STAUBLI MA425 EvoTrak Lite Mid Power Modular Connector Instruction Manual

STAUBLI MA425 EvoTrak Lite Mid Power Modular Connector

Product Information

The product is called EvoTrak lite and it is a two-pole solution. It is designed for assembly and installation by electrically skilled or instructed persons who must observe all applicable safety regulations. The product has protection against electric shock, which should be checked in the end-use applications as well. The connector should be inspected for external defects before each use. Unmated plug connectors must be protected from moisture and dirt. Further technical data can be found in the product catalog.

Product Usage Instructions

1. Inspect the connector for external defects, especially the insulation, before each use. If there are any safety concerns, consult an electrically skilled person or replace the connector.
2. Protect unmated plug connectors from moisture and dirt.
3. Refer to the product catalog for additional technical data.
4. For assembly and installation, follow all applicable safety regulations.
5. Check the protection against electric shock in the end-use applications.

Safety instructions

• Use only the components and tools specified by Stäubli. In case of self-assembly, do not deviate from the preparation and assembly instructions as stated herein, otherwise, Stäubli cannot give any guarantee as to safety or conformity with the technical data. Do not modify the product in any way.
• Connectors not originally manufactured by Stäubli which can be mated with Stäubli elements and in some cases are even described as ”Stäubli-compatible” by certain manufacturers do not conform to the requirements for safe electrical connection with long-term stability, and for safety reasons must not be plugged together with Stäubli elements. Stäubli, therefore, does not accept any liability for any damages resulting from mating such connectors (i.e. lacking Stäubli approval) with Stäubli elements.
• Stäubli Electrical Connectors (Stäubli) does not accept any liability in the event of failure to observe these warnings.

Installation, electrotechnical expertise

• The products may be assembled and installed by electrically skilled or instructed persons duly observing all applicable safety regulations.

Caution, risk of electric shock

Work in a de-energized state
Follow the five safety rules, when working on electrical installations. After the respective electrical installations have been identified, the following five essential requirements shall be undertaken in the specified order unless there are essential reasons for doing otherwise:

• disconnect completely;
• secure against re-connection;
• verify absence of operating voltage;
• carry out grounding and short-circuiting;
• provide protection against adjacent live parts.

Any person engaged in this work activity shall be electrically skilled or instructed, or shall be supervised by such a person. Source: EN 50110-1:2013
Protection against electric shock shall be checked in the end-use applications too.

Do not disconnect under load

• Plugging and unplugging when live is permitted.

Caution

• Each time the connector is used, it should previously be inspected for external defects (particularly the insulation). If there are any safety concerns, an electrically skilled person must be consulted or the connector must be replaced.
• The plug connectors are watertight in accordance with the product specific IP protection class.
• Unmated plug connectors must be protected from moisture and dirt. The male and female parts must not be plugged together when soiled.

Useful hint or tip

• For further technical data please see the product catalog.

Delivery state of components

Male configuration body

Receptacle configuration body

Female configuration body

• A Configuration body
• B Coding pin (optional)
• C Contact
• D Cable gland
• E Shield clamp (contact + retaining ring)
• F IP2X protection, optional

Possible combinations

Suggested tools

Crimp contact| Cable cross-section mm2| Hydraulic crimping tool and die holder| Crimping die| Flat side mm| Width mm|
---|---|---|---|---|---|---
Pin| Socket|
Hex. crimp|

19.3506

|

19.3520

|

10

| MECATRACTION SU 210 K + S21

oder/or

MECATRACTION ESU 137 + U137C12

| ELSV20

C12 ELS

|

5.8 ± 0.15

|

7

|

19.3507

|

19.3521

|

16

| MECATRACTION SU 210 K + S21

oder/or

MECATRACTION ESU 137 + U137C12

| FLSV20

C12FLS

|

6.8 ± 0.15

|

7

|

19.3508

|

19.3522

|

25

| MECATRACTION SU 210 K + S21

oder/or

MECATRACTION ESU 137 + U137C12

| TN25V20

C12TN25

|

8.1 ± 0.15

|

8

|

19.3509

|

19.3523

|

35

| MECATRACTION SU 210 K + S21

oder/or

MECATRACTION ESU 137 + U137C12

| TN35V20

C12TN35

|

9.3 ± 0.15

|

8

|

19.3510

|

19.3524

|

50

| MECATRACTION SU 210 K + S21

oder/or

MECATRACTION ESU 137 + U137C12

| TN50V20

C12TN50

|

11± 0.15

|

12

|

19.3511

|

19.3525

|

70

| MECATRACTION SU 210 K + S21

oder/or

MECATRACTION ESU 137 + U137C12

| TN70V20

C12TN70

|

12.6 ± 0.15

|

12

|

(ill. 2)

