STAUBU MPC3-BS Power Connector Instruction Manual

STAUBU MPC3-BS Power Connector

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 installa-tions
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

Safety instructions

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 connectors in the housing are protected from water in accordance with the IP protection class stated for the relevant product
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

Components delivered

Status of components delivery

1. Connector body male or female
2. Socket and pin
3. Cable gland cap + insert
4. Contact to be crimped
5. Locking clips
6. Protection cover
7. Marking pins
8. Coding pins

Possible combinations

Suggested tools

Tab. 1

Crimping contact

| Contact cross section mm2|  Hydraulic crimping tool and die holder| Crimping die| Flat side mm|  Width mm
---|---|---|---|---|---
19.2347| 16| MECATRACTION SU 210 K + S21

nebo/or MECATRACTION ESU 137 + U137C12

| FLSV20

C12 FLS

| 6,8 ± 0,15| 7
19.2348| 25| MECATRACTION SU 210 K + S21

nebo/or MECATRACTION ESU 137 + U137C12

| TN25V20

C12TN25

| 8,1 ± 0,15| 8
19.2349| 35| MECATRACTION SU 210 K + S21

nebo/or MECATRACTION ESU 137 + U137C12

| TN35V20

C12TN35

| 9,3 ± 0,15| 8
19.2350| 50| MECATRACTION SU 210 K + S21

nebo/or MECATRACTION ESU 137 + U137C12

| TN50V20

C12TN50

| 11± 0,15| 12

• 19.2351
• 19.2355

| 70|

• MECATRACTION SU 210 K + S21
• nebo/or MECATRACTION ESU 137 + U137C12

| TN70V20

C12TN70

| 12,6 ± 0,15| 12

• 19.2352
• 19.2356

| 95|

• MECATRACTION SU 210 K + S21
• nebo/or MECATRACTION ESU 137 + U137C12

| TN95V20

C12TN95

| 14,6 ± 0,15| 13

• 19.2357
• 19.2360

| 120|

• MECATRACTION SU 210 K + S21
• nebo/or MECATRACTION ESU 137 + U137C12

| TN120V20

C12TN120

| 16,4 ± 0,15| 15

• 19.2358
• 19.2361

| 150|

• MECATRACTION SU 210 K + S21
• nebo/or MECATRACTION ESU 137 + U137C12

| TN150V20

C12TN150

| 18,4 ± 0,15| 15
19.2362| 185|

• MECATRACTION SU 210 K + S21
• nebo/or MECATRACTION ESU 137 + U137C12

| TN185V20

C12TN185

| 20,4 ± 0,15| 16
19.2363| 240|

• MECATRACTION SU 210 K + S21
• nebo/or MECATRACTION ESU 137 + U137C12

| TN240V20

C12TN240

| 23 ± 0,15| 10

Note:
Observe the manufacturer’s operating instructions www.mecatraction.de

Note:
Contact us for AWG /MCM cables www.staubli.com/electrical

• (ill. 2)
  Electrician knife to strip the cable

• (ill. 3)
  Torque wrench (not provided by Stäubli) and inserts:
  A – MPC-TO/CGM-B/2, 19 2927 (for size 1)
  B – MPC-TO/CGM-C/2, 19 2928 (for size 2)

• (ill. 4)
  Socket screwdriver 1/2” for hexagonal M8 metric socket head screws (flat side 6 mm)

  • Length 140 mm
  • Type: MPC-TO/SCD-M8
  • Order No : 19 2940
    (Torque wrench not provided by Stäubli)

• (ill. 5)
  Short half-round nose pliers Use pliers with nose dimensions less than the described dimensions

• (ill. 6)
  Allen key 4 mm

• (ill. 7)
  Mounting and dismounting tool for female and male contacts
  MPC3-TO/BS/CT14-20
  Order No : 19 2915

Preparation of the connector body Coding

(ill. 8)
Multi-pole connectors must be coded to avoid parts being incorrectly connected
Coding consists in inserting pins into the connector bodies on both the fixed and mobile parts Each single-pole insulator has 2 holes on the connection side into which a coding pin is clipped Select the connector body for the fixed and mobile parts then insert a pin according to the desired combination
The final position of the pin is achieved

• when it comes to a stop in the insulator,
• when a click is heard

It is essential to comply with the coding order on the fixed and mobile parts

Multi-pole versions coding

Marking

(ill. 9)
Marking consists in inserting pins into the connector bodies on the cable gland/cable side in both the fixed and mobile parts

