30 DS-L Spacer for securing air tube adapter (item 15a) in receptace she (item 1b) LV80 LV-P LV160/30 LV-P for air tube with inside Ø 6 mm LV80 H1 LV80 H LV80 H1/S LV80 H/S LV160/30 H1 LV160/30 H LV160/30 H1/S LV160/30 H/S LV80/160/30 V-S 6/6 LV80/160/30 V-S 6/10 Snap-on hande for receptace or pug she Screw-on hande for receptace or pug she, set incuding screws for air tube with inside Ø 6 mm for air tube with inside Ø mm

6 6 LV30 Features Rated operating current: Main contacts 400 A Piot/aux. contacts 0 A Rated votage: 150 V DC Rugged, fiber gass reinforced shes: Resistant to 1.34 g/cm³ suphuric acid Temperature range -40 C C Resistant to shock and vibration due to interocking Intermateabe with connectors of other manufacturers Keying to DIN EN : Votage keying: 4 / 36 / 48 / 7 / 80 / 96 V DC Different keying pugs for dry-ce and wet-ce batteries Universa keying pug for vehice pug Contacts: Sotted socket contacts, same as in LB-L Series; pin contacts: cod-heading die (E-Cu), siver pated; w/ crimping Can be retrofitted with piot and/or auxiiary contacts max., screw-machined, siver pated; crimping LV30 series LV30 Series: Charging connector with option for eectroyte circuation Dimension diagrams Charging pug / vehice pug, battery receptace LV30 series Charging pug / vehice pug with snap-on hande Ø6.65 Charging pug / vehice pug with screw-on hande Ø Hande optiona LV160/30 H1 or LV160/30 H 41.5 Hande optiona LV160/30 H1/S or LV160/30 H/S Battery receptace with snap-on hande Ø6.65 Battery receptace with screw-on hande Ø Hande optiona LV160/30 H1 or LV160/30 H Hande optiona LV160/30 H1/S or LV160/30 H/S

7 7 LV30 P10/xx, LV30 S10/xx Main contacts, reducing bushings LV30 series Main contacts for charging pug / vehice pug Maximum current carrying capacity curves LV30 Ø A Ø B L1 Ordering code Wire cross-section* 1 L1 ØA ØB LV30 P10/95* 95 mm² LV30 P10/70 70 mm² LV30 P10/50 50 mm² Current (A) /95 10/70 10/ Ambient temperature ( C) Main contacts for battery receptace, sotted *3 Ø A Ø B L Ordering code Wire cross-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 tabe on our homepage: Current (A) Derating curves LV30 (according to IEC , test 5b) 10/95 10/70 10/ Ambient temperature ( C) Pease refer to the crimping and assemby instructions on page 14. The vaues shown in the diagram of the maximum current carrying capacity are ony vaid for w/ crimping. W/ crimping is required for our main contacts. * Dimensiona deviation at termination of 95 mm² wire * 3 We recommend regreasing of the socket contacts with e.g. Cramoin Paste or any comparabe product after 500 mating cyces at a time, in order to ensure 5,000 cyces of mechanica operation at a constant ow contact resistance Reducing bushings for main contacts For connecting wires with smaer cross-sections reducing bushings are avaiabe reducing 70 mm² down to 50 mm². L3 Ø A Ø B Ordering code Rated operating current with reducing bushing L3 ØA ØB LV RH-70/50 50 A Exampe 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 scae diagrams / dimensions in mm

8 8 LV160 Features LV160 series Rated operating current: Main contacts 50 A Piot/aux. contacts 0 A Rated votage: 150 V DC Rugged, fiber gass reinforced shes: Resistant to 1.34 g/cm³ suphuric acid Temperature range -40 C C Resistant to shock and vibration due to interocking Intermateabe with connectors of other manufacturers Keying to DIN EN : Votage keying: 4 / 36 / 48 / 7 / 80 / 96 V DC Different keying pugs for dry-ce and wet-ce batteries Universa keying pug for vehice pug Contacts: Socket contacts featuring hyperboic stamped grid made of BeCu for increased amperage; pin contacts: codheading die (E-Cu), siver pated; w/ crimping Can be retrofitted with piot and/or auxiiary contacts max., screw-machined, siver pated; crimping LV160 Series: Charging connector with option for eectroyte circuation Dimension diagrams Charging pug / vehice pug, battery receptace LV160 series Charging pug / vehice pug with snap-on hande Ø6.65 Charging pug / vehice pug with screw-on hande Ø Hande optiona LV160/30 H1 or LV160/30 H Hande optiona LV160/30 H1/S or LV160/30 H/S 60 IP3 160A 150V DC IP3 160A 150V DC Ø6.65 Ø Battery receptace with snap-on hande Battery receptace with screw-on hande 34 Hande optiona LV160/30 H1 or LV160/30 H 34 Hande optiona LV160/30 H1/S or LV160/30 H/S A 150V DC A 150V DC