• Torque wrench (not provided by Stäubli) and insert.
• LITE-TO/CGM25, Order No. 19.2929
• (ill. 3)
  • Electrician knife to strip the cable.
• (ill. 4)
  • Screwdriver with Vernier Adjustment 2 – 10 N m (example: FACOM A 404).
  • Hexagon socket for M6 screws. length approx. 100 mm.
  • Not supplied by Stäubli.
• (ill. 5)
  • Allen key 4 mm.
• (ill. 6)
  • Electrical tape
• (ill. 7)
  • Wire cutter to strip the metallic braid of the shielded cable.
  • Not supplied by Stäubli.
• (ill. 8)
  • Special pliers to install the retaining ring on the shield clamp (Facom, 411A. 17).
  • Not supplied by Stäubli.
• (ill. 9)
  • Removal tool and pusher for disassembling contacts.
  • LITE-TO/CT,  Order No. 19.2916
  • LITE-TO/CT-PSH, Order No.19.2917

Preparing the configuration body

(ill. 10)

• Multipole connectors must be polarized to prevent improper mating.
• Coding consists of using coding pins that will be inserted into the configuration bodies of both fixed and mobile parts. Each single pole has 2 holes to clip in a coding pin.
• Select the configuration body for the fixed and mobile part, then insert a coding pin according to the desired combination (see below for coding sequence options).
• The final position of the coding pins in the insulator is obtained when a “click” sound is heared. The correct fit is additionally checked by pulling the coding pin.
• It is necessary to respect the coding sequence between the fixed and mobile part.

Mobile configuration body/Fixed configuration body or panel mount

Assembling the contacts into the insulators

Positioning of cable gland

(ill. 11)

• Place the cable gland on the cable.

Note (Tab. 2)

• The cable gland depends on the cable’s outer diameter and must be compliant to railway standards. The user is responsible for choosing accordingly.

Note

• The cable glands are not suitable for dynamic application (lateral movements). A cable flanging system must be provided by the customer or the integrator.

Cable gland| Type of cable gland insert| Bestell-Nr. Order No.| Tightening range (mm)
---|---|---|---

M25

| LITE/CG-N5HT| 19.2746| 6 – 9
LITE/CG-N4HT| 19.2747| 8 – 12.5
LITE/CG-N2HT| 19.2749| 11 – 16
LITE/CG-N3HT| 19.2748| 14 – 18
LITE/CG-N1HT| 19.2745| 16 – 20
LITE/CG-N9HT| |

Cables preparation

Unshielded cables

(ill. 12)

• Strip the cable with the electrician knife, according to the lengths in Tab.3.

• Insert the stripped cable in the crimp-ing sleeve until the end.
• Crimp the sleeve with the hexagonal dies, Tab. 1. Hold the conductor in position of the sleeve (push axially).
• Carefully align the dies while crimping.

Attention

• Conductor wires must be visible in the sight hole before and after crimping.

Shielded cables

Cable stripping

• By using the special pliers, slide the retaining ring over the upper insulator on the cable.
• Insert the shield clamp between the metallic braid and the inner insulator. Be sure to respect length Z (see Tab.4).
• Block the metallic braid onto the shield clamp by using the retaining ring and the special pliers.
• Fold the metallic braid over the retaining ring and cut off the excess braid.

Attention

• Do not damage the MULTILAM!
• Cover with electrical tape.

(ill. 21)

• Insert the cable in the crimping sleeve until the end.
• Crimp the sleeve with the hexagonal dies, Tab. 1. Hold the conductor in position of the sleeve (push axially).
• Carefully align the dies while crimping.

Attention

• Conductor wires must be visible in the sight hole before and after crimping.

(ill. 22)

• Verify the distance Y between the shield clamp and the shoulder of the contact (male or female) is 53.5 +/- 0,5 mm.

Inserting the crimped contacts into the insulator

1. Insert the crimped contact into one of the insulators in the configuration body.
2. Push and insert the shielding contact into the metallic part of the configuration body (shielded versions).
3. Check for proper contact placement.
   • The claws must hold the contact.
   • Female contact: It should be slightly recessed from the edge of the insulation.
   • Male contact: it should be slightly exceed from the edge of the insulation.
   • Pull on the cable to check that the contact is correctly clipped in the insert.

Cable gland tightening

• Tighten the cable gland to ensure seal-ing in the back of the cable by using the torque wrench and insert.

Recommended torque:

• Cable gland CG-M25: 15 N m

• Repeat this operation for each pole.