 Connector body insulation| Type of cable gland insert| Order No.|  Tightening range (in mm)
---|---|---|---

M32

| MPC/CG-L1| 19.2733| 20 až/to 25
MPC/CG-L2| 19.2734| 18,5 až/to 23,5
MPC/CG-L4| 19.2736| 15 až/to 20
MPC/CG-L5| 19.2737| 12,5 až/to 17,5
MPC/CG-L6| 19.2738| 9,5 až/to 14,5
MPC/CG-L9| 19.2701| Záslepka/Blind plug

M40

| MPC/CG-M1| 19.2739| 26 až/to 32
MPC/CG-M2| 19.2740| 23,5 až/to 29,5
MPC/CG-M4| 19.2742| 20 až/to 26
MPC/CG-M5| 19.2743| 17,5 až/to 23,5
MPC/CG-M6| 19.2744| 15,5 až/to 21,5
MPC/CG-M9| 19.2702| Záslepka/Blind plug

Cable preparation

Note:
Contact us for AWG /MCM cables www.staubli.com/electrical

(ill. 10)
Put the cable gland insert on the cable

Note (Tab. 3):
The choice of the cable gland insert depends on the cable outer diameter and must be in compliance with railway cable standards User is responsible for their choice

Note
The cable glands are not suitable for dynamic applications (lateral movements) A cable clamp system must be used See MA404 Clamp bar DCO for MPC range

3/Tab. 3

 Connector body insulation| Type of cable gland insert| Order No.|  Tightening range (in mm)
---|---|---|---

M32

| MPC/CG-L1| 19.2733| 20 až/to 25
MPC/CG-L2| 19.2734| 18,5 až/to 23,5
MPC/CG-L4| 19.2736| 15 až/to 20
MPC/CG-L5| 19.2737| 12,5 až/to 17,5
MPC/CG-L6| 19.2738| 9,5 až/to 14,5
MPC/CG-L9| 19.2701| Záslepka/Blind plug

M40

| MPC/CG-M1| 19.2739| 26 až/to 32
MPC/CG-M2| 19.2740| 23,5 až/to 29,5
MPC/CG-M4| 19.2742| 20 až/to 26
MPC/CG-M5| 19.2743| 17,5 až/to 23,5
MPC/CG-M6| 19.2744| 15,5 až/to 21,5
MPC/CG-M9| 19.2702| Záslepka/Blind plug

Cable stripping
(ill. 11)
Strip the cable with the electrician knife according to the lengths, see Tab 4

4/Tab. 4

Crimping
(ill. 12)

• A Insert the stripped cable in the crimping sleeve up to the stop
• B Crimp with the according crimping die, Tab 1, page 6 Hold the con-ductor in position (push axially) The wire must be visible before and after crimping in the sight hole Make sure to align the crimping dies before crimping

Note: (ill. 13)
1crimp die needed for all copper cables with cross-section up to 185 mm² included 2 crimping dies for all cross section from 240 mm² and higher

Inserting the crimped contacts into the insulators

(ill. 14)

• A Insert the cable fitted with the crimped contact into the insu-lator
• B Insert the contact into the insulator until it comes to a stop The contact must be aligned with the connection axis

Inserting the pins

Preparation

(ill. 15)
Make sure that the spring is in place in the groove of the pin It must be aligned with axis A1

Assembly

• (ill. 17)
  Position the pin in the insulator The groove of the pin should be in line with the cable axis

• (ill. 18)
  Use mounting tool 19 2915 to push then twist through a quarter turn Release the pressure The pin should be correctly positioned in its housing

Checking

(ill. 19)
Check that the pin is correctly positioned The groove should be perpendicular to the cable axis
Fit the mounting tool into the slot and try to twist the pin without pushing It should no longer turn

Inserting the sockets
Preparation

(ill. 20)
Make sure that the spring is in place in the groove of the socket It must be aligned with axis A1

Assembly

• (ill. 22)
  Position the socket in the insulator The groove of the socket should be in line with the cable axis

• (ill. 23)
  Use mounting tool 19 2915 to push then twist through a quarter turn Release the pressure The socket should position itself in its housing

Checking

(ill. 24)
Make sure that the socket is correctly positioned The groove should be perpendicular to the cable axis
Fit the mounting tool into the slot and try to twist the socket with-out pushing It should no longer turn