9 9 LV160 P8.5/50, LV160 S8.5/50 Main contacts, reducing bushings LV160 series Main contacts for charging pug / vehice pug Ø A Ø B L1 Ordering code Wire cross-section* L1 ØA ØB LV160 P8.5/50 50 mm² Current (A) Maximum current carrying capacity curves LV160* /50 8.5/50 + RH- 50/35 8.5/50 + RH- 50/ Ambient temperature ( C) Main contacts for battery receptace Ø A Ø B L Ordering code Wire cross-section* L1 ØA ØB LV160 S8.5/50 50 mm² * For AWG sizes refer to the conversion tabe on our homepage: Reducing bushings for main contacts Current (A) Derating curves LV160* (according to IEC , test 5b) /50 8.5/50 + RH- 50/35 8.5/50 + RH- 50/ Ambient temperature ( C) Pease refer to the crimping and assemby instructions on page 14. The vaues shown in the diagram of the maximum current carrying capacity are ony vaid for w/ crimping. W/ crimping is required for our main contacts. For connecting wires with smaer cross-sections reducing bushings are avaiabe reducing 50 mm² down to 35 mm² and 5 mm² respectivey. L3 Ø A Ø B Ordering code Rated operating current with reducing bushing L3 ØA ØB LV RH-50/35 00 A LV RH-50/5 160 A Exampe 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 scae diagrams / dimensions in mm

10 10 LV80 Features LV80 series Rated operating current: Main contacts 160 A Piot/aux. contacts 0 A Rated votage: 150 V DC Rugged, fiber gass reinforced shes: Resistant to 1.34 g/cm³ suphuric acid Temperature range -40 C C Resistant to shock and vibration due to interocking Intermateabe with connectors of other manufacturers Keying to DIN EN : Votage keying: 4 / 36 / 48 / 7 / 80 / 96 V DC Different keying pugs for dry-ce and wet-ce batteries Universa keying pug for vehice pug Contacts: Socket contacts featuring hyperboic stamped grid made of BeCu for increased amperage; pin contacts: codheading die (E-Cu), siver pated; w/ crimping Can be retrofitted with piot and/or auxiiary contacts max., screw-machined, siver pated; crimping LV80 Series: Charging connector with adapter for piot contacts Dimension diagrams Charging pug / vehice pug, battery receptace LV80 series Charging pug / vehice pug with snap-on hande Charging pug / vehice pug with screw-on hande Ø6.4 Hande optiona LV80 H1 or LV80 H Ø6.4 Hande optiona LV80 H1/S or LV80 H/S Battery receptace with snap-on hande Battery receptace with screw-on hande Ø6.4 Hande optiona LV80 H1 or LV80 H Ø6.4 Hande optiona LV80 H1/S or LV80 H/S

11 11 LV80 P6/5, LV80 S6/5 Main contacts, reducing bushings LV80 series Main contacts for charging pug / vehice pug Ø A Ø B L1 Ordering code Wire cross-section* L1 ØA ØB LV80 P6/5 5 mm² Current (A) Maximum current carrying capacity curves LV /5 6/5 + RH-5/ Ambient temperature ( C) Main contacts for battery receptace Ø A Ø B L Ordering code Wire cross-section* L1 ØA ØB LV80 S6/5 5 mm² * For AWG sizes refer to the conversion tabe on our homepage: Current (A) Derating curves LV80 (according to IEC , test 5b) 6/5 6/5 + RH-5/ Ambient temperature ( C) Reducing bushings for main contacts Pease refer to the crimping and assemby instructions on page 14. The vaues shown in the diagram of the maximum current carrying capacity are ony vaid for w/ crimping. W/ crimping is required for our main contacts. For connecting wires with smaer cross-sections reducing bushings are avaiabe reducing 5 mm² down to 16 mm². L3 Ø A Ø B Ordering code Rated operating current with reducing bushing L3 ØA ØB LV RH-5/16 15 A Exampe LV RH-5/16 Reducing bushing 5 mm² 16 mm² Note: The use of reducing bushings has no bearing on the derating and maximum current carrying capacity curves. Reduced scae diagrams / dimensions in mm

