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F121-M.de

1. Only Schaltbau approved crimping tools may be used 1 1 5 Installation 1 2 When installing the coupling socket ensure that everything is kept clean particularly the earthing surfaces The coupling socket is attached with M6 Allen screws Select screws of a length to suit the installation position Commissioning Before commissioning the plug connection must be tested as defined in EN 50215 N Before commissioning the coupling socket must be subjected to a high voltage test Schaltbau GmbH Page 9 20 Status 2009 11 06 J TOP A S SCHALTEAU Connect Contact Control 1 3 Maintenance It is vital to observe the following points before starting any work on the con nector 1 The system must be switched off 2 The system must be secured against switching on again 3 Absence of voltage must be ascertained 4 The system must be earthed and short circuited 5 Neighbouring parts that are live must be covered or cordoned off Pay attention to additional and auxiliary circuits as well as the main circuits 1 3 1 Recommended inspection and maintenance Description of test steps Test interval Visual inspection Every time the coupling is used Maintenance 35 to 42 days 1 3 1 1 Visual inspection A visual inspection of the coupling socket must be made every time it is plugged or un plugged If this visual inspection reveals damage to the housing the cap or the insulation ele ment the coupling
2. N A conductive transition between coupling socket and attachment surface must be ensured 3 1 4 Electrical requirements 3 1 5 Installation When installing the dummy socket ensure that everything is kept clean particularly the earthing surfaces The dummy socket is attached with M6 Allen screws Select screws of a length to suit the installation position Schaltbau GmbH Page 17 20 Status 2009 11 06 J TL S SCHALTEAU Connect Contact Control 3 2 Commissioning Before commissioning the plug connection must be tested as defined in EN 50215 N Before commissioning the coupling socket must be subjected to a high voltage test 3 3 Maintenance It is vital to observe the following points before starting any work on the con nector 1 The system must be switched off 2 The system must be secured against switching on again 3 Absence of voltage must be ascertained 4 The system must be earthed and short circuited 5 Neighbouring parts that are live must be covered or cordoned off Pay attention to additional and auxiliary circuits as well as the main circuits 3 3 1 Recommended inspection and maintenance Description of test steps Test interval Visual inspection Every time the coupling is used Maintenance 35 to 42 days 3 3 1 1 Visual inspection A visual inspection of the plug must be made every time it is plugged or unplugged If this visual inspection reveals damage to the plug it must
3. 1 3 Assembly of the coupling socket Assembly must be carried out by qualified specialist staff only Earthing surfaces Spray galvanised 120 3 i d e QUU Schaltbau GmbH Page 7 20 Status 2009 11 06 J DP SAA Connect Contact Control A conductive transition between coupling socket and attachment surface must be ensured AE Thread the screw gland Item 1 with the integrated strain relief Item 2 and the end housing Item 3 onto the cable Cut the mantle off the cable and strip the individual cores Item 4 as show in the drawing Then crimp the contacts Item 5 Take care that the insulation of the cores goes right up to the crimp Insert the crimped contacts Item 5 in the contact inset Item 6 Ensure that the clip snaps into the contact inset After that insert the contact inset Item 6 in the housing Item 9 and screw the end housing Item 3 to the housing Item 9 Assemble the snap switch Item 10 with the accessories Item 8 and lay the cores Item 11 The cores must be secured with a protection sleeve Then set the seal Item 7 on the socket housing and assemble the coupling socket Schaltbau GmbH Page 8 20 Status 2009 11 06 RO E SCHALTEAD Connect Contact Control Electrical requirements Various cable cross sections must be used for the wiring Contacts 1 2 3 4 10 mm Contacts A B 6 mm Contacts C E 0 75 1 0 mm