Tightening the cable glands

(ill. 25)
Using the torque wrench and the appropriate insert, tighten the cable gland nut to ensure the rear of the cable is sealed

The recommended torques are: (Insert 19 2927) M32 = 15 N m (Insert 19 2928) M40 = 20 N m

Mounting the protection covers

 Application| Body configuration size| Version|  Number of poles|  Order No. of metallic protection covers| Number of clips (19.2550) per cover
---|---|---|---|---|---

MPC-B na/on MPC-B nebo/or MPC-S

| Velikost 1

Size 1

| Samec Male| 1| 19.2538| 2
2| 19.2539| 4
3| 19.2540| 6
4| 19.2541| 8

Samice Female

| 1| 19.2500| 2
2| 19.2501| 4
3| 19.2502| 6
4| 19.2503| 8

Velikost 2

Size 2

| Samec Male| 1| 19.2546| 4
2| 19.2547| 8
3| 19.2548| 12
4| 19.2549| 16
Samice Female| 1| 19.2504| 4
2| 19.2505| 8
3| 19.2506| 12
4| 19.2507| 16

MPC-B na/on MPC-X

|

Velikost 1

Size 1

|

Samec Male

| 1| 19.2538| 2
2| 19.2539| 4
3| 19.2540| 6
4| 19.2541| 8
Velikost 2

Size 2

| Samice Female| 1| 19.2590| 4
2| 19.2591| 8
3| 19.2592| 12
4| 19.2593| 16

Insert the protection cover

(ill. 26)

• Insert the protection cover into the grooves provided for this purpose (A), moving it in a downward direction from the top of the connector body Slide it as far as it will go
• Position the latches in the notches provided for this purpose
• Check the various control points (circled) to ensure the correct positioning of the cover

Lock the protection cover

(ill. 27)
Place the locking clip in the cut-outs, using the short half round nose pliers Repeat this operation as many times as there are holes in the protection cover

(ill. 28)
Make sure the clips are well positioned by trying to slide them manually
Metallic parts grounding (option depending on the wiring system)

Grounding braid installation

(ill. 29)
In order to connect a grounding cable, respect the dimensions in Tab 5 and take care to not go over the depth max of the fixation hole (see max length in the table) Don’t damage the insulator The metallic end plate is equipped with a stainless steel A2-70 nut

Mounting the fixed connector
The MPC3-BS-M-Px and MPC3-BS-F-Px connector bodies can be mounted as fixed parts on a horizontal or vertical plane

Mounting holes
6/Tab. 6

Velikost 1/Size 1

| 1| 86,5 ±0,2| ****

100 ± 0,2

2| 131 ±0,2
3| 175,5 ± 0,2
4| 220 ± 0,2

Velikost 1/Size 2

| 1| 96,5 ±0,2
2| 151 ±0,2
3| 205,5 ± 0,2
4| 260 ± 0,2

• Use the 4 fastening holes on the 2 end plates of the fixed con-nector to attach the connector to a panel
• Refer to Tab 6 of the connector body to know the distances between the attachment holes

The attachment assembly and the support must ensure the fixed connector is held securely. Therefore it must be desi-gned for a railway environment (resistant to vibrations).

Screws, M8 x 30 mm min.
Tightening torque depending on the support used.

Connecting and disconnecting

Check before connecting
Check :

• The 4 fastening screws are in place on the mobile part MPC3-BS-M
• The red seals are in place (one seal per pole) on the
• MPC3-BS-F-Px and the blue seals on the MPC3-BS-M-Px (one seal per pole) They must not be damaged
• There is no pollution on the pins and sockets
• No degradation on the insulators (cracks or broken corners)

To connect

(ill. 30)

• Engage the parts with guidings
• Screw the 4 fastening screws with low torque in the following order: screw 1=> 2 => 3 => 4
• Use the screwdriver for M8 screws to tighten the 4 fastening screws – Hexagonal socket head screws, M8 x 20 mm min
• Tightening torque: 12-13 N m

(ill. 31)
Make sure that the end parts are correctly joined There should be no space between them

To disconnect
Unscrew the 4 fastening screws on the end parts and remove the mobile part from the fixed part

Check before connecting Check :

• The 4 fastening screws are in place on the mobile part MPC3-BS-M-Px/X
• The seals are in place (one seal per pole) on the MPC2-XA They must not be damaged
• The spacers (19 2460) are in place on the panel
• There is no pollution on the pins and sockets
• No degradation on the insulators (cracks or broken corners)