12 1 Pre-assembed cabes Do you need assembed connectors? If so, do not hesitate to contact us! On request we suppy receptaces and pugs assembed compete with cabes of different engths and cross-sections, and with a variety of cabe termina ends for the battery to suit your requirements. Schatbau guarantees a constant high quaity of the assembed connector. LV80, LV160 or LV30 Series Battery termina conductor 'Fex' Battery termina conductor 'Perfect' Charging pug, vehice pug Battery termina conductor with cabe ug Battery receptace Pre-assembed cabes: Schatbau suppies pre-assembed battery termina conductors of different engths and cross-sections to meet your requirements. Features Pre-assembed cabes Stock item cabes and battery termina conductors: Weding cabes with rubber jackets according to DIN VDE 08-6, e.g. H01N-D Frötek Perfect battery termina conductor Frötek Fex battery termina conductor Wire cross-section*: mm² Connection: Main contacts: Piot /aux. contacts Strain reief: w/ crimping crimping A cabes are secured against stress and strain by the strain reief camp integrated in the pug and receptace she of the connector. * For AWG sizes refer to the conversion tabe on our homepage: Marking of cabes: Red shrink tube Bue shrink tube - termina - termina Product named on rubber jacket of cabe Air passage for eectroyte circuation: Air tube with inside diameter 6 mm, wa thickness 1.5 mm, Shore 73 hardness. For tubes with other inside diameter or wa thickness we recommend our extra air tube adapters (see page 16). Quaity assurance: DIN EN ISO 9001:000 EN ISO 14001:1996 Minimum ordering quantities: A minimum quantity of 50 appies for orders directy from Schatbau. For orders beow that minimum quantity we can recommend an authorized manufacturing and saes partner in your vicinity.

13 13 Extra air tube adapter Accessories The extra air tube adapter becomes necessary when air tubes are used with: inside Ø mm inside Ø 6 mm and thicker was. LV80 LV-S LV80 LV-P LV160/30 LV-S LV160/30 LV-P Fig. 1 Ø6 Air tube Air tube inside Ø 6 mm Ordering code Extra air tube adapter Fig. LV80/160/30 V-S 6/6 for 6 mm air tubes with greater 1 wa thickness LV80/160/30 V-S 6/10 from 6 mm to 10 mm LV80 LV-S LV80 LV-P LV160/30 LV-S LV160/30 LV-P Fig. Ø6 Air tube Air tube inside Ø mm Stocko WHPH 10 Crimp toos, extracting toos Accessories Stocko WHPH 10 Crimp too for main contacts The appicabe standard for crimping of main contacts is IEC Soderess crimped connections - Genera requirements, test methods and practica guidance. Schatbau requires w/ crimping of the main contacts. Crimp too WHPH 10: For that purpose Schatbau recommends the use of hand too WHPH 10 and for major quantities the hydrauic crimping heads WHK 8S, WHK 8 or WHK 9 respectivey of the company Stocko (or comparabe toos of other manufacturers). Crimp too Stocko WHPH 10 for the main contacts CWZ-600 Crimp too mm² (AWG9... AWG9) for piot and auxiiary contacts The appicabe standard for crimping the main contacts is IEC Soderess crimped connections - Genera requirements, test methods and practica guidance. Crimp too CWZ-600: Schatbau recommends the use of crimp too CWZ-600. Crimping of the piot contacts is done by means of a set of dies for wire gauge AWG 13 (.5 mm²). For that purpose, side crimp ferrue of contact (pin or socket) over the stripped wire unti it shows in the inspection hoe. Feed the contact with the inserted wire in the crimp too as far as it wi go. Cose the too handes beyond the ock-in position. Crimp too CWZ-600 for both piot and auxiiary contacts AWZ-C/H Extraction too for piot and auxiiary contacts Series Type of contact Extraction too Piot contacts LV80 BBC-.5-Ag LV80 SBC-.5-Ag LV80 Aux. contacts LV80 BBC-.5-Ag LV80 SBC-.5-Ag Piot contacts BCC-.5-Ag SCC-.5-Ag LV160 Aux. contacts LV160 BBC-.5-Ag LV160 SBC-.5-Ag Piot contacts BCC-.5-Ag SCC-.5-Ag LV30 Aux. contacts LV30 BCC-.5-Ag LV30 SCC-.5-Ag * 1 LV30 Series auxiiary contacts are secured from faing out of the she by means of the sider. Reduced scae diagrams / dimensions in mm LV80 AWZ-B AWZ-C/H LV160 AWZ-B AWZ-C/H * 1 Extraction too AWZ-C/H for piot contacts LV160, LV30 Extraction too LV160 AWZ-B for auxiiary contacts Extraction too LV80 AWZ-B for piot and auxiiary contacts