4. E 16 3 1 Installation Instr ctlonsg iei eri agite p hen Doe Hera ee doce d e Pelei e er euge ees 16 3 1 1 Unpacking and further handling sessi en nennen nnne nennen 16 3 1 2 Interfaces to the vehicle essssssisssessssessseeennee enne enne sn treten reser nsi s nnne snnt sentes 16 Schaltbau GmbH Page 2 20 Status 2009 11 06 SCHALTBAU Connect Contact Control 3 1 8 Assembly of the dummy socket sssssssssssssssseseeenenen nennen sene nennen rs nnns entes 16 3 1 4 Electrical requirements 2uadaesa caute Pn en nner vee ere eee 17 cS ESSEN CIC e 17 39 2 Commissioning esc Sheed ceed case adds ccc seeded act iu n gu g ead qeu Pune cade Ranca ute pxRdex aas 18 3 3 MalniteriafiC8 si iscritti eene Le retener denne EA eie e FUHR Eaa ER EERE ended 18 3 3 1 Recommended inspection and maintenance esses nenne nnne tnnt 18 CECINIT 18 3 1 2 Maintenant ERE 18 3 4 Replacement RES aeu cie E Du UR EODEM USE Le 19 3 4 1 aKele iFei mE pee ee rv Tce LIUM 19 312 Standards o casi e atras eta econ merce enon ee cee Un LERRA eerie 20 Introduction This plug connector conforms to the regulations of standard UIC 541 5 The extremely robust Schaltbau connectors make the electrical connection between the vehicles in a train for the elec tric pneumatic braking system EP brake and for the electric pneumatic emergency bra
5. J J seem Connect Contact Control Railway Connector Plug connector as defined in UIC541 5 User Manual SCHALTBAU Connect Contact Control IMEFOGQUCUOMN P E 3 rude 6 General safety UNS US RR RET ee DO OTT 6 1 Coupling Socket UIC54 iia uiui iai nei detecte ade cene eee kde da ded ler kde edd bd ard d e beatas 7 1 1 Installation instructions sssessssssssseeeenenenee enne nennen enne nnns nnns intres etre n nnns nnne nnns 7 1 1 1 Unpacking and further handling sser tuaina iiaa aandie nennen nnne nnne nnne 7 1 1 2 Interfaces to the vehicle eeessssssssessseeeseseennee entente nnne entente sinn nennt nitens 7 1 1 8 Assembly of the coupling socket sssssssssssssssssseeseeene ener enne enne sinerent nns 7 UNE Ere requirements RR 9 m E MMEEclEinc EES 9 1 2 GomimisslOnilgz oe ierit iter pa E Rec ne Mere e ab use Mura ce tEse xe dapat ex ansv educ EE 9 EN Cru rc 10 1 8 1 Recommended inspection and maintenance sssseeeeeenenetn nnne 10 TERES eme Ri 10 IEEE PAM EIC 11 1 4 Replacement parts sss tete nnnntnn nennen tenete nen tnnt tenete nnn 11 EB Cu
6. be replaced by a new one immediately 3 3 1 2 Maintenance Schaltbau GmbH Page 18 20 Status 2009 11 06 J TOP eared Connect Contact Control Maintenance Steps Requirements Notes Visual and functional in spection Spring force noticeable when opening Ease of movement No apparent damage No loose or missing attach ment elements Torsion spring not broken No cracks or porous places in cap seal Visual inspection of rubber seal on attach ment flange No cracks or porous places Visual inspection of socket inset No apparent damage No dirt In case of faults repair or replace the affected parts 3 4 Replacement parts 3 4 1 Technical data Item Designation 1 Spring washer 2 EP bellows seal You will find the technical data in catalogue F120 and the relevant dimensioned draw ings Schaltbau GmbH Page 19 20 Status 2009 11 06 SCHALTBAU Connect Contact Control 3 4 2 Standards Brake Electric pneumatic brake EP brake Electric pneumatic emer UIC541 5 2005 gency brake override Rail applications Electrical equipment on rail vehicles EN60077 1 2003 S General operating conditions and general rules Rail applications Environmental conditions for equipment EN50125 1 2000 Equipment on rail vehicles EN50215 2009 Testing of rail vehicles after completion and before commiss
7. ioning Schaltbau GmbH Page 20 20 Status 2009 11 06
8. ke over ride Both systems are served by a common electric cable laid in the train The feedback for the pres ence of a plug is given by a pilot contact integrated in the coupling socket switching element and detection of the end of the train through a pin contact in the dummy socket The Schaltbau plug connector as defined in UIC541 5 is the modern solution for the electrical in terconnection of these two systems It is a reliable complement to the 18 pin signal line as de fined in UIC558 The Schaltbau plug connector as defined in UIC541 5 provides both energy and signal transmission The EP brake system ensures immediate parallel response of the air brake The system short ens the braking distance and thus the travelling time The emergency brake override system allows the guard to override emergency braking caused by the communication cord being pulled for example to drive out of a tunnel The Schaltbau UIC541 5 connector ensures the reliable functioning of both these systems In addition Schaltbau provides components such as emergency brake switches in modern styling The Schaltbau UIC541 5 plug connector can also be used for goods wagons though here the emergency brake bypass function is omitted Feedback Plug present Feedback via optional switching element in the coupling socket End of train Feedback via pin contact in the dummy socket Schaltbau GmbH Page 3 20 Status 2009 11 06 SCHALTBAU Con