• Tighten pressure screw visual until pressure screw and sealing insert are at the same level.

Note

The cable glands are not suitable for dynamic application (lateral movements). The integrator must comply with the cable retention standards of the application:
Unless stated otherwise by the cable manufacturer, cables must be fixed in place at intervals no larger than the following values:

• 300 mm if the cables are placed horizontally along a surface
• 500 mm if the cables are placed vertically

Cable lug or busbar mounting

(ill. 25)

Connecting the cable lug or busbar to the contact LITE-X/CT-S10-IT-M8 consists of the following steps:

• Place cable lug or busbar on the contact
• Place flat washer on the cable lug
• Position lock washer (e.g RipLock washer)
• Tighten A2 stainless steel M8x20 screw. Tightening torque: 12 to 13 N m

Protection cap

(ill. 26)

• Protection cap (on request) against dust.
• To protect the unmated contacts when outside use

Assembling the female IP2X protection

•  Position the claws of the IP2X protection between the claws of the insulator.
• Push the IP2X protection until you hear a click.

Mounting the fixed connector part

Receptacle assembly

Mounting the connector on the panel

• To mount the connector on the panel, drill according to the drilling plan.

1. Place the connector on the outside of the panel.
2. Pass the four M4 screws through the 4 mounting holes on the connector. Place a nut-type system on the screws on the inside of the cabinet.
3. From the outside, tighten the 4 mounting screws. Tightening torque: 2 to 2.5 N m.#

Note

The mounting assembly must securely hold the fixed connector in place. To ensure this, it must be designed for a railway environment (vibration-proof). M4*30 mini screws.

Example

• Exterior part: A2 stainless steel M4*30 screw and RipLock locking washer
• Interior part: RipLock locking washer and A2 stainless steel nut

Mounting the straight fixed connector

Mounting holes

29 ±0.2

|

33.25 ±0.2

2| 92 ±0.2
3| 127 ±0.2
4| 162 ±0.2

Grounding the metal parts of straight connectors (optional)

• To connect a ground braid, use the holes provided on the end plates of the connectors (see the circled holes in the image above).
• Hole diameter: 7 mm
• The LITE-X panel receptacle has a flat metal surface in contact with the customer’s panel so that a grounding braid is not necessary.

Connecting and Disconnecting

LITE-S-M-Px; LITE-S-F-Px

Before connecting

Check for:

• 2 locking screws.
• blue seals (1 seal/pole) on the LITE-S-M-Px. They must not be damaged.
• no pollution on pins and sockets.
• no cracks or broken corners on black insulator parts.

Connection

• Use the 2 threaded holes in the end plates of the fixed part in order to connect and lock the mobile connector on to the fixed connector.
• Keep both parts together.
• Screw the 2 locking screws.
• Tighten the 2 screws of the fixed part with screwdriver Allen for M6 screw.
• Tighten with tightening torque: 8 à 10 N m.

• Make sure that metallic parts are fully aligned and mated. Check that there is no space between the sides plates.

Disconnection

• Unscrew the 2 locking screws in the end plates, then disconnect the mobile part of your connector.

LITE-S-M-Px; LITE-X-Px

Before connecting

Check for

• 2 locking screws.
• blue seals (1 seal/pole) on the LITE-S-M-Px. They must not be damaged.
• no pollution on pins and sockets.
• no cracks or broken corners on black insulator parts.

Connection

• Use the 2 threaded holes in the end plates from the fixed part in order to connect and lock the mobile connector on to the fixed connector.
• Keep both parts together.
• Screw the 2 fixing screws.
• Tighten the 2 screws of the fixed part with screwdriver Allen for M6 screw.
• Tighten with tightening torque: 8 to 10 N m.

• Make sure that metallic parts are correctly mated. Check that there is no space between the sides plates.

Disconnection

• Unscrew the 2 locking screws in the end plates, then disconnect the mobile part of your connector.

Extracting contacts

• Using the torque wrench and the appropriate insert, remove the nut from the cable gland.
• Be sure to use the tool (ill. 9) in the right orientation:
  • The M mark is for the pin connector side
  • The F marking is for the socket connector side
• Place the tool flush to the claws of the insulator.
• Using the push-piece, push on the contact to release it from the claws of the insulator.

Contact

Hersteller/Manufacturer

• Stäubli Electrical Connectors AG Stockbrunnenrain 8
• 4123 Allschwil/Switzerland
• Tel.: +41 61 306 55 55
• Fax: +41 61 306 55 56
• mail: [email protected]
• www.staubli.com/electrical

© by Stäubli Electrical Connectors AG, Switzerland – MA425 – 03.2023, Index a, Marketing Communications. Subject to alterations.

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