14 14 Main contacts Crimping instructions Appicabe standard The appicabe standard for crimping of the main contacts is IEC Soderess crimped connections. Contact resistance With w/ crimping, done according to the rues, contact resistance of crimped contact in new condition ranges between 10 and 90 μω - depending on the cross-sectiona area of the conductor. Permissibe conventiona therma current Ony rubber insuated conductors may be used (harmonized weding cabes with rubber jackets according to DIN VDE 08-6, e.g. H01N-D). In accordance with DIN EN these conductors may carry currents of 1.1-fod or 1.37-fod maximum capacity. Crimping of main contacts Ony w/ crimping ensures a sufficient deformation. W/ crimping causes ony ow oxidation during operation and resuts in permanenty ow contact resistance and, for this reason, a ow sef-heating of crimped contacts carrying high currents. Crimp toos and size of dies Schatbau recommends the use of the hand too WHPH 10 and for major quantities the hydrauic crimping heads WHK 8S, WHK 8 or WHK 9 respectivey of the company Stocko (or comparabe toos of other manufacturers). For the right size of dies pease refer to the opposite tabe. 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 , test 5b. The derating curve with correction factor 0.8 I n (base curve) is, therefore, vaid for currents which may continuousy and not intermittenty fow through the main contacts of the charging connector, with piot contacts simutaneousy carrying currents of 0 A, without exceeding the upper imiting temperature of +110 C. Size of dies (Stocko WHPH 10, WHK 6, WHK 9) for w/ crimping Wire crosssection* Reducing bushing Size of dies with # embossed in Anvi Indentor 16 mm² LV RH5/ mm² 35 mm² 50 mm² LV RH50/ LV RH50/ LV RH70/ mm² mm² * For AWG sizes refer to the conversion tabe on our homepage: Piot and auxiiary contacts Crimping instructions Appicabe standard The appicabe standard for crimping the piot and auxiiary contacts is IEC Soderess crimped connections - Genera requirements, test methods and practica guidance. Crimp too Schatbau recommends the use of crimp too CWZ-600. (See aso previous page) Crimping of piot and auxiiary contacts Crimping of piot and auxiiary contacts is done by means of a set of dies for wire gauge.5 mm². For that purpose, side crimp ferrue of contact (pin or socket) over the stripped wire unti it shows in the inspection hoe. Feed the contact with the inserted wire in the crimp too as far as it wi go. Cose the too handes beyond the ock-in position. Maximum current carrying capacity dependent on wire gauge The foowing tabe informs about the maximum current carrying capacity dependent on wire gauge. Main contacts must be w/ crimped. In addition to that, pease stricty observe the maximum current carrying capacity and derating curves of the respective charging connector. Wire cross-section* Reducing bushing LV80 LV160 LV30 95 mm² 380 A* 70 mm² 30 A 50 mm² LV RH-70/50 used with LV30 50 A 50 A 35 mm² LV RH-50/35 used with LV A 5 mm² LV RH-50/5 used with LV A 160 A 16 mm² LV RH-5/16 used with LV80 15 A