9. l times Should anything be unclear the unit type and manufacturing number must be specified for clarification It is assumed for the purposes of assembly operation and maintenance that planning and execution of the mechanical and electrical installation transport set up and commissioning as well as maintenance and repair are carried out by responsible specialists with the appropriate skills This applies both to the observance of the general installation and safety regulations ap plying to work on low voltage systems and to the proper use of approved tools Electri cal devices should be protected as well as possible from moisture and dust during as sembly and storage The housings of the coupling socket and the dummy socket must be earthed Note The plug may become warm during operation General safety instructions Inspection and maintenance must be carried out only by trained specialist staff working to the Schaltbau maintenance instructions When exchanging parts only Schaltbau replacement parts may be used Schaltbau GmbH Page 6 20 Status 2009 11 06 J Yo SEHATTRAD Connect Contact Control 1 Coupling Socket UIC541 1 1 Installation instructions 1 1 1 Unpacking and further handling Before assembling the components inspect them visually for damage in transit 1 1 2 Interfaces to the vehicle The dimensions of the vehicle interfaces will be found in the relevant data sheets and or the catalogue 1
10. letion and before commissioning Schaltbau GmbH Page 12 20 Status 2009 11 06 J WY occas Connect Contact Control 2 UIC541 Plug 2 1 Installation instructions 2 1 1 Unpacking and further handling Before assembling the components inspect them visually for damage in transit 2 1 2 Interfaces to the vehicle The dimensions of the vehicle interfaces will be found in the relevant data sheets and or the catalogue 2 1 3 Assembly of the plug Assembly must be carried out by qualified specialist staff only 175 Please note that the supplied contacts must be crimped to the cable be fore assembly Schaltbau GmbH Page 13 20 Status 2009 11 06 J DP SATA Connect Contact Control 6 Thread the screw gland Item 1 with the integrated strain relief Item 2 and the end housing Item 3 onto the cable Cut the mantle off the cable and strip the individual cores Item 4 as show in the drawing Then crimp the contacts Item 5 Take care that the insulation of the cores goes right up to the crimp Insert the crimped contacts Item 5 in the contact inset Item 6 Ensure that the clip snaps into the contact inset After that insert the contact inset Item 6 in the housing Item 7 and screw the end housing Item 3 to the housing Item 7 ttt 2 1 4 Electrical requirements Various cable cross sections must be used for the wiring Contacts 1 2 3 4 10 mm Contacts A B 6
11. mm Contacts C E 0 75 1 0 mm Only Schaltbau approved crimping tools may be used 2 1 5 Installation When assembling the plug ensure that it is kept absolutely clean Contacts must be straight no inclination The strain relief must be checked for sufficiently firm attachment Schaltbau GmbH Page 14 20 Status 2009 11 06 J TOP A S SCHALTEAU Connect Contact Control 2 2 Commissioning Before commissioning the plug connection must be tested as defined in EN 50215 N Before commissioning the coupling socket must be subjected to a high voltage test 2 3 Maintenance It is vital to observe the following points before starting any work on the con nector 1 The system must be switched off 2 The system must be secured against switching on again 3 Absence of voltage must be ascertained 4 The system must be earthed and short circuited 5 Neighbouring parts that are live must be covered or cordoned off Pay attention to additional and auxiliary circuits as well as the main circuits 3 3 1 Recommended inspection and maintenance Description of test steps Test interval Visual inspection Every time the coupling is used Maintenance 35 to 42 days 2 3 1 1 Visual inspection A visual inspection of the plug must be made every time it is plugged or unplugged If this visual inspection reveals damage to the plug it must be replaced by a new one immediately Schaltbau GmbH Page 15 20 Stat