To connect

(ill. 32)

• Engage the parts with guidings
• Screw the 4 fastening screws with low torque in the following order: screw Vis 1=> 2 => 3 => 4
• Use the screwdriver for M8 screws to tighten the 4 fastening screws in the mobile part – Hexagonal socket head screws, M8 x 20 mm min
• Tightening torque: 12-13 N m

Note:
See MA084 to fix MPC2-XA www.staubli.com/electrical

(ill. 33)
Make sure that the end parts are correctly joined There should be no space between them

To disconnect
Unscrew the 4 fastening screws on the end parts and remove the mobile part from the fixed receptacle

Check before connecting Check :

• The 4 fastening screws are in place on the mobile part MPC3-BS-M-Px
• The red seals are in place (one seal per pole) on the MPC2-S/SB and the blue seals on the MPC3-BS-M-Px (one seal per pole) They must not be damaged
• There is no pollution on the pins and sockets
• No degradation on the black insulators (cracks or broken cor-ners)

To connect

(ill. 34)

• Engage the parts with guidings
• Screw the 4 fastening screws with low torque in the following order: screw 1=> 2 => 3 => 4
• Use the screwdriver for M8 screws to tighten the 4 fastening screws in the mobile part Hexagonal socket head screws, M8 x 20 mm min
• Example of fastening kit for bottom screws:
  • CHC screw M8 x 20 mm A2 stainless steel
  • M8 nut H0 8D
  • 2 Safety washers M8 medium series NFE 25-511
  • A2 stainless steel (1 for screw head, 1 for nut)
• Tightening torque: 12 – 13 N m

Note:
See MA403 to fix MPC2-S/SB www.staubli.com/electrical

(ill. 35)
Make sure that metallic parts are correctly joined Check that there is no space between the side plates

To disconnect
Unscrew the 2 fastening screws on the end parts and remove the mobile part of your connector

Note:
See MA403 to fix MPC2-S/SB www.staubli.com/electrical

Check before connecting

Check

• The 4 fastening screws are in place on the mobile part MPC2-S/SB
• The red seals are in place (one seal per pole) on the MPC3-BS-F-Px and the blue seals on the MPC2-S/SB (one seal per pole) They must not be damaged
• There is no pollution on the pins and sockets
• No degradation on the black insulators (cracks or broken corners)

To connect

(ill. 36)

• Engage the parts with guidings
• Screw the 2 fastening screws with low torque
• Use the screwdriver for M8 screws to tighten the 2 fastening screws in the mobile part – Hexagonal socket head screws, M8 x 30 mm min
• Tightening torque: 12-13 N m

Note:
See MA403 to fix MPC2-S/SB www.staubli.com/electrical

(ill. 37)
Make sure that metallic parts are correctly joined Check that there is no space between the sides plates

To disconnect
Unscrew the 2 fastening screws on the end parts and remove the mobile part of your connector

Note:
See MA403 to fix MPC2-S/SB www.staubli.com/electrical

Removing the protection cover

(ill. 38)
Remove the clips using the mounting pliers

1. Use a screwdriver to release the protection cover latches 2-3 Slide the protection cover upwards on the connector to extract it from its housings

Disassembling the contacts Extracting the pin

(ill. 39 + 40)

• Push mounting tool 19 2915 onto the pin until it comes to a stop Insert a 4 mm Allen key into the tool and tighten the tool’s screw in the pin
• Remove the Allen key then turn the tool through 90° in the insulator Unscrew the tool with the pin from the insulator

Extracting the socket

(ill. 41 + 42)

• Push mounting tool 19 2915 onto the socket until it comes to a stop Insert a 4 mm Allen key into the tool and tighten the tool’s screw in the socket
• Remove the Allen key then turn the tool through 90° in the insulator Extract the tool with the socket from the insulator

Extracting of the crimped contact

(ill. 43)
Unscrew with a torque wrench and the correct insert the cable gland

(ill. 44)
Remove the cable from the connector body

Producer:
Stäubli Electrical Connectors AG Stockbrunnenrain 8

• 4123 Allschwil/Switzerland
• Tel. +41 61 306 55 55
• Fax +41 61 306 55 56
• mail ec.ch@staubli.com
• www.staubli.com/electrical

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