15 15 Assemby instructions a b 8 7 Assemby of main contacts: Use the recommended toos to crimp main contacts (item 1) to weding cabes. Important: Pease observe information for proper crimping as mentioned in our master cataogue. See aso page 1. Mark and cabe termina end by using red and bue shrink tube respectivey. Insert main contacts (item 1) incuding crimped cabes into contact cavities (item 6) of the she as far as it wi go. Note: Mind poarity marking for and cabe on pug and receptace she (item 6). Assemby of piot/auxiiary contacts: Use the toos as recommended by Schatbau to crimp piot contacts (item 7) and auxiiary contacts (item ) respectivey to signa cabes. See aso page 1. Insert auxiiary contacts (item ) incuding crimped cabes into the contact cavities of the she (item 6) unti ocked in pace, so they cannot be pued out. Note concerning LV30: Here the auxiiary contacts are secured from faing out of the she by means of the sider (item 9). Adapter for piot contacts or air bow-in system: Assemby of piot contact adapter: Insert pin piot contacts (item 7) incuding crimped cabes into adapter for piot contacts (item 8) unti ocked in pace, so they cannot be pued out. After that insert piot contact adapter (item 8) into the she (item 6) unti ocked in pace, so the adapter cannot be pued out. There is a preassembed piot contact adapter (item 8) in the receptace she (item 6). Insert socket piot contacts (item 7) with crimped cabes into adapter (item 8) unti ocked in pace, so they cannot be pued out. Note: For accommodating socket contacts (item 7) a piot contact adapter (item 8) is pre-assembed in the receptace (item 6). Assemby of air tube adapter: Push air tube (inside diameter 6 mm) onto adapter (item 3a / 3b) as far as possibe. The receptace she aways comes with an added air tube adapter and spacer (item 11). For air tubes with a arger inside diameter use the extra adapter (see page 16). Insert air tube adapter into the she (item 6) unti ocked in pace, so it cannot be pued out. Assemby of keying pug: Insert keying pug for votage keying (item 4) from front to back into pug/receptace she (item 6) unti ocked in pace, so the nomina votage of the battery shows in the inspection hoe. Important note: Keying pugs for charging pug and vehice pug respectivey must show the same votage keying as the battery receptace. With LV80 Series connectors mount keying pug (item 4) prior to sider (item 9). Caution! Worn or damaged keying pugs in the mating area must be repaced. Assemby of she: Insert sider (item 9) for arresting the main contacts into she (item 6) unti ocked in pace. Note: Sighty pu at weding cabes to check whether the main contacts rest in pace. After the assemby of the main contacts, we recommend mating of the connector haves before tightening the strain reief screws. This ensures an idea concentricity of the main contacts. See aso page 16. Screw-connect the upper and ower haves of the strain reief camp (item 5), so that the cabes are best protected against stress and strain. Tightening torque 1.5 Nm max. Use appropriate crosstip screwdriver. Cabe diameter may be between 17 mm max. and 9 mm min. - the draw-off force 00 N per cabe. Use cabe ties for strain reief to fix cabes of piot/auxiiary contacts to main cabes. The same can be done with the air tube as used with options for eectroyte circuation systems. Snap-on hande: Pace hande (item 10) over provided mounting hoes and snap it on unti ocked in pace. LV160 and LV30 snap-on handes can be additionay fixed by means of two extra screws (tightening torque 0.5 Nm max.). Aternativey, screw-on handes are aso avaiabe. The tightening torque for the screws is.0 Nm. Use appropriate crosstip screwdriver.

16 16 Assemby detais Mating and unmating forces In order to ensure easy engaging and disconnecting the mating and unmating forces shoud remain within norma range (150 N max.). Note: To minimize torsion forces in the cabe: adjust both main contacts eveny in the she (see eft-hand diagram) aign crimp points in parae to bearing surface of cabe ug; this is particuary important in case of short cabes where there is not much room for manoeuvre (see right-hand diagram). By observing the instructions mentioned above optima mating and unmating forces can be achieved. She-side assemby of main contacts After the assemby of the main contacts, we recommend mating of the connector haves before tightening the strain reief screws. This ensures an idea concentricity of the main contacts. See aso page 15. Bearing surface (here: at cabe ug) Main contacts with w/ crimp points Main contact (here: socket contact) Cabe (e.g. H01N-D) Battery termina end (here: cabe ug) Even adjustment of main contacts in pug/receptace she improves mating and unmating forces Mounting of pug or receptace she For mounting the pug or receptace she of LV160 and LV30 Series connectors onto materias handing vehices or equipment use M6 screws with Ø 6.4 mm Parae aignment of crimp points of main contacts and cabe ugs to bearing surface washers (according to DIN 134). For LV80 Series connectors use M6 pan head and socket head screws (according to DIN 91) without washers. Tightening torque 3 Nm max. Safety instructions Disconnecting when ive or under oad Disconnecting the connector when ive or under oad is generay ony permitted under exceptiona circumstances or in the case of imminent danger to operationa safety according to EN Optiona auxiiary contacts are avaiabe for switching off the oad before disengaging the connector and switching on the oad after engaging the connector, respectivey. If the charging connector is used without auxiiary contacts the ife of the main contacts can be consideraby shortened because of contact weding when engaging or disengaging the connector. When unmating the connector when ive or under oad, an arc is generated. That is why disconnecting under oad is prohibited in the neighbourhood of exposives and other ignition sources. LV80/160/30 Series: Inverse-poarity protection Inverse-poarity protection guaranteed when engaging connectors of the same LV Series In order to guarantee inverse-poarity protection the LV80/160/30 Series must aways be fitted with a piot contact adapter or an air tube adapter when intended for intermating with existing connectors of comparabe design made by other manufacturers. Schatbau, therefore, deivers LV80/160/30 Series stock items (see page 4) generay with a piot contact adapter pre-assembed in the receptace she or an added air tube adapter with connectors for eectroyte circuation systems! Visua inspections Be sure to make visua inspections reguary. Improper handing of the connector, e.g. when hitting the foor with some impact, can resut in breakage, visibe cracks and deformation. Defective and/or eaky parts must be repaced instantaneousy!