12. n hh me 12 142 choc c E 12 2 WIC 541 Plu Ges 13 241 Installation Instr ctlOns iit erroe ge Ain eet Lo dentin diel laden aie 13 2 1 1 Unpacking and further handling essent nennen nnne nnns 13 2 1 2 Interfaces to the vehicle seessssssssssessseesesesennen entente nnne nrte enne siens sinn daaarna 13 213 Assembly of the plug tet ree Re P tenebre cete edt averne kaa aata ere eae 13 2 WAP Bleeincal Tegll e IMCS oue teet metae isisa bet ricette AE nera ESEE E metteur epe beris eina 14 2 1 5 jnstallationzs ooi ee bere iai be isse rerree corer ercer tdm Las 14 2 2 COMMISSIONING uade cien Fra sao da sick ete ta aosan ig id dada e diee aaike Edd ae aeta ada tace ded t o Td dne 15 2 9 Mani BIB TIGE Geister peces rris mea choc e stro E E da pepe bruit siad 15 3 3 1 Recommended inspection and maintenance coran t tace ue ELE roten cabe eere inion eR REDE S 15 2 9 1 1 Visual Inspectii i oett xao z debt e aee dea bed era bra Una sep Rv ardua ad read reddens 15 2 9 1 2 Mainteriarice ee dept enit t Er E ee ERE CE Dru rte Ep ere o e Re EE ER Rn a ree o Ee e Eos 16 2 4 Replacement paS 16 2 4 1 Fechnical dataserie ienien aiii eera a aeaaea aeaaaee aea aadatan dend 16 3 Dummy Socket UIG541 ree e et rte i adults Fico at de aret lta Fe tea ava ert ea AE
13. nect Contact Control Housing Socket housing with metal handle Snap point when locking the cap Locking of plug in socket Improved waterproofing through new design Contacts High quality solid turned contacts Gold or silver plated surface Crimped connection Schaltbau GmbH Page 4 20 Status 2009 11 06 SCHALTBAU Connect Contact Control The plug connectors in the UIC541 5 series consist of the following components Coupling socket Plug Dummy socket Junction box The contact inset has 4 power contacts of 10 mm 2 power contacts of 6 mm 2 control contacts of 0 75 1 0 mm and 1 control contact of 2 5 mm cross section Material characteristics Increased corrosion resistance against chemical influences in particular against cleaning agents with acidic or alkaline additives Configuration Socket and plug can be configured to customer specifications on request Schaltbau GmbH Page 5 20 Status 2009 11 06 J SNTE Connect Contact Control Safety notice The connectors described here are part of special purpose low voltage systems They are constructed and tested according to the recognised technical rules In principle elec trical equipment can cause serious injury and damage if improperly used wrongly oper ated inadequately maintained or tampered with These instructions for operating the plug connectors must therefore be followed at al
14. socket must be replaced by a new one immediately Schaltbau GmbH Page 10 20 Status 2009 11 06 1 3 1 2 Maintenance J TO LS ECHALTEAU Connect Contact Control Maintenance Step Requirements Notes Visual and functional in spection Spring force noticeable when opening Ease of movement No apparent damage No loose or missing attach ment elements Torsion spring not broken No cracks or porous places in cap seal Visual inspection of rubber seal on attach ment flange No cracks or porous places Visual inspection of socket inset No apparent damage No dirt In case of faults repair or replace the affected parts 1 4 Replacement parts Item Designation Spring washer EP bellows seal Schaltbau GmbH Page 11 20 Status 2009 11 06 SCHALTBAU Connect Contact Control 1 4 1 Technical data You will find the technical data in catalogue F121 and in the relevant dimensioned draw ings 1 4 2 Standards Brake Electric pneumatic brake EP brake Electric pneumatic emer UIC541 5 2005 gency brake override Rail applications Electrical equipment on rail vehicles EN60077 1 2003 LL General operating conditions and general rules Rail applications Environmental conditions for equipment EN50125 1 2000 Equipment on rail vehicles EN50215 2009 Testing of rail vehicles after comp
15. us 2009 11 06 J TOP eared Connect Contact Control 2 3 1 2 Maintenance Maintenance Step Requirements Notes e No apparent damage to hous ing e Effective strain relief e No damage to guide pin Visual and functional in spection Visual inspection of rubber seal on attach e No cracks or porous areas In case of faults repair or ment flange replace the affected parts e No visible damage Visual inspection of plug Noun inset Visual inspection of ca e No apparent damage to ble mantle e No signs of mechanical stress 2 4 Replacement parts Item Designation 1 Plug 2 4 1 Technical data You will find the technical data in catalogue F120 and the relevant dimensioned draw ings 3 Dummy Socket UIC541 3 1 Installation Instructions 3 1 1 Unpacking and further handling Before assembling the components inspect them visually for damage in transit 3 1 2 Interfaces to the vehicle The dimensions of the vehicle interfaces will be found in the relevant data sheets and or the catalogue 3 1 3 Assembly of the dummy socket Assembly must be carried out by qualified specialist staff only Schaltbau GmbH Page 16 20 Status 2009 11 06 J Yo ccna Connect Contact Control Earthing surfaces spray galvanised E Ld e LJ When installing the dummy socket ensure that everything is kept clean particu larly the earthing surfaces

F121-M.de

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