17 17 Keying Keying Schatbau charging connectors feature keying to DIN Keying pugs of different coours with markings of six different standard battery votages from 4 V to 96 V prevent mating with the wrong votage or battery type. Types of keying Appication keying: This type of keying ony aows for mating of connector haves for the same battery type. Thus a battery receptace for dry-ce batteries is ony intermateabe with the pug of the charging station for dry-ce batteries. Votage keying: There are six standard battery votages to choose from: 4, 36, 48, 7, 80, 96 V. The votages are marked on the sides of the hexagona keying pug. The keyed votage shows in the inspection hoe of the pug and receptace she. LV Series: Keying pugs for wet-ce battery / charging station (grey), vehice pug (yeow), and dry-ce battery / charging station (green) Appication keying for 4 V rated operating votage Keying receptace she Battery green: dry-ce battery `T Dry-ce battery `T Wet-ce battery `N grey: wet-ce battery `N Front view receptace she Keying pug she Charging station green for charging station dry-ce battery `T Cross section of impemented 4 V keying when mated grey for charging station wet-ce battery `N Front view pug she Front view pug she Keying pug she Materias handing vehice yeow: universa `U Charging station dry-ce battery `T Materias handing vehice `U Charging station wet-ce battery `N Votage keying LV80, LV160 or LV30 Series Pin Socket Appication keying Votage keying Impemented in Receptace she Pug she Appication keying Keying pug for LV80 Ngr, LV160/30 Ngr Pug she Charging station wet-ce battery «N» Battery receptace Wet-ce battery «N» LV80 Tgn, LV160/30 Tgn Pug she Charging station dry-ce battery «T» Battery receptace Dry-ce battery «T» LV80 Uge, LV160/30 Uge Pug she Vehice pug (universa) «U» Battery receptace

18 18 RoHS 00/95/EC Schatbau GmbH manufactures in compiance with RoHS. The LV Series connectors are RoHS compiant. Schatbau GmbH has an environment management system that has been certified since 00. Schatbau GmbH has a quaity management system that has been certified since Eectrica Components and Systems for Raiway Engineering and Industria Appications Connectors Connectors manufactured to industry standards Connectors to suit the specia requirements of communications engineering (MIL connectors) Charging connectors for battery-powered machines and systems Connectors for raiway engineering, incuding UIC connectors Specia connectors to suit customer requirements Snap-action switches Snap-action switches with positive opening operation Snap-action switches with sef-ceaning contacts Enabing switches Specia switches to suit customer requirements Contactors Singe and mutipoe DC contactors High-votage AC/DC contactors Contactors for battery powered vehices and power suppies Contactors for raiway appications Termina bots and fuse hoders DC emergency stop switches Specia contactors to suit customer requirements Eectrics for roing stock Equipment for driver s cab Equipment for passenger use High-votage switchgear High-votage heaters High-votage roof equipment Equipment for eectric brakes Design and engineering of train eectrics to customer requirements Schatbau GmbH Hoerithstrasse München Germany Phone Fax Emai contact@schatbau.de Internet A184/091/1.5 Printed in Germany with compiments: We reserve the right to make technica aterations without prior notice. For updated product information visit Issued 